Instruction Manual Doc Number CI-ControlWave EFM Part Number D301383X012 December 2013 ControlWave® EFM (Electronic Flow Meter) Remote Automation Solutions www.EmersonProcess.
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.
ControlWave EFM Instruction Manual Contents Chapter 1 – Introduction 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1-1 Scope of the Manual ...............................................................................................................1-2 Physical Description ...............................................................................................................1-3 Housings and Enclosure .......................................................................................................
ControlWave EFM Instruction Manual 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.2.1 Local Termination ....................................................................................................... 3-3 3.2.2 Shielding and Grounding ........................................................................................... 3-4 Non-isolated Digital Input/Output (DI/O) Module ................................................................. 3-5 Non-isolated Analog Input/Output & Analog Input Module ................
ControlWave EFM Instruction Manual 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 used with the EFM, refer to Getting Started with ControlWave Designer (D5085), the ControlWave Designer Programmer’s Handbook (D5125), and the online help in ControlWave Designer.
ControlWave EFM Instruction Manual 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 contains the following chapters: 1-2 Chapter 1 Introduction Provides an overview of the hardware and general specifications for the ControlWave EFM.
ControlWave EFM Instruction Manual 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 Troubleshooting Provides information on service and troubleshooting procedures. 1.2 Physical Description ControlWave EFMs are furnished in a NEMA 3X rated Hoffman® enclosure.
ControlWave EFM Instruction Manual 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 connects internally to RS-232 communication port 1 for local communications. The front cover includes a liquid crystal display (LCD) and keypad for local operator access. 1.
ControlWave EFM Instruction Manual 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 battery provides backup power for the real-time clock and the system’s Static RAM (SRAM).
ControlWave EFM Instruction Manual 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).
ControlWave EFM Instruction Manual 1.6 Expansion Communications Modules Expansion Comm. Modules provide two additional serial communications ports and optionally the choice of a piggy-backed dialline modem or piggy-backed 900 MHz Spread Spectrum radio (or both). The top port (labeled C1) supports RS-232 operation while the second one (labeled C2) supports RS-485 operation. You can optionally order the RS-485 port with isolation to 500Vdc.
ControlWave EFM Instruction Manual 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 shows a typical I/O module housing. Configuration jumpers on I/O modules accommodate individual field I/O user configuration. Terminations are pluggable and accept a maximum wire size of #14 AWG.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 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).
ControlWave EFM Instruction Manual 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 computer and all its associated meter runs. Each meter run refers to measurement of natural gas through a single pipeline. The ControlWave EFM supports up to four meter runs. Meter runs can use orifice, turbine, or ultrasonic meters.
ControlWave EFM Instruction Manual 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 complete flow calculation using the process variables every second. Each calculation includes instantaneous rate according to API 14.
ControlWave EFM Instruction Manual 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 integrates and accumulates volume and energy at the end of every calculation cycle. The application calculates the volume for a cycle by multiplying the calculated rate by the flow time for that cycle.
ControlWave EFM Instruction Manual 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 Utilities Manual (D5081) for help on interpreting audit records.
ControlWave EFM Instruction Manual 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 change the contract hour so the contract gas day starts at some time other than midnight. The daily log holds 62 entries; this ensures that the previous calendar month of daily data is always resident in flash memory.
ControlWave EFM Instruction Manual 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 to detect the presence of natural gas in the event of a gas leak. 1.9.
ControlWave EFM Instruction Manual 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 Chapter 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................
ControlWave EFM Instruction Manual Caution To ensure safe use of this product, please review and follow the instructions in the following supplemental documentation: Specifications for Temperature, Humidity and Vibration 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) See document 1660DS-5i available on our website for detailed technical specifications fo
ControlWave EFM Instruction Manual Figure 2-1.
ControlWave EFM Instruction Manual Figure 2-2.
ControlWave EFM Instruction Manual 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 mode switch as needed, then re-install it in chassis slot 1. (See Section 2.5.) 3. Remove the CPU, enable the backup battery jumper and set switches as needed then re-install it in chassis slot 2. (See Section 2.9.) 4.
ControlWave EFM Instruction Manual 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 to re-install modules into the housing, follow these guidelines: Notes: Do not install modules in the housing until you mount and ground the housing at the designated installation site.
ControlWave EFM Instruction Manual 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 Revised Dec-2013 You must position the ControlWave EFM vertically with the transducer (MVT) at its base. Make sure clearances are adequate so that you can open the door, and ensure the front of the assembly is visible and accessible for service, installation, and for operator access to the LCD display/keypad.
ControlWave EFM Instruction Manual You can mount the unit to a wall, or to a vertical 2 inch pipe clamped at the rear of the unit with two clamps and four bolts. You must anchor the pipe in cement deep enough to conform to local building codes associated with frost considerations. If your unit requires a solar panel, make sure there is sufficient clearance. You can mount the solar panel to the same 2” pipe that secures the unit.
ControlWave EFM Instruction Manual Figure 2-5.
ControlWave EFM Instruction Manual Figure 2-6.
ControlWave EFM Instruction Manual Figure 2-7.
ControlWave EFM Instruction Manual Figure 2-8.
ControlWave EFM Instruction Manual 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 an added precaution, run a #14 AWG wire from SCM power connector TB1-3 (chassis ground) to the same known good earth ground.
ControlWave EFM Instruction Manual 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 damage the sensor module assembly during this procedure. Once you position the flange, tighten the bolts in an alternating sequence to about 20-30 foot-pounds of torque.
ControlWave EFM Instruction Manual 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 run between the EFM’s ground lug and Earth ground (rod or bed) even though the ControlWave EFM’s multivariable transducer (MVT) may be grounded to the pipeline.
ControlWave EFM Instruction Manual Transducer to Manifold Dielectric Isolation Kit Multivariable Transducer (MVT) Dielectric Gasket & Flange Seals (2) AWG 4 Ground Wire Valve Block Manifold Top Washers (4) Dielectric Bolt Sleeves (4) Isolating Fittings Bottom Washers (4) Mounting Bolts (4) 2” Pipe-mounting Package Note: Mounting Pipe does not contact the Main Pipeline. Ground Rod or System Clamp(s) Figure 2-11.
ControlWave EFM Instruction Manual 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 the strength of the pipe stand. See F1670SS-0a for information on PGI direct mount systems and manifolds. 2.
ControlWave EFM Instruction Manual WATCHDOG LED JP5, JP6, JP7, JP8 & JP9 1-to-2 Installed = 12V Bulk System 2-to-3 Installed = 6V Bulk System (Red) CR27 IDLE LED (Red) CR26 CR25 CR24 Staus LEDs (Red) 1 JP6 JP7 1 1 JP5 JP8 1 JP9 1 SW1 = Mode Switch J2 Display Intf. Connector 2 J2 RJ-45 TB1 Input Power Connector 1A P1 TB2 RTD Interface Connector P2 MVT Interface Connector (+4.5/4.9Vdc to +16.0Vdc for +6V supply) TB1-1 +VIN (+9.6/10.3Vdc to +16.
ControlWave EFM Instruction Manual 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 whether your external DC bulk power supply provides +12V or +6V. See Section 2.5.3. 3. If your SCM includes a mode switch (SW1) set it according to Section 2.5.4. 4. Slide the SCM into slot #1 of the housing. 5.
ControlWave EFM Instruction Manual 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 Activates Local mode, used for (Open) and lower switch (SW-2) set to normal operation. (This is the factory left (Closed) default) Note: Only the SCM SW1 switch settings listed in the table have been tested. 2.5.
ControlWave EFM Instruction Manual 2.5.6 Wiring a Bulk DC Power Supply to the SCM 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 terminal block connectors TB1 to the SCM until after you install, wire, and configure the CPU module. Caution Follow the instructions in Section 2.5.5 General Wiring Guidelines when wiring connections.
ControlWave EFM Instruction Manual Terminal Block Unplug removable connector TB1 from the SCM and wire DC power to Connector TB1 the connector. We recommend you do not plug the connector back into the SCM until the CPU module is already installed in the housing. TB1 provides three input connections for bulk DC power: TB1-1: (+VIN) (+4.5V/4.9V to +16V dc for +6V supply) (+9.6/10.
ControlWave EFM Instruction Manual A A B B D C E Note 2: Item D slots accommodate Tilt Angle Adjustment. A A NOTE 1: To Attach item C to item D: Slide two bolts (A) through the top and bottom Solar Panel (Centered) Channel Holes. Affix item C to item D via 2 sets of item A hardware as follows: Flat Washer, Lock Washer & Hex Nut (Max. Torque = 120 Inch-Pounds). A B A E C B D Adjustable Tilt Angle A E Vertical Pole A - 6 places consists of the following hardware: A A D A B 5/16-18 x .
ControlWave EFM Instruction Manual Table 2-3. Solar Panel Tilt Angle Latitude 0-4° Tilt Angle 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 Internally, you connect the solar panel wires directly to the rechargeable Solar Panel to lead acid battery: the Lead Acid PWR (red wire) terminal Battery GND (black wire) terminal See Section 2.6.
ControlWave EFM Instruction Manual Figure 2-15.
ControlWave EFM Instruction Manual 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 Relay I/O Board Case-mounted radio or modem The power distribution board, as well as the 21V power supply board and the digital to relay I/O board mount inside the enclosure using a Snap Track and dual PCB mounting bracket. Figure 2-16.
ControlWave EFM Instruction Manual 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 - Fused Power Output 3: (two-conductor) (optional use - similar to TB5) TB6-1 = FPWR3+ to Radio/Modem Power+ TB6-2 = FPWR3– to Radio/Modem Power– (PWR GND) Note: Fuse F1 is rated at 1.5A and protects the solar panel regulator circuitry.
ControlWave EFM Instruction Manual 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. The 21V power supply has two terminal blocks that accommodate power connections between the EFM and the remote transmitters. TB1 is a three-position terminal block that provides input power from the power distribution board (see Section 2.7).
ControlWave EFM Instruction Manual 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 components) with the Expansion Communication module (ECOM), which does not have a CPU component or a battery backup but does have additional communication components. Identify the carton holding the CPU module and remove it from that carton.
ControlWave EFM Instruction Manual 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 JPn) when n in the jumper number. See Figure 2-19 or Figure 2-20 to locate the jumpers. Note: When present, jumpers 1, 2, 3, 5, 6, and 9 (JP1, JP2, JP3, JP5, JP6, and JP9) are reserved for factory use only. Do not alter these jumpers from their factory settings.
ControlWave EFM Instruction Manual 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 install the CPU module by placing JP8 on pins 1-2. Jumper 8 (JP8) enables/disables the lithium backup battery on the CPU module. Pins 1-2: Enables the CPU module’s backup battery.
ControlWave EFM Instruction Manual Table 2-6. CPU Module Switch SW2 SW2 Setting Function Mode 1 Watchdog Enable Controls whether the system enters a watchdog state 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 Soft Switches Controls the ability to modify soft switches, other configurations, and flash files.
ControlWave EFM Instruction Manual Notes: Table 2-7 describes switch settings for the RS-485 port. You may want to review Section 2.9.4 Connections to RS-485 Serial Port(s) before you set these switches. Table 2-7 applies to the following switches: o SW3 on CPU Module – controls COM3 o SW1 on Type 1 ECOM Module – controls COM5/COM9 o SW1 on Type 2 ECOM Module – controls COM6/COM10 o SW2 on Type 2 ECOM Module – controls COM7/COM11 Table 2-7.
ControlWave EFM Instruction Manual 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 RS-232 ports. If you require additional RS-232 ports, you can purchase an optional expansion communication module that can include either one (ECOM Type 1) or two (ECOM Type 2) RS-232 ports.
ControlWave EFM Instruction Manual RS-232 COM For the ControlWave EFM, half-duplex communications use Modbus or Port Cables BSAP protocol, while full-duplex communications use point-to-point protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 222) to connect with other devices (such as a PC, a printer, another ControlWave [except the CW_10/30/35]) when the ControlWave EFM uses the full-duplex PPP protocol.
ControlWave EFM Instruction Manual 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_10/30/35). 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 2-23. Figure 2-23.
ControlWave EFM Instruction Manual 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 Figure 2-25 along with the cable shown in Figure 2-22 or Figure 2-23. Figure 2-25. Full-duplex and Half-duplex Cable If you use the local port circular connector see Figure 2-26, Figure 2-27 and Table 2-11. Figure 2-26.
ControlWave EFM Instruction Manual Figure 2-27. PC Connected to ControlWave EFM via Circular Local Port (use Cable P/N 395402-018 [10 foot cable] or P/N 395402-02-6 [25 foot cable]) Table 2-11.
ControlWave EFM Instruction Manual 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 is always ON. Ensure that DTR is always high when port is active; DTR enables RS-232 transceivers. Note: Control DTR using the PORTCONTROL function block and the _Pn_AUTO_DTR system variable in your ControlWave project.
ControlWave EFM Instruction Manual Table 2-12. RS-485 Connectors on CPU Connector Name # Pins Function Notes J5 COM3 9-pin 9-pin male D-sub (RS-485) See Figure 2-19 and Figure 2- 20. Table 2-13. RS-485 Connectors on Type 1 Expansion Communications Modules Connector Name # Pins Function Notes J5 COM5 (when in slot 3) 9-pin 9-pin male D-sub (RS-485) See Figure 2-31 & Table 2-14 COM9 (when in slot 4) Only available on ECOM Type 2 models. Table 2-14.
ControlWave EFM Instruction Manual 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 data on opposite lines; all slaves (from the first to the nth) are paralleled (daisychained) 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).
ControlWave EFM Instruction Manual 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 Display/Keypad port or damage to the SCM will result. ControlWave EFMs can support up to two Ethernet ports. These use a 10/100Base-T RJ-45 modular connector that provides a shielded twisted pair interface to an Ethernet hub.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 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 component.
ControlWave EFM Instruction Manual Transmit LEDs Receive LEDs Comm. Port 4/8 CR1 1-2 Installed = LEDs Enabled 2-3 installed = LEDs Disabled W1 1 W2 for Comm. Port 4/8 W1 Comm. Port 4/8 RS-232 J4 Comm. Port 5/9 2 1 W2 1-2 Installed = Loopback Disabled & 2-3 installed = RTS/CTS Loopback W3 CR2 W3 for Comm. Port 5/9 P1 1 J2 - for Factory Use ONLY Comm. Port 5/9 RS-232 J5 Comm. Port 6/10 CR3 T1 Comm. Port 6/10 RS-485 J6 O N 1 2 3 4 5 6 7 8 SW1 Comm.
ControlWave EFM Instruction Manual When connecting a ControlWave EFM to an external (case-mounted) modem, use the cable configuration in Figure 2-33. Figure 2-33. Full-duplex and Half-duplex Cable Figure 2-34. ECOM Modem Installation 2.10.3 Modem Port (Type 1 ECOM only) You can mount an optional 56Kb PSTN Hayes-type modem on a Type 1 ECOM (see Figure 2-34). The ControlWave EFM then assigns the modem COM7 (if in slot #3) or COM11 (if in slot #4).
ControlWave EFM Instruction Manual 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 then use the Ports page in the Flash Configuration utility (in NetView, LocalView, or TechView) to assign ports. Configure a profile for the modem using AT commands submitted using a terminal emulation program (such as HyperTerminal).
ControlWave EFM Instruction Manual 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 following items to make sure you meet all FCC requirements: 2-48 Connections to party line service are subject to state tariffs. Connections to telephone company-provided coin service (central office implemented systems) are prohibited.
ControlWave EFM Instruction Manual 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 on a given line. Make any direct connections to PSTN lines through standard plugs and jacks as specified in the FCC rules. The PSTN line connector plugs into J1 on the modem.
ControlWave EFM Instruction Manual 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 the factory with a user selected radio or modem installed within the enclosure (beneath the battery mounting bracket) or as a radio-ready unit, in other words, ready for field installation of a factory-supplied radio.
ControlWave EFM Instruction Manual 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 the RJ-45 equipped with two plugs). This cable connects between the RJ-45 display jack (J2) on the SCM module and RJ-45 jack (J1) on the remote Display/Keypad assembly.
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ControlWave EFM Instruction Manual 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 balance of the chapter includes specific details for configuring and wiring each type of I/O module. In This Chapter 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Module Placement ...........................................................................
ControlWave EFM Instruction Manual 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 software, configure the ControlWave EFM to accept the new I/O modules and download the revised ControlWave project.
ControlWave EFM Instruction Manual 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 that accommodate up to #14 AWG wire. Consult with the field device manufacturer for recommendations if using smaller wire sizes. Insert the wire’s bared end (approx. ¼” max) into the clamp beneath the screw and secure the wire.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 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 jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly. The DI/O module connects with the backplane using a 36-pin gold-plated cardedge connector.
ControlWave EFM Instruction Manual Jumper W14 Purpose Description Pins 2-3 installed = allows software enabling of LEDs Programs Serial EEPROM Reserved for factory use only Wiring the Module Figure 3-3 shows the terminal block assignments for the locally terminated DI/O module. Figure 3-3. Non-isolated DI/O Module (Local Termination) Software Configuration To use data from a non-isolated DI/O module you must add a CWM_MD board in ControlWave Designer’s I/O Configurator, and then configure it.
ControlWave EFM Instruction Manual 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 configurable 4–20 mA or 1–5 Vdc analog outputs. Non-isolated Analog Input (AI) modules are identical to AI/O modules but have a depopulated AO section.
ControlWave EFM Instruction Manual 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). Setting Jumpers AI/O and AI modules have jumpers you can use to configure each of the six AIs.
ControlWave EFM Instruction Manual 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 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 these modules.
ControlWave EFM Instruction Manual 3.5 Non-isolated High Speed Counter (HSC) Input Module Non-isolated High Speed Counter (HSC) Input modules provide up to four inputs.
ControlWave EFM Instruction Manual 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 add a CWM_HSC4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
ControlWave EFM Instruction Manual 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 10-point terminal block assemblies (TB1 and TB2) for local termination, 28 configuration jumpers, and a module cover. The MI/O PCB connects to the backplane using a 36-pin gold-plated card-edge connector.
ControlWave EFM Instruction Manual Table 3-8.
ControlWave EFM Instruction Manual Figure 3-6.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 3.7 Resistance Temperature Device (RTD) Inputs on SCM System controller module connector TB2 provides connection to a 3wire 100 ohm platinum bulb RTD (using the DIN 43760 curve). Wire the RTD according to Table 3-9, Figure 3-8 and Figure 3-9. In this configuration, the return lead connects to the RTD- terminal and the two junction leads (Sense and Excitation) connect to the RTD+ and RTD EXC terminals.
ControlWave EFM Instruction Manual Installing the RTD To install the RTD probe, screw the fitting body into the thermowell Probe 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 thermowell (so that the probe tip is in contact with the bottom of the thermowell), tighten the 9/16” nut using an open-end wrench against the 7/8” fitting body. Figure 3-9.
ControlWave EFM Instruction Manual 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 minimum current load will be 100mA. Figure 3-10 provides a component view of the Digital to Relay I/O Board.
ControlWave EFM Instruction Manual 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 R1A and R1B. When you install jumper W1, it ties the common (C) associated with outputs R0A and R0B to ControlWave EFM power ground; when jumper W1 is not installed, the common is floating.
ControlWave EFM Instruction Manual 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 mixed I/O module provides up to 6 DO). Each output is wired to the source terminal of an N Channel MOSFET capable of switching up to 16 Volts at up to 100mA. When closed, the FET shorts the output to ground with resistance of .5 Ohms or less.
ControlWave EFM Instruction Manual 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 switch SW3 on the CPU module to configure COM3. Use switch SW1 on the ECOM module to configure COM5 or COM9. Figure 3-13. 3808 Transmitter to ControlWave EFM RS-485 Comm.
ControlWave EFM Instruction Manual You can connect up to eight (8) Bristol 3808 transmitters to a ControlWave EFM using a half-duplex RS-485 network. See Figure 314 for an illustration of this type of network. Figure 3-14.
ControlWave EFM Instruction Manual Chapter 4 – Operation This chapter provides general operational details for using the ControlWave EFM. In This Chapter 4.1 4.2 4.3 4.4 Powering Up/Powering Down the ControlWave EFM .....................4-1 Communicating with the ControlWave EFM ....................................4-2 4.2.1 Default Comm Port ...............................................................4-2 4.2.2 Changing Port Settings ........................................................4-3 4.2.
ControlWave EFM Instruction Manual 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 ControlWave EFM in Local mode, which is used for normal running operations. Figure 4-1. Mode Switch 4.
ControlWave EFM Instruction Manual 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 Designer protocol ECOM Type 2 RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol ECOM Type 1 Radio port ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designe
ControlWave EFM Instruction Manual 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.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual 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. 4.4.2 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.
ControlWave EFM Instruction Manual 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. 4.4.3 Backing up Data You can back up certain types of data and restore it if needed.
ControlWave EFM Instruction Manual Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave EFM. In This Chapter 5.1 5.2 5.3 5.4 5.5 Equipment Upgrading Firmware ........................................................................5-2 Removing or Replacing Components ..............................................5-5 5.2.1 Accessing Modules for Testing ............................................5-6 5.2.2 Removing/Replacing the Bezel ..
ControlWave EFM Instruction Manual 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 manual control) any associated processes. This precaution prevents any processes from accidentally running out of control when you conduct tests.
ControlWave EFM Instruction Manual 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.
ControlWave EFM Instruction Manual 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). Figure 5-2. HyperTerminal (Ready to Download) 8. 5-4 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 “CWExxxxx.
ControlWave EFM Instruction Manual 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 (SW1) for Local Mode, i.e., SW1-1 in the OPEN (Right) position and SW1-2 in the CLOSED (Left) position or if CPU Module Switch SW1-3 was set for Recovery Mode, set it to the OFF position (OFF = Recovery Mode Disabled). 11.
ControlWave EFM Instruction Manual 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 or housings to the factory for authorized service. 5.2.1 Accessing Modules for Testing Only technically qualified personnel should test and/or replace EFM modules. Read completely the disassembly and test procedures described in this manual before starting.
ControlWave EFM Instruction Manual 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 any critical control processes under manual control and shut down the unit by disconnecting power from the SCM. 2. Unplug the SCM’s modular connectors. 3.
ControlWave EFM Instruction Manual 8. 5.2.6 Apply power and test the unit. Removal/Replacement of an Expansion Communication Module Use this procedure to remove or replace an expansion communication (ECOM) module. 5.2.7 1. If the EFM is running, place any critical control processes under manual control and shut down the unit by disconnecting power from the SCM. 2. Disconnect any ECOM module communication cables.
ControlWave EFM Instruction Manual 5.2.8 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 215 and place the battery into the battery mounting bracket (battery clamp must be in the released position. 6. Raise the battery clamp and rotate it forward until you can lower it to secure the rechargeable lead-acid battery. Tighten the two 11/32” nuts on the ends of the battery clamp. 7.
ControlWave EFM Instruction Manual 5.2.10 Removal/Replacement of a Digital to Relay I/O Board Use this procedure to remove or replace the optional digital to relay I/O board. 1. If the EFM is running, place any critical control processes under manual control and shut down the unit by disconnecting power from the SCM. 2. Unplug wiring harnesses from digital to relay I/O board connector J1. 3. Slide the digital to relay I/O board toward the front of the unit and remove it from its snap track holder. 4.
ControlWave EFM Instruction Manual 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. The battery then provides backup power for the real-time clock (RTC) and the system SRAM on the CPU module. Caution You lose SRAM contents when you remove the backup battery. If you replace a backup battery, wait at least one minute before repowering the system.
ControlWave EFM Instruction Manual 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 ControlWave EFM. 3. Remove the CPU module from the housing. 4. To remove the lithium battery, gently pry up the tab holding the battery in the coin cell socket and remove the battery with a pair of tweezers or needle-nosed pliers. Install the replacement battery.
ControlWave EFM Instruction Manual Module LED Name LED Color Function SCM 6 STATUS Red See Table 5-2 and Figure 5-5 CPU C1 RX (Comm 1) Red ON = RX activity (top left; see Figure 5-6) CPU C1 TX (Comm 1) Red ON = TX activity (top right; see Figure 5-6) CPU C2 RX (Comm 2) Red ON = RX activity (middle left; see Figure 5-6) CPU C2 TX (Comm 2) Red ON = TX activity (middle right; see Figure 5-6) CPU C3 RX (Comm 3) Red ON = RX activity (bottom left; see Figure 5-6) CPU C3 TX (Comm 3) R
ControlWave EFM Instruction Manual SCM System As the EFM runs its application, status codes post to the six LEDs on Status LED the SCM. Table 5-2 provides activity descriptions of the LEDs; Figure Codes 5-5 shows what the LEDs look like for each hex code. Table 5-2.
ControlWave EFM Instruction Manual Figure 5-5. SCM Status LED Hexadecimal Codes CPU Module The CPU module has six comm port activity LEDs on the CPU board. LEDs Units equipped with an Ethernet port have two additional LEDs located on the Ethernet RJ-45 connector. Table 5-3 details assignments for the LEDs on the CPU module. An ON LED indicates an associated transmit (TX) or receive (RX) activity. Table 5-3.
ControlWave EFM Instruction Manual Figure 5-6.
ControlWave EFM Instruction Manual SLOT # 3 Receive LEDs SLOT # 4 Transmit LEDs Comm. Port 4 Status LEDs Comm. Port 8 Status LEDs Comm. Port 5 Status LEDs Comm. Port 9 Status LEDs Comm. Port 6 Status LEDs Comm. Port 10 Status LEDs Comm. Port 7 Status LEDs Comm. Port 11 Status LEDs Comm. Port 4 RS-232 Comm. Port 8 RS-232 Comm. Port 5 RS-485 Comm. Port 9 RS-485 Comm. Port 6 Radio Comm. Port 10 Radio (Radio no longer offered) (Radio no longer offered) Comm. Port 7 Modem Comm.
ControlWave EFM Instruction Manual 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 respective terminal blocks (see Figure 3-2 for wiring diagrams). 5.3.3 Calibration Checks To calibrate the MVT and the RTD, use TechView software. See the TechView User’s Guide (D5131) for more information. 5.3.
ControlWave EFM Instruction Manual 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 EFM is compatible with the range of IP addresses defined for the communication line on which the unit resides.
ControlWave EFM Instruction Manual Port Module Default Configuation COM3 CPU RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol. COM4 ECOM Types 1 or 2 RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol. COM5 ECOM Type 1 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol. ECOM Type 2 RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol.
ControlWave EFM Instruction Manual 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 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 EFM units to test.
ControlWave EFM Instruction Manual 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 Diagnostics Menu (see Figure 5-11) provides the following diagnostic selections: Port Loop-back Test Option Tests CPU & Peripherals Checks the CPU module (except for RAM & PROM). Analog Output Checks AOs on AI/O, AO, or Mixed I/O modules.
ControlWave EFM Instruction Manual 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 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 comm ports.
ControlWave EFM Instruction Manual 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 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.
ControlWave EFM Instruction Manual Figure 5-15. 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.
ControlWave EFM Instruction Manual 4. Enter 1 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.
ControlWave EFM Instruction Manual 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 or both to the left (closed). 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. 5.
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ControlWave EFM Instruction Manual 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 suitable for use in Class I, Division 2, Groups C and D hazardous locations or non-hazardous locations only. Read this appendix carefully before installing a nonincendive ControlWave Electronic Flow Meter (EFM).
ControlWave EFM Instruction Manual 7. The UL listed nonincendive ControlWave EFM may include radio/modem communications (listed on the model spec.) that is used in conjunction with a 30W Solar Panel and 12V, 33AH Lead Acid Battery System. Connection to the radio or modem is approved as a nonincendive circuit, so that Division 2 wiring methods are not required. 8. The UL listed nonincendive ControlWave EFM may include a Digital to Relay I/O Board (option).
ControlWave EFM Instruction Manual Table A-1. Module/Board Customer Wiring Connectors Module/Item CPU Module CPU Module Connector J3 – COM1, 9-pin Male Dsub J4 – COM2, 9-pin Male Dsub RS-232 J5 – COM3, 9-pin Male Dsub RS-485 Wiring Notes Factory connected to local comm. port. Refer to item 3 of this appendix. Remote comm. port: For radio or external network comm. Refer to model spec. and item 6 of this appendix. When used for network comm., use Div 2 wiring methods.
ControlWave EFM Instruction Manual Module/Item Connector TB5 – 2-pin terminal block TB6 – 2pin terminal block Wiring Notes 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 – 3-pin terminal block TB2 – 4-pin terminal block 12V power input – Factory wired * 21V Transmitter Power – Field wired TB2 is unrated, use Div. 2 wiring methods. Enclosure bottom Local Port circular connector Local comm.
ControlWave EFM Instruction Manual 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 the ECOM Module from the controller (see Figure D1). Figure D1. Expansion Comm. Module Component Identification Diagram 1. Unplug the antenna cable from the RF Connector on any installed radio module. Grasp the ECOM Module with one hand.
ControlWave EFM Instruction Manual 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 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 connector of an installed radio module(s). 5. Snap the cover panel onto the ECOM Module PCB and insert the ECOM Module into the appropriate backplane slot, i.e., Slot 3 or 4. 6. Apply power and test the unit. D2.1.
ControlWave EFM Instruction Manual 5. D-4 Bits per second: 9600 Data bits: 8 Parity: None Stop bit: 1 Flow Control: None Send Factory Default AT&F0. Disable Flow Control AT&K0. Set baud rate using AT Command for example: AT$SB9600, (Modify for whatever baud rate you require.) Write to memory AT&W. Set ECOM Module configuration jumper JP2 into a storage position.
ControlWave EFM Instruction Manual 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 Description DURACELL (DL 2032) http://www.duracell.com PANASONIC (CR 2032) LITHIUM MANGANESE DIOXIDE COIN CELL BATTERY Emerson Part Number & Media Notes W15020X0012 http://www.panasonic.
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ControlWave EFM Instruction Manual Index A D ACCOL3 Firmware Library ................................. 1-9 Analog averaging .............................................. 1-12 Defaults Comm Ports .................................................... 4-2 Diagnostic software........................................... 5-19 Digital to relay I/O board removing and replacing ................................ 5-10 Disconnecting RAM Battery ..................... 5-11, 5-12 Display/Keypad .........................
ControlWave EFM Instruction Manual 2-11. ControlWave EFM Remote Installation with Cathodic Protection .................................... 2-16 2-12. System Controller Module Component ID Diagram ...................................................... 2-18 2-13. SCM TB1 Wiring ................................. 2-22 2-14. 30 or 40 Watt Solar Panel Mounting Diagram ...................................................... 2-23 2-15. Enclosure with Sealed Lead-acid Battery Installed ...............................
ControlWave EFM Instruction Manual L Lead acid battery removing and replacing .................................. 5-8 LEDs Checking....................................................... 5-12 CPU module ................................................. 5-15 LocalView............................................................ 5-3 Loop-back Test ........................................ 5-22, 5-23 S M Material Safety Data Sheets (MSDS) how to obtain ..................................................
ControlWave EFM Instruction Manual 2-14. RS-485 Connectors on Type 2 ECOM 2-40 2-15. RS-485 Port Connector Pin Assignment .240 2-16. RS-485 Network Connections............. 2-41 2-17. Ethernet 10/100Base-T CPU Module Pin Assignments ............................................... 2-43 4-1. Default Comm Port Settings (by PCB) .... 4-2 5-1. LED Assignments on Modules .............. 5-12 5-2. System Status LED Codes on SCM ..... 5-14 5-3. CPU Module LEDs ................................ 5-15 5-4.
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ControlWave EFM CI-ControlWave EFM Instruction Manual December 2013 Headquarters: Emerson Process Management Remote Automation Solutions 6005 Rogerdale Road Houston, TX 77072 U.S.A. T +1 281 879 2699 | F +1 281 988 4445 www.EmersonProcess.com/Remote Europe: Emerson Process Management Remote Automation Solutions Unit 8, Waterfront Business Park Dudley Road, Brierly Hill Dudley UK DY5 1LX T +44 1384 487200 | F +44 1384 487258 www.EmersonProcess.
