Emerson ControlWave EFM 3808- Manuals

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-1 Chapter 1 – Introduction This manual focuses on the hardware aspects of the ControlWave  Electronic Flow Meter (EFM) (called the “ControlWave EFM” or “EFM” throughout the rest of this manual). For information about the software us...

ControlWave EFM Instruction Manual 1-2 Introduction Revised Dec-2013  Nonincendive Class I, Division 2 (Groups C and D) Hazardous Location approvals Figure 1-1. ControlWave EFM Enclosure ( shown with 25-Button Display/ Keypad Assembly and local circular port) 1.1 Scope of the Manual This manual con...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-3 optional keypad. Chapter 3 I/O Modules Provides general information and wiring diagrams for the I/O modules. Chapter 4 Operation Provides information on day-to-day operation of the ControlWave EFM. Chapter 5 Service and Troubleshoo...

ControlWave EFM Instruction Manual 1-4 Introduction Revised Dec-2013 the enclosure’s right side secure the cover when you close it. A weatherproof communication connector, either a 9-pin male D-type connector or a circular 3-pin connector (the local port) mounts to the bottom of the enclosure and co...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-5 Figure 1-2. 33MHz CPU Module with Three Serial Ports (left), 150 MHz CPU Module with Three Serial Ports and One Ethernet Port (right) CPU Backup Battery CPU modules have a coin cell socket that accepts a lithium battery. This batte...

ControlWave EFM Instruction Manual 1-6 Introduction Revised Dec-2013 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...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-7 1.6 Expansion Communications Modules Expansion Comm. Modules provide two additional serial communications ports and optionally the choice of a piggy-backed dial-line modem or piggy-backed 900 MHz Spread Spectrum radio (or both). Th...

ControlWave EFM Instruction Manual 1-8 Introduction Revised Dec-2013 1.7 I/O Modules The ControlWave EFM supports factory-configured I/O modules including analog I/O, analog input, digital I/O, high speed counter and mixed I/O. Refer to Chapter 3 for information on specific I/O modules. Figure 1-4 s...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-9 Figure 1-5. 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 strate...

ControlWave EFM Instruction Manual 1-10 Introduction Revised Dec-2013  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 th...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-11 The ControlWave standard gas flow measurement application collects static pressure, differential pressure and temperature data and computes flow, energy, and volume for a station. A station typically refers to a single flow comput...

ControlWave EFM Instruction Manual 1-12 Introduction Revised Dec-2013  AGA3-1992 with selectable AGA8 Gross or AGA8 Detail  AGA7/NX-19  AGA7 with selectable AGA8 Gross or AGA8 Detail  Auto-adjust AGA7/NX-19  Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail The application performs a c...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-13 1.9.6 Energy Calculation The application offers the option of using a fixed volumetric heating value or calculating the energy content of the gas according to AGA Report No. 5. 1.9.7 Volume and Energy Integration The application i...

ControlWave EFM Instruction Manual 1-14 Introduction Revised Dec-2013  Any operator change to a configuration variable  Any change in the state of an alarm variable  A system restart  Certain other system events You can view audit records on-screen in the audit log. See Appendix K of the OpenBSI...

ControlWave EFM Instruction Manual Revised Dec-2013 Introduction 1-15  uncorrected count ControlWave EFM maintains an hourly historical log for each of up to four runs. Daily Historical Data Log Each meter run maintains a daily data log that holds one record for every contract gas day. You can chan...

ControlWave EFM Instruction Manual 1-16 Introduction Revised Dec-2013 1.9.11 Sampler and Odorizer Samplers are external devices which measure the quality of the gas stream. Because natural gas is odorless and colorless, devices called odorizers inject an additive to the gas stream that allows people...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-1 Chapter 2 – Installation This chapter discusses the physical configuration of the ControlWave EFM, considerations for installation, and instructions for setting switches and jumpers on the CPU, SCM, and ECOM modules. In This Chapte...

ControlWave EFM Instruction Manual 2-2 Installation Revised Dec-2013 Caution 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 Wiri...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-5 2.2 Installation Overview Installing a ControlWave EFM involves several general steps: 1. Unpack, mount and ground the unit. (See Section 2.3 and Section 2.4 .) 2. Remove the System Controller Module (SCM) and configure jumpers and...

ControlWave EFM Instruction Manual 2-6 Installation Revised Dec-2013 2.3 Unpacking Components Packaging The ControlWave EFM ships from the factory fully assembled with all components installed except for the unit’s solar panel and battery (if provided); these items ship separately. If you ever need ...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-7 Figure 2-3. 8/4-Slot ControlWave EFM Housing - The 4-Slot Chassis is shown with ECOMs in Slots 3 & 4) 2.4 Mounting the EFM Housing  You must position the ControlWave EFM vertically with the transducer (MVT) at its base. Make s...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-9 Figure 2-5. Side View of ControlWave EFM Mounted to a 2” Pipe

ControlWave EFM Instruction Manual 2-12 Installation Revised Dec-2013 Figure 2-8. ControlWave EFM NEMA 3X Enclosure Dimensions

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-13 2.4.1 Grounding the Housing The ControlWave EFM enclosure includes a ground lug. Once you have installed the unit, run a ground wire (#4 AWG max wire size) between the ground lug (see Figure 2-4 ) and a known good earth ground. As...

ControlWave EFM Instruction Manual 2-14 Installation Revised Dec-2013 Four bolts and nuts hold the two process flange assemblies in place. When you remove the bolts, you can reposition the flanges so that the connections can emanate from the front, rear or bottom of the transducer. Take care not to ...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-15 2.4.3 Process Pipeline Connection (Meter Runs without Cathodic Protection) You can mount the ControlWave EFM directly on the pipeline or remotely on a vertical stand-alone two-inch pipe or on a wall. The Earth ground cable must ru...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-17 from the EFM. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU 3140. This black tubing easily slips over the 2-inch pipe and then after uniform heating (with a rosebud torch) it electrically insulates and increases ...

ControlWave EFM Instruction Manual 2-18 Installation Revised Dec-2013 JP5, JP6, JP7, JP8 & JP91-to-2 Installed = 12V Bulk System2-to-3 Installed = 6V Bulk System JP1 - Factory Configured (Not Shown) JP5 - Power Fail Trip Point Selection1-to-2 Installed = 12V Bulk System2-to-3 Installed = 6V Bulk...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-19 2.5.2 SCM Installation Overview There are several steps you need to follow when you install the SCM. 1. Identify the carton holding the SCM and remove it from that carton. See Section 2.3. 2. Set jumpers on the SCM based on whethe...

ControlWave EFM Instruction Manual 2-20 Installation Revised Dec-2013 Table 2-1. SCM Switch SW1 Switch position Mode Both switches set to right (Open) or both switches set to left (Closed) Activates Recovery mode, used for firmware upgrades or core updumps. Upper switch (SW-1) set to right (Open) an...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-21 2.5.6 Wiring a Bulk DC Power Supply to the SCM Caution At this time you can also connect power wiring. However; for safety reasons and to prevent accidental damage to the your bulk DC power supply, do not connect the pluggable ter...

ControlWave EFM Instruction Manual 2-22 Installation Revised Dec-2013 Terminal Block Connector TB1 Unplug removable connector TB1 from the SCM and wire DC power to the connector. We recommend you do not plug the connector back into the SCM until the CPU module is already installed in the housing. TB...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-23 2-3/8 U-Clamp Assembly B - 2 places: NOTE 1: To Attach item C to item D:Slide two bolts (A) through the top and bottomSolar Panel (Centered) Channel Holes. Affix itemC to item D via 2 sets of item A hardware asfollows: Flat Washer...

ControlWave EFM Instruction Manual 2-24 Installation Revised Dec-2013 Table 2-3. Solar Panel Tilt Angle Latitude Tilt Angle 0-4° 10° from Horizontal 5-20° Add 5° to the Local Latitude 21-45° Add 10° to the Local Latitude 46-65° Add 15° to the Local Latitude 66-75° 80° from Horizontal Connecting the ...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-25 Figure 2-15. Enclosure with Sealed Lead-acid Battery Installed

ControlWave EFM Instruction Manual 2-26 Installation Revised Dec-2013 2.7 Power Distribution Board (Optional) If your ControlWave EFM includes any of the following optional components, it also requires the power distribution board.  21V Power Supply Board for external transmitters  Digital to Rela...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-27  TB4-2 = FPWR1– to J1-9 on D-to-R I/O Bd. (PWR GND) TB5 - Fused Power Output 2: (two-conductor) (to External Modem/Radio Pwr. Connector)  TB5-1 = FPWR2+ to Radio/Modem Power+  TB5-2 = FPWR2– to Radio/Modem Power– (PWR GND) TB6 ...

ControlWave EFM Instruction Manual 2-28 Installation Revised Dec-2013 2.8 21V Power Supply (Optional) The 21V power supply is typically used to provide power to temperature and pressure transmitters (such as the Bristol 3508) that require higher than +12V but lower than +21.4V (± .8V) to operate. Th...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-29 2.9 CPU Module The CPU module, which controls the ControlWave EFM and handles memory and communication functions, can only be installed in Slot #2 of the backplane. Note : Do not confuse the CPU module (which has communication com...

ControlWave EFM Instruction Manual 2-30 Installation Revised Dec-2013 Figure 2-20. CPU Module with Three Serial Ports and One Ethernet Port 2.9.1 Setting Jumpers on the CPU Module Each CPU module contains a number of jumpers (labeled with JP n ) when n in the jumper number. See Figure 2-19 or Figure...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-31 power conservation is an issue, you can disable these LEDs by removing the jumper. Note: For maximum shelf life, the CPU module ships from the factory with the installed lithium backup battery disabled. You must enable it when you...

ControlWave EFM Instruction Manual 2-34 Installation Revised Dec-2013 2.9.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules An RS-232 port provides point-to-point, half-duplex and full-duplex communications (for a maximum of 20 feet using data quality cable). Your CPU module includes two...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-35 RS-232 COM Port Cables For the ControlWave EFM, half-duplex communications use Modbus or BSAP protocol, while full-duplex communications use point-to-point protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 2- 22 ) ...

ControlWave EFM Instruction Manual 2-36 Installation Revised Dec-2013 Figure 2-22. Full-duplex and Half-duplex Cable Use the half-duplex cable (shown in the bottom part of Figure 2-22 ) when connecting the ControlWave EFM to another ControlWave series unit (again, with the exception of the CW_10/30/...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-37 Figure 2-24. Communication Interface Cable for Connection to Case-Mounted (External) Radio or Modem When interfacing to the COM3 port of a ControlWave, or the COM5 or COM6 port a ControlWaveEXP unit, use the cable presented in Fig...

ControlWave EFM Instruction Manual 2-38 Installation Revised Dec-2013 Figure 2-27. PC Connected to ControlWave EFM via Circular Local Port (use Cable P/N 395402-01- 8 [10 foot cable] or P/N 395402-02-6 [25 foot cable]) Table 2-11. RS-232 Port (COM1) Connector Pin Assignment (COM1 Connectors – Circul...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-39  Verify that each RS-232 transceiver has one active receiver while disabled (in power down mode); connect the DCD signal to the active receiver.  Set CTS to high to transmit.  If the port is set for full-duplex operation, RTS i...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-41 Since the RS-485 port is intended for network communications, refer to Table 2-16 for the appropriate connections for wiring the master, first slave, and nth slave. Essentially, the master and the first slave transmit and receive ...

ControlWave EFM Instruction Manual 2-42 Installation Revised Dec-2013 2.9.5 Connections to Ethernet Port on the CPU Module Caution The RJ45 Ethernet port is located on the CPU module (150 MHz version only). The SCM also has one RJ45 port for the optional Display/Keypad. Never connect Ethernet to the...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-43 Table 2-17. 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...

ControlWave EFM Instruction Manual 2-44 Installation Revised Dec-2013 2.10 Expanded Communications Module (ECOM) ControlWave EFM can support up to two optional expanded communications modules (ECOMs) which you can install only in slots #3 or #4 (in place of I/O modules). ECOMSs do not have a CPU com...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-45 SW1 Comm. Port 6/10RS-485 Network Configuration T1 T2 Isolation Transformers for Isolated RS-485 SW2 Comm. Port 7/11 RS-485 Network Configuration O N 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 1-2 Installed = LEDs Enabled2-3 installed = ...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-47 also clock DTE/DCE serial data into (transmit) or out of (receive) the modem at rates up to 115.2 kHz. The factory supplies the modem pre-installed or in kit form with all required hardware. You install it on the ECOM1 module and ...

ControlWave EFM Instruction Manual 2-48 Installation Revised Dec-2013 Figure 2-35. PTSN Field Connections for ControlWave Micros (and EFMs) Figure 2-36. Phone Cord Wiring The 56K PSTN modem is FCC-approved for use with public telephone lines. However, before you place a modem in operation, check the...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-49 o Ringer Equivalence Number (REN): 0.3B Note : The sum of all the RENs on your telephone lines should be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may not be usable o...

ControlWave EFM Instruction Manual 2-50 Installation Revised Dec-2013 Figure 2-37. Bezel Assembly 2.12 Case Mounted Radio/Modem An alternative to using a Type 1 ECOM module with an integrated modem/radio is to order a case-mounted modem/radio. In this configuration, the ControlWave EFM ships from th...

ControlWave EFM Instruction Manual Revised Dec-2013 Installation 2-51 Figure 2-38. Optional 2-Button and 25-Button Keypads Both keypads use the same 4-line by 20-character LCD displays. You connect the keypad to the ControlWave EFM using a cable, one end of which has an RJ-45 jack (connected into th...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-1 Chapter 3 – I/O Modules This chapter discusses the placement and wiring for I/O modules for the ControlWave EFM. The chapter begins with some general instructions on module installation that are common to most I/O modules. The balan...

ControlWave EFM Instruction Manual 3-2 I/O Modules Revised Dec-2013 5. After installing and wiring two I/O modules into adjacent slots in the housing, cover the modules with a protective bezel. The bezels snap on and off for maintenance. 6. Using a PC running the ControlWave Designer and OpenBSI sof...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-3 Figure 3-1. ControlWave EFM Slot Assignments 3.2 Wiring I/O modules support local termination where field wiring connects directly to the module’s removable terminal blocks. ControlWave EFM I/O modules use compression-type terminals...

ControlWave EFM Instruction Manual 3-4 I/O Modules Revised Dec-2013 module assembly between the terminal block and the terminal housing. All I/O wiring should be routed in/out of the enclosure through the 1” NPT conduit hub. Figure 3-2. Module Wiring: Local Termination 3.2.2 Shielding and Grounding ...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-5 3.3 Non-isolated Digital Input/Output (DI/O) Module Non-isolated DI/O modules consist of a digital input/output PCB with two 10-point terminal block assemblies for local termination. The DI/O module also includes 14 configuration ju...

ControlWave EFM Instruction Manual 3-6 I/O Modules Revised Dec-2013 Jumper Purpose Description Pins 2-3 installed = allows software enabling of LEDs W14 Programs Serial EEPROM Reserved for factory use only Wiring the Module Figure 3-3 shows the terminal block assignments for the locally terminated D...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-7 3.4 Non-isolated Analog Input/Output & Analog Input Module Non-isolated Analog Input/Output (AI/O) modules support six externally sourced 4–20mA or 1–5 Vdc single-ended analog inputs and optionally, two independently configurabl...

ControlWave EFM Instruction Manual 3-8 I/O Modules Revised Dec-2013 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 termina...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-9 Figure 3-4. Non-isolated AI/O and AI Module Configuration (Local Termination) Software Configuration To use data from a non-isolated AI/O module you must add a CWM_MA board in ControlWave Designer’s I/O Configurator, and then config...

ControlWave EFM Instruction Manual 3-10 I/O Modules Revised Dec-2013 3.5 Non-isolated High Speed Counter (HSC) Input Module Non-isolated High Speed Counter (HSC) Input modules provide up to four inputs. You can individually configure HSC module inputs for either a 10 KHz (high speed) or 300 Hz (low ...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-11 Wiring the Module Figure 3-5 shows field wiring assignments for the locally terminated HSC module. Figure 3-5. Non-isolated HSC Module (Local Termination) Software Configuration To use data from a high speed counter module you must...

ControlWave EFM Instruction Manual 3-12 I/O Modules Revised Dec-2013 3.6 Non-isolated Mixed I/O (MI/O) Module Non-isolated Mixed I/O (MI/O) modules provide up to six individually field configurable DI/Os, four AIs, two HSC Inputs and, optionally, one AO. MI/O modules consist of an MI/O PCB with two ...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-13 Table 3-8. Jumper Assignments: Non-isolated MI/O Module Jumper Purpose Description W1 1 Configures optional AO for voltage or current output Pins 1-2 installed = Sets AO for current output Pins 2-3 installed = Sets AO for voltage o...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-15 Figure 3-7. Non Isolated Mixed I/O Module Configuration Diagram Software Configuration To use data from a mixed I/O module you must add a CWM_MIX board in ControlWave Designer’s I/O Configurator, and then configure it. See the Cont...

ControlWave EFM Instruction Manual 3-16 I/O Modules Revised Dec-2013 3.7 Resistance Temperature Device (RTD) Inputs on SCM System controller module connector TB2 provides connection to a 3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve). Wire the RTD according to Table 3-9, Figure 3-8 and...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-17 Installing the RTD Probe To install the RTD probe, screw the fitting body into the thermowell with a 7/8” open-end wrench. While you apply pressure against the sheath to force the tip of the RTD probe into the bottom of the thermow...

ControlWave EFM Instruction Manual 3-18 I/O Modules Revised Dec-2013 3.8 Digital to Relay I/O Board Option Digital to relay I/O boards accept up to two discrete input signals from an open drain MOSFET device and convert them to Form C relay output signals using solid state relay (SSR) logic. The min...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-19 You can optionally tie the commons associated with each form C relay (R0COM and R1COM) to the ControlWave EFM power ground or to a floating ground. Jumper W1 is associated with Outputs R0A and R0B and W2 is associated with outputs ...

ControlWave EFM Instruction Manual 3-20 I/O Modules Revised Dec-2013 The DI/DO module (Section 3.3) and the mixed I/O module (Section 3.6) provide independent firmware controlled open drain outputs, which can be used for control or signaling functions (DI/DO Modules provide up to four DO while the m...

ControlWave EFM Instruction Manual Revised Dec-2013 I/O Modules 3-21 Figure 3-12. 3808 Transmitter to ControlWave EFM RS-232 Comm. Cable Diagram Figure 3-13 details RS-485 wiring connections required between the ControlWave EFM and the 3808 transmitter. Note: For loopback and termination control use...

ControlWave EFM Instruction Manual 3-22 I/O Modules Revised Dec-2013 You can connect up to eight (8) Bristol 3808 transmitters to a ControlWave EFM using a half-duplex RS-485 network. See Figure 3- 14 for an illustration of this type of network. Figure 3-14. ControlWave EFM to 3808s - RS-485 Network...

ControlWave EFM Instruction Manual Revised Dec-2013 Operation 4-1 Chapter 4 – Operation This chapter provides general operational details for using the ControlWave EFM. In This Chapter 4.1   Powering Up/Powering Down the ControlWave EFM ..................... 4-1   4.2   Communicating with the Contro...

ControlWave EFM Instruction Manual 4-2 Operation Revised Dec-2013 Recovery mode. Use Recovery mode for a firmware upgrade or a core updump (see Chapter 5 ).  Set SW1-1 (the upper DIP switch) to the Open (right) position and SW1-2 (the lower DIP switch) to the Closed (left) position to place the Con...

ControlWave EFM Instruction Manual Revised Dec-2013 Operation 4-3 Port PCB Default Configuration COM8 ECOM Type 1 or Type 2 RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol COM9 ECOM Type 1 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave D...

ControlWave EFM Instruction Manual 4-4 Operation Revised Dec-2013 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 fil...

ControlWave EFM Instruction Manual Revised Dec-2013 Operation 4-5 2. Download the project according to instructions in the Downloading section of the ControlWave Designer Programmer's Manual (D5125). 3. After the download completes successfully, leave Mode switch (SW1) in local mode . 4.4 Creating a...

ControlWave EFM Instruction Manual 4-6 Operation Revised Dec-2013 Figure 4-2. 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 4-2 we chose the name mynewproj . 3. In the Save as type field, choose Zipped Project Fil...

ControlWave EFM Instruction Manual Revised Dec-2013 Operation 4-7 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 int...

ControlWave EFM Instruction Manual 4-8 Operation Revised Dec-2013 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 F...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-1 Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave EFM. In This Chapter 5.1   Upgrading Firmware .................................................

ControlWave EFM Instruction Manual 5-2 Service & Troubleshooting Revised Dec-2013  Depending on the type of battery holder, either a small flat head screwdriver, or tweezers/needle nose pliers. Note : When you service a ControlWave EFM on site, we recommend that you close down (or place under m...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-3 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 in...

ControlWave EFM Instruction Manual 5-4 Service & Troubleshooting Revised Dec-2013 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...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-5 Figure 5-3. Send File dialog box 9. Exit HyperTerminal and power down the ControlWave EFM. If desired, you can disconnect the null modem cable between the ControlWave EFM and the PC. 10. Set the SCM’s mode switch (...

ControlWave EFM Instruction Manual 5-6 Service & Troubleshooting Revised Dec-2013 Caution Field repairs to ControlWave EFMs are strictly limited to the replacement of complete modules. Replacing module components constitutes tampering and violates the product warranty. Return defective modules o...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-7 7. Replace any communication cables, apply power, and test the module. 5.2.4 Removing/Replacing the SCM Use this procedure to remove or replace the System Controller Module (SCM). 1. If the EFM is running, place an...

ControlWave EFM Instruction Manual 5-8 Service & Troubleshooting Revised Dec-2013 8. Apply power and test the unit. 5.2.6 Removal/Replacement of an Expansion Communication Module Use this procedure to remove or replace an expansion communication (ECOM) module. 1. If the EFM is running, place any...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-9 5. To replace the battery, align the unit so that the negative battery terminal is oriented to the top and right as illustrated in Figure 2-15 and place the battery into the battery mounting bracket (battery clamp ...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-11 The CPU module accommodates a lithium coin cell backup battery housed in a coin-cell socket (S1). A supervisory circuit on the CPU switches to battery power when the regulated 3.3 Vdc falls out of specification. T...

ControlWave EFM Instruction Manual 5-12 Service & Troubleshooting Revised Dec-2013 Removing / Replacing the Battery – Clip Type Holder Battery Part Numbers: BR2330, BR2335, BR2335-B 1. If the EFM is running, place any critical control processes under manual control. 2. Remove power from the Cont...

ControlWave EFM Instruction Manual 5-14 Service & Troubleshooting Revised Dec-2013 SCM System Status LED Codes As the EFM runs its application, status codes post to the six LEDs on the SCM. Table 5-2 provides activity descriptions of the LEDs; Figure 5-5 shows what the LEDs look like for each he...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-15 Figure 5-5. SCM Status LED Hexadecimal Codes CPU Module LEDs The CPU module has six comm port activity LEDs on the CPU board. Units equipped with an Ethernet port have two additional LEDs located on the Ethernet R...

ControlWave EFM Instruction Manual 5-16 Service & Troubleshooting Revised Dec-2013 Figure 5-6. CPU Module Comm Connectors and LEDs

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-17 Comm. Port 4 Sta tus LEDs Comm. Port 7 Sta tus LEDs Comm. Port 6 Sta tus LEDs Comm. Port 5 Sta tus LEDs Comm. Port 4 RS-232 Comm. Port 5 RS-485 Comm. Port 6 Ra d io Comm. Port 7 Mod em Tra nsmit LEDs SLOT # 3 SLOT...

ControlWave EFM Instruction Manual 5-18 Service & Troubleshooting Revised Dec-2013 Figure 5-9. I/O Module LEDs 5.3.2 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 res...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-19  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 in...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-21 Figure 5-10. NetView 2. Select Start > Programs > OpenBSI Tools > Common Tools > Diagnostics . The Main Diagnostics menu ( Figure 5-11 ) displays. Figure 5-11. WINDIAG Main Diagnostics Menu 3. Select t...

ControlWave EFM Instruction Manual 5-22 Service & Troubleshooting Revised Dec-2013 5. Set switch SW2-8 on the CPU module to ON (open). The EFM should resume normal operation. 5.4.1 Available Diagnostics Using WINDIAG, you can test all EFM modules with the exception of the SCM. WINDIAG’s Main Dia...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-23 Figure 5-13. RS-485 Loop-back Plug These tests verify the correct operation of the serial ports. Note : You cannot test a communications port while you are using it. You can only test currently unused ports. After...

ControlWave EFM Instruction Manual 5-24 Service & Troubleshooting Revised Dec-2013 Figure 5-14. 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 whi...

ControlWave EFM Instruction Manual Revised Dec-2013 Service & Troubleshooting 5-27 3. Connect the ControlWave EFM’s Comm Port 1 to a PC using a null modem cable. 4. If the SCM’s mode switch has a Run/Remote/Local switch, set it as follows. Set both SW1-1 and SW1-2 to the right (open) operation o...

ControlWave EFM Instruction Manual Revised Dec-2013 Appendix A A-1 Appendix A – ControlWave EFM Electronic Flow Meter – Special Instructions for Class I, Division 2 Hazardous Locations 1. The ControlWave Electronic Flow Meter (EFM) is listed by Underwriters Laboratories (UL) as nonincendive and is s...

ControlWave EFM Instruction Manual A-4 Appendix A Revised Dec-2013 Module/Item Connector Wiring Notes TB5 – 2-pin terminal block TB6 – 2pin terminal block Fused Power Out 2 – Factory wired * Fused Power Out 3 – Factory wired * 21V Power Supply Board (See warning #1 and item 9 of this appendix) TB1 –...

ControlWave EFM Instruction Manual Revised Dec-2013 Modem Installation D-1 Appendix D – Modem Installation D2.1 Modem Installation & Configuration D2.1.1 Installing an Internal MultiTech Modem (MT9234SMI) To install a Model MT9234SMI Modem onto an ECOM Module, perform the following steps: Remove...

ControlWave EFM Instruction Manual D-2 Modem Installation Revised Dec-2013 Figure D2. MultiTech Modem Installation Diagram Note: If necessary, you can use a small screwdriver to pry the cover panel from the PCB. 2. Install the nylon support post included in the kit onto the ECOM Module.

ControlWave EFM Instruction Manual Revised Dec-2013 Modem Installation D-3 3. Mount the MultiTech Modem to the ECOM Module making sure that the interface connectors (J6, J7, J9 & J10 on the ECOM Module) align. 4. Plug the antenna cable(s) (if present - removed in Step 2) into the appropriate RF ...

ControlWave EFM Instruction Manual Revised Dec-2013 Appendix Z Z-1 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 ...

ControlWave EFM Instruction Manual Revised Dec-2013 Index IND-1 Index A ACCOL3 Firmware Library ................................. 1-9 Analog averaging .............................................. 1-12 B Backplanes ......................................................... 1-3 Backups .................