Bristol PIP CW_30 DPC 3330 Upgrade Kit Control Wave D301437x012

User Manual: Bristol ControlWave CW_30

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www.EmersonProcess.com/Bristol

Product Information Package

PIP-CW_30 Upgrade Kit

Mar., 2007

CW_30 Hardware

ControlWave_30

HARDWARE INSTALLATION GUIDE

For u

rade of the 3330 DPC

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 main-

tenance. Should problems arise that are not covered sufficiently in the text, the pur-

chaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for

whatever reason, may leave an operating process without protection. Depending upon

the application, this could result in possible damage to property or injury to persons.

It is suggested that the purchaser review the need for additional backup equipment

or provide alternate means of protection such as alarm devices, output limiting, fail-

safe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional

in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note

the following: The party sending such materials is responsible to ensure that the

materials returned to Bristol are clean to safe levels, as such levels are defined and/or

determined by applicable federal, state and/or local law regulations or codes. Such

party agrees to indemnify Bristol and save Bristol harmless from any liability or

damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be

grounded in accordance with OSHA rules and regulations pertaining to "Design

Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April

16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic in-

struments that include electrically-operated devices such as lights, switches, relays,

alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by

exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude

and duration of the ESD, this can result in erratic operation or complete failure of the

equipment. Read supplemental document S14006 at the back of this manual for

proper care and handling of ESD-sensitive components.

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment

unless otherwise agreed to by Bristol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and workmanship for a period to the end of the original warranty

or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or

modified without Bristol's consent, (iii) not installed, maintained and operated in

strict compliance with instructions furnished by Bristol, or (iv) worn, injured or

damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION

WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY

REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY

BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE

NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE

FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

REMEDIES

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be

defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days

of discovery of the alleged defect and within the warranty period stated above, and if

the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water-

town office designates a different location, transportation prepaid, within thirty (30)

days of the sending of such notification and which upon examination by Bristol

proves to be defective in material and workmanship. Bristol is not responsible for

any costs of removal, dismantling or reinstallation of allegedly defective or defective

goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can

arrange to have a Bristol service person come to the site. The Service person's

transportation time and expenses will be for the account of the Buyer. However,

labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential

damages resulting from breach of any agreement relating to items included in this

quotation, from use of the information herein or from the purchase or use by Buyer,

its em-ployees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify

proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return

Authorization) number and thus ensure an optimal lead time. Completing the form is very

important since the information permits the Bristol Repair Dept. to effectively and

efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX

Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair

Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL

Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)

and sending it via E-Mail to brepair@bristolbabcock.com. A Bristol Repair Dept.

representative will return E-Mail (or other requested method) with a RA number.

C. Mail

Mail the form (GBU 13.01) to

Bristol Inc.

Repair Dept.

1100 Buckingham Street

Watertown, CT 06795

A Bristol Repair Dept. representative will return call (or other requested method)

with a RA number.

D. Phone

Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Depart-

ment representative will record a RA number on the form and complete Part I, then

send the form to the Customer via fax (or other requested method) for Customer

completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in-

cluded with the product being returned. This will allow us to quickly track, repair, and

return your product to you.

Bristol Inc. Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required

to receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________

Standard Repair Practice is as follows: Variations to this is

practice may be requested in the “Special Requests” section.

• Evaluate / Test / Verify Discrepancy

• Repair / Replace / etc. in accordance with this form

• Return to Customer

Please be aware of the Non warranty standard charge:

• There is a $100 minimum evaluation charge, which is

applied to the repair if applicable (√ in “returned”

B,C, or D of part III below)

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________

Phone: Fax: E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Range/Calibration S/N

Reason for return : Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,

would you like the product: repaired returned replaced scrapped?

C. If product is deemed not repairable would you like your product: returned replaced scrapped?

D. If Bristol is unable to verify the discrepancy, would you like the product: returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact

that has the most knowledge of the problem is: ______________________________ phone_____________________

If we are unable to contact this person the backup person is: _________________________ phone_____________________

Special Requests: ____________________________________________________________________________________

____________________________________________________________________________________________________

Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: 860-945-2442 Fax: 860-945-3875 Form GBU 13.01 Rev. B 04/11/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

• Avoid Delays and problems in getting your system on-line

• Minimize installation, start-up and maintenance costs.

• Make the most effective use of our hardware and software.

• Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full

schedule of classes conducted by full-time, professional instructors. Classes are offered

throughout the year at three locations: Houston, Orlando and our Watertown, CT

headquarters. By participating in our training, your personnel can learn how to install,

calibrate, configure, program and maintain any and all Bristol products and realize the full

potential of your system.

For information or to enroll in any class, contact our training department in Watertown at

(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Inc.

For over 100 years, Bristol® has been providing innovative solutions for the measurement

and control industry. Our product lines range from simple analog chart recorders, to

sophisticated digital remote process controllers and flow computers, all the way to turnkey

SCADA systems. Over the years, we have become a leading supplier to the electronic gas

measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water

company, there are Bristol Inc. instruments, controllers, and systems running year-in and

year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis-

tance in using this product from the following sources:

Help Files / Release Notes

Many Bristol software products incorporate help screens. In addition, the software typically

includes a ‘read me’ release notes file detailing new features in the product, as well as other

information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,

Connecticut 06795, U.S.A.

Our main phone numbers are:

(860) 945-2200

(860) 945-2213 (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,

excluding holidays and scheduled factory shutdowns. During other hours, callers may leave

messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol's Application Support Group can provide telephone

support for your technical questions.

For technical questions about TeleFlow products call (860) 945-8604.

For technical questions about ControlWave call (860) 945-2394 or (860) 945-2286.

For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865

or e-mail: scada@bristolbabcock.com

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other

software except for ControlWave and OpenEnterprise products, call (860) 945-2286.

For technical questions about Network 3000 hardware, call (860) 945-2502.

You can e-mail the Application Support Group at: bsupport@bristolbabcock.com

The Application Support Group maintains an area on our web site for software updates and

technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication

Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464.

You can e-mail the Communication Technology Group at:

orlandoRFgroup@bristolbabcock.com

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery

information, etc.) should be directed to the nearest sales office (listed on the rear cover of

this manual) or to your Bristol-authorized sales representative.

Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office

covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Inc. and its products, please visit our site on the

World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and

software at our Watertown, Connecticut headquarters, and at selected Bristol regional

offices, throughout the year. Contact our Training Department at (860) 945-2343 for course

information, enrollment, pricing, and scheduling.

PIP-CW_30 Upgrade Kit Contents / 0 - 1

PIP-CW_30 Upgrade Kit

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 1 – ControlWave_30 INTRODUCTION...................................... 1

SECTION 2 – ControlWave PROGRAMMING ENVIRONMENT......................... 1

SECTION 3 – PHYSICAL DESCRIPTION ............................................ 3

3.1 CW_30 CPU Board Overview............................................................................................ 3

3.1.1 CW_30 CPU Board Serial Comm. Port Connectors......................................................... 6

3.1.2 CW_30 CPU Board Ethernet Ports .................................................................................. 6

3.1.2.1 Ethernet CPU Engine 10/100Base-T Connectors ............................................................ 6

3.1.3 CW_30 CPU Board Memory.............................................................................................. 8

3.1.4 CW_30 CPU Board Configuration Jumpers..................................................................... 8

3.1.5 CW_30 CPU Board Configuration Switches .................................................................... 9

3.1.6 CW_30 CPU Board LEDs................................................................................................ 10

3.2 CW_30 Communication Board (CB) Overview .............................................................. 12

3.2.1 Setting CB Board DIP Switches ..................................................................................... 12

3.2.2 Setting CB Board Configuration Jumpers ..................................................................... 15

3.2.3 CB Board LED Indicators ............................................................................................... 16

3.2.4 CB Board Communication Port Information ................................................................. 17

SECTION 4 – ControlWave_30 CONFIGURATION.................................. 18

4.1 Step 1 - Hardware Configuration ................................................................................... 18

4.2 Step 2 - Software Installation on the PC Workstation.................................................. 23

4.3 Step 3 - Establish Communications using either LocalView or Netview,

and Run the Flash Configuration Utility ....................................................................... 23

4.4 Step 4. - Create an Application-specific Control Strategy in

ControlWave Designer..................................................................................................... 23

4.5 Step 5 - Create Application Specific Web Pages OPTIONAL) ...................................... 24

4.6 Step 6 - Create an Open BSI Network Containing the CW_30,

or add the CW_30 to an Existing Open BSI Network ................................................... 25

4.7 Step 7 - Download the Application-specific Control Strategy

into the CW_30 DPC........................................................................................................ 25

SECTION 5 – OPERATIONAL DETAILS........................................... 25

5.1 Downloading the Application Load................................................................................. 26

5.2 Upgrading CW_30 Firmware.......................................................................................... 26

5.2.1 Using LocalView to Upgrade CW_30 Firmware ............................................................ 26

5.2.2 Using Hyperterminal to Upgrade CW_30 Firmware .................................................... 30

5.2.3 Remote Upgrade of CW_30 Firmware............................................................................ 32

5.3 Core Updump ................................................................................................................... 32

SECTION 6 – GENERAL SERVICE NOTES ........................................ 33

6.1 Extent of Field Repairs.................................................................................................... 33

6.2 Disconnecting RAM Battery ........................................................................................... 33

0 - 2 / Contents PIP-CW_30 Upgrade Kit

PIP-CW_30 Upgrade Kit

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 6 – GENERAL SERVICE NOTES (Continued) ............................ 33

6.3 Maintaining Backup Files............................................................................................... 34

SECTION 7 – WINDIAG DIAGNOSTICS ........................................... 34

7.1 Diagnostics Using WINDIAG ......................................................................................... 36

7.1.1 Communication Diagnostic Port Loop-back Tests......................................................... 36

7.1.2 Serial Comm. Port External Loop-back Test Procedure ............................................... 36

7.1.3 Ethernet Port Diagnostics............................................................................................... 38

7.1.3.1 10/100Base-T (RJ-45 – Twisted Pair) Port Hardware Setup ........................................ 39

7.1.3.2 Ethernet Port Diagnostic Test Execution ...................................................................... 39

7.1.3.3 Loop-back Out Twisted Pair Test RUN Button ............................................................. 40

7.1.3.4 Return Hardware Address Test RUN Button................................................................ 40

7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages........................................................ 40

SECTION 8 – DISPLAY/KEYPAD ASSEMBLY OPERATION ......................... 40

8.1 Operation of the Dual-button/Display/Keypad Assembly ............................................. 41

SECTION 9 – CW_30 SPECIFICATIONS ........................................... 44

9.1 CW_30 CPU Board Specifications .................................................................................. 44

9.1.1 CPU Board Communication Port Specifications ........................................................... 44

9.1.2 CPU Board 3.3V Power Supply Specifications............................................................... 44

9.1.3 CPU Board Environmental Specifications ..................................................................... 45

9.2 CW_30 Communication Board (CB) Specifications ....................................................... 45

9.2.1 CB Board Connectors ...................................................................................................... 45

9.2.2 CB Board Communication Port Specifications .............................................................. 45

9.2.3 CB Board 3.3V Power Supply Specifications ................................................................. 45

9.2.4 CB Board Environmental Specifications........................................................................ 45

APPENDICES

4 X 20 DISPLAY-KEYBOARD ASSEMBLY..........................................................Appendix DKA

MATERIAL SAFETY DATA SHEETS..........................................................................Appendix Z

REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS

WINDIAG - Windows Diagnostics for Bristol Controllers......................................D4041A

Open BSI Utilities Manual ...................................................................................... D5081

Getting Started with ControlWave Designer.......................................................... D5085

ACCOL Translator User Guide ............................................................................... D5086

Web_BSI Manual...................................................................................................... D5087

ControlWave Designer Reference Manual .............................................................. D5088

ControlWaveMICRO Quick Setup Guide ................................................................ D5124

ControlWave Designer Programmer’s Handbook................................................... D5125

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 1

ControlWave_30

HARDWARE INSTALLATION GUIDE

SECTION 1 - ControlWave_30 INTRODUCTION

DPC 3330 can be field upgraded to become a ControlWave_30 DPC (herein referred to as

CW_30) by utilizing the hardware provided in an installation kit. Upgrade will require

removal of the standard DPC 3330 CPU and Comm./ECOM Boards and then adding the

CW_30 CPU (CPU) and CW_30 Communication (CB) Boards provided in the upgrade kit.

ControlWave® products have been designed and integrated as a highly adaptable, high

performance Distributed Open Controller family with exceptional networking capability

that provides a complete Process Automation Management Solution. The CPU and CB

Boards were designed with an emphasis on providing high performance with low power

consumption and scalability.

The CPU Module utilizes Sharp’s LH7A400 System-on-Chip Advanced RISC Machine

(ARM) microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC)

Core. In addition to the microprocessor and control logic, the CPU Board includes two com-

munication ports that can be individually configured for RS-232 or RS-485 operation, 1MB

of battery backed Static RAM (SRAM), 4MB of Synchronous Dynamic RAM (SDRAM),

512kB Boot/Downloader FLASH, 16MB simultaneous read/write FLASH, an I/O Bus

Connector, up to two optional Ethernet ports.

In addition to Idle and Watchdog LEDs, there are six status LEDs located on the CPU

Board that will display run time status information. Two LEDs are also provided for each

Comm. Port.

CW_30 Distributed Process Controllers provide the following key features:

• ARM processor provides exceptional performance and low power consumption

• Ten independently configurable asynchronous serial communication ports (RS-

232/RS-485) and one 3-wire serial RS-232 Utility Port

• Up to two optional Ethernet ports (10/100Base-T)

• Optional Expansion Comm. Modules with/without built-in modem

• Wide temperature range: (-40 to +70°C) (-40 to 158°F)

• Utilizes existing DPC 3330 Chassis, Power Supply and I/O Boards

• RS-232/RS-485 Comm. Ports provided with LED status Indicators

• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,

300mA-hr lithium coin cell battery located on the CPU Board Ass’y.

• Class I, Div. 2 Hazardous Location approval

SECTION 2 - ControlWave PROGRAMMING ENVIRONMENT

The ControlWave programming environment uses industry-standard tools and protocols to

provide a flexible, adaptable approach for various process control applications in the water

treatment, wastewater treatment, and industrial automation business.

Pg. 2 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

The ControlWave programming environment consists of a set of integrated software tools

which allow a user to create, test, implement, and download complex control strategies for

use with Bristol’s CW_30 Distributed Process Controller.

The tools that make up the programming environment are:

• ControlWave Designer load building package offers several different methods for

generating and debugging control strategy programs including function blocks, ladder

logic, structured languages, etc. The resulting process control load programs are fully

compatible with IEC 61131-3 standards. Various communication methods are offered,

including TCP/IP, serial links, as well as communication to Bristol’s Open BSI soft-

ware and networks.

• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,

allows you to define process I/O modules in the CW_30 and configure the individual

mapping of I/O points for digital and analog inputs and outputs.

• The ACCOL3 Firmware Library, which is imported into ControlWave Designer, in-

cludes a series of Bristol specific function blocks. These pre-programmed function blocks

accomplish various tasks common to most user applications including alarming,

historical data storage, as well as process control algorithms such as PID control.

• The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows

real-time data access to any OPC [Object Linking and Embedding (OLE) for Process

Control] compliant third-party software packages.

• A series of Configuration Controls are available for setting up various aspects of the

system such as historical data storage, system security, and soft switches. Additional

Data Access Controls are also available for retrieval of real-time data values and

communication statistics. The configuration controls and the data access controls utilize

ActiveX technology and are called through a set of fixed Web pages, compatible with

Microsoft® Internet Explorer. Alternatively, developers can place the controls in third-

party ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.

• User-defined Web Pages - If desired, user-defined web pages can be stored within a

PC to provide a customized human-machine interface (HMI).

• Flash Configuration Utility – Parameters such as the BSAP local address, IP ad-

dress, etc. are set using the Flash Configuration Utility, accessible via Open BSI

LocalView or NetView.

Note: DPC 3330s that are upgraded with “CW_30 Hardware,” must have their

ACCOL application load converted to an IEC 61131 ControlWave Program Load.

This is accomplished via the ACCOL Translator (see User Guide D5086).

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 3

Figure 1 - ControlWave - Control Strategy Software Diagram

SECTION 3 - PHYSICAL DESCRIPTION

CW-30 Upgrade kits are comprised of the following major components:

• CW_30 CPU Board (CPU) Overview (Section 3.1)

• CW_30 Communication Board (CB) Overview (Section 3.2)

3.1 CW_30 CPU Board Overview

The multilayer CPU Board provides CW_30 CPU, I/O monitor/control, memory and

communication functions. CW_30 CPU Boards operate over an extended temperature range

with long-term product reliability.

Pg. 4 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

CW_30 CPU Boards are based on a 32-bit ARM9TDMI RISC Core Processor. The CPU

Board is specified to operate on CW_30 (+12Vdc or +24Vdc systems) and with a system

clock speed of 150 MHz. In addition to the microprocessor and control logic, the CPU Board

includes two independently (DIP-Switch) configurable communication ports (RS-232/RS-

485) (COM5 & COM6), up to two optional Ethernet ports (10/100Base-T), CPU Memory

consists of 1MB of battery backed Static RAM (SRAM), 512kB Boot/Downloader FLASH

and 16MB simultaneous read/write FLASH.

CPU Boards are provided backup power via a coin cell socket that accepts a 3.0V, 300mA-hr

lithium battery. This 3.0V battery provides backup power for the real-time clock and the

system’s Static RAM (SRAM). Backup power is enabled when Configuration Jumper W3

(just below the battery) is installed in position 1 to 2.

If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the CPU

Board switches the battery voltage to the CPU’s SRAM and RTC.

The system SRAM is specified to have a standby current of 20:A for each part (1MB),

(40:A maximum) (plus 2uA for the RTC). For a system containing 2MB of system SRAM, a

worst-case current draw of 42:A allows a battery life of approximately 7142 hours.

A supervisory circuit is used to switch to battery power when VCC falls out of specification.

For maximum shelf life, the battery may be isolated from the circuit by removing the

Backup Enable Jumper W3 from position 1 to 2 and then installing it in position 2 to 3. If

the Real-time clock looses its battery backup a ControlWave Designer system variable bit

(_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the

ControlWave Designer Programmer’s Handbook - D5125, System Variables Section).

Basic CPU Board components and features are summarized as follows:

• LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor

• Supports process control loads that are fully compatible with IEC 61131-3 standards

• 512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access

• 1MB SRAM, 3.3V, 256 x 16, 70 nsec., with Battery Back-up

• 4 MB SDRAM via two 1M x 16, 100MHz SDRAMs configured as a 1M x 32-bit array.

• 16MB simultaneous read/write FLASH, 90 nsec.

• 2 user configurable serial Comm. ports (RS-232/RS-485) (COM5 & COM6) (compatible

with existing 3330 communication cables)

• 2 optional Ethernet ports (10/100Base-T)

• I/O Bus Interface, control for up to 12 I/O Boards

• MAC address in serial EEPROM

• Spread Spectrum clock for lower EMI

• Serial Real Time Clock with battery backup

• 8-Position general-purpose switch bank plus a 4-Position recovery switch bank

• Coin cell socket accepts a 3.0V, 300mA-hr lithium battery

• Six Status LEDs, 6 Comm. Port LEDs plus Watchdog, Idle and Comm. Port LEDs

• 3-wire (RS-232) Utility Port: Provides compatibility with existing FLASH load cable

used with the 3330 CPU.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 5

Figure 2 – CW_30 CPU Board Component Identification Diagram

Pg. 6 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

3.1.1 CW_30 CPU Board Serial Comm. Port Connectors

The CPU Board supports up to two serial communication ports (COM5 and COM6). COM5

and COM6 are interconnected to a Comm. Interface Board Assembly that contains two

Female D-Type connectors (see Table 10 for Comm. Port D-type connector pin

assignments). The interface cable is connected to J5 on the CW_30 CCPU Board and P2 on

the Comm. Interface Board Assembly (Bristol Part No. 392574-01-2). Comm. Interface

Board Assembly Connector BIP1 supports Comm. Port 5 while connector BIP2 supports

Comm. Port 6. When configured for RS-485 operation Comm. Port 5 and Comm. Port 6

receivers are enabled by DTR the RS-485 driver is enabled by RTS. An eight position DIP-

Switch (SW3) is assigned to Comm. Port 5 and another (SW4) is assigned to Comm. Port 6.

These switches provide user configuration of RS-485 port receiver biasing and termination

as well as 2-wire or 4-wire operation.

3.1.2 CW_30 CPU Board Ethernet Ports

Connection to the Ethernet can be established via one or two Ethernet Ports situated on the

CPU Board. Ethernet Ports utilize 10/100Base-T RJ45 modular connectors (J1 & J2) that

typically provide a twisted pair interface to an Ethernet Hub. Ethernet Port Jacks are

equipped with two LEDs that function as follows: yellow = TX, green = RX activity.

3.1.2.1 Ethernet CPU Engine 10/100Base-T Connectors J2 & J3

8-pin 10/100Base-T Connectors J2 and J3 typically provide connection to a twisted pair

Ethernet via an Ethernet Hub. Both ends of the Ethernet cable are equipped with modular

RJ45 connectors. A typical hub provides eight (8) 10/100Base-T RJ45 ports (with port 8

having the capability to link to another hub or to an Ethernet communication port. The

cable used between a CPU Module Expansion Board’s Ethernet 10/100Base-T connector

and an Ethernet Hub has a one-to-one wiring configuration as shown in Figure 4. Table 1

provides the assignment and definitions of 8-pin 10/100Base-T Connectors J2 & J3.

It is possible to connect two nodes in a point-to-point configuration without the use of a

Hub. However; the cable used must be configured such that the TX± Data pins are

connected to the RX± Data pins (swapped) at the opposite ends of the cable (see Figure 3).

The maximum length of one segment (CPU to Hub) is 100 meters (328 feet). The use of

Category 5 shielded cable is recommended.

Table 1 - Ethernet 10/100Base-T Connectors J2 & J3 Pin Assignments

Pin # Description Pin # Description

1TX+ Transmit Data+ 5 Not Connected

2TX- Transmit Data- 6RX- Receive Data-

3RX+ Receive Data+ 7 Not Connected

4 Not Connected 8 Not Connected

Note: TX & RX are swapped at Hub’s.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 7

Figure 3 - Point-to-Point 10/100Base-T Ethernet Cable

Figure 4 - Standard 10/100Base-T Ethernet Cable (CPU Board to Hub)

Figure 5 - 10/100Base-T Connector (P2) with Cable Configured for Loopback

Pg. 8 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

3.1.3 CW_30 CPU Board Memory

Boot/downloader FLASH

Boot/download code is contained in a single 512Kbytes FLASH IC. 4-Position DIP-Switch

SW1’s position 3 allows start-up menu options to be displayed or boot-up from system

FLASH. If SW1-3 is closed (ON) when a reset occurs, the boot-up code will cause a recovery

menu to be sent out the Utility Port (on the CPU Board) to a terminal program running on

an external host computer. Note: Recovery Mode will also be initiated if CPU Board Switch

SW1 positions 1 and 2 are both set ON or OFF when a reset occurs.

FLASH Memory

The base version of the CPU Board has 16Mbytes of 3.3V, simultaneous read/write (DL)

FLASH memory. System Firmware and the Boot Project are stored here.

System Memory (SRAM)

The CPU Board has 1Mbyte of static RAM, implemented with two 256K x 16, 70

nanosecond asynchronous SRAMs. All random access memory retained data is stored in

SRAM. During power loss periods, SRAM is placed into data retention mode (powered by a

backup 3.0V lithium battery). SRAM’s operates at 3.3V and are packaged in a 44-pin

uTSOP. Critical system information that must be retained during power outages or when

the system has been disabled for maintenance is stored here. Data includes: Last states of

all I/O, historical data, retain variables and pending alarm messages not yet reported.

Synchronous Dynamic RAM (SDRAM)

The CW_30 CPU Board contains 4 Mbytes of Synchronous Dynamic RAM (SDRAM)

implemented with two 1M x 16, 100MHz Synchronous DRAMs. The running application is

stored here. This allows the system to run faster than it will from the FLASH memory.

SDRAM is not battery-backed.

3.1.4 CW_30 CPU Board Configuration Jumpers

CW_30 CPU Boards provide 18 User Configuration Jumpers that function as follows:

• W3 - Enable/Disable Battery Back-up Selection

1 to 2 = Enable Battery Back-up

2 to 3 = Disable Battery Back-up

• W5 - Status LED Enable/Disable Selection

1 to 2 = Enable Status LEDs

2 to 3 = Disable Status LEDs

• W8 - Serial Comm. Port Status LED Enable/Disable Selection

1 to 2 = Enable Serial Comm. Port Status LEDs

2 to 3 = Disable Serial Comm. Port Status LEDs

• W9 - BIP1 (Comm. Port 5) Configuration Selection Note: W10 through W13 ditto

1 to 2 = Set for RS-232 Operation

2 to 3 = Set for RS-485 Operation

• W14 - BIP1 (Comm. Port 5) DSR/DTR Control

1 to 2 = DSR on Pin-8 of D-type Connector

2 to 3 = DTR on Pin-8 of D-type Connector

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 9

• W15 - BIP1 (Comm. Port 5) Control

1 to 2 = CTS Source is from Port

2 to 3 = RTS to CTS Loopback

• W16 - BIP2 (Comm. Port 6) Configuration Selection Note: W17 through W20 ditto

1 to 2 = Set for RS-232 Operation

2 to 3 = Set for RS-485 Operation

• W21 - BIP2 (Comm. Port 6) DSR/DTR Control

1 to 2 = DSR on Pin-8 of D-type Connector

2 to 3 = DTR on Pin-8 of D-type Connector

• W22 - BIP2 (Comm. Port 6) Control

1 to 2 = CTS Source is from Port

2 to 3 = RTS to CTS Loopback

• W23 - Power Good LED Control

1 to 2 = Enable Power Good LED

2 to 3 = Disable Power Good LED

3.1.5 CW_30 CPU Board Configuration Switches

Four user-configurable DIP Switches are provided on the CW_30 CPU Board. Eight-bit

DIP-Switch SW2 is provided for user configuration settings while four-bit DIP-Switch SW1

provides forced recovery functions. Eight-bit DIP-Switch SW3 provides loopback,

termination control, and receiver bias settings for the Comm. Port 5 when it has been

configured for RS-485 operation (via jumpers W9 through W13). Eight-bit DIP-Switch SW4

provides loopback, termination control, and receiver bias settings for Comm. Port 6 when it

has been configured for RS-485 operation (via jumpers W16 through W20).

Table 2 – CW_30 CPU Board (General Purpose Switch SW2) Assignments

Note: Except for SW2-4, ON = Factory Default

SW# Function Setting - (ON = Factory Default)

SW2-1 Watchdog Enable ON = Watchdog circuit is enabled

OFF = Watchdog circuit is disabled

SW2-2 Lock/Unlock

Soft Switches

ON = Write to Soft Switches and FLASH files

OFF = Soft Switches, configurations and FLASH files are locked

SW2-3 Use/Ignore

Soft Switches

ON = Use Soft Switches (configured in FLASH)

OFF = Ignore Soft Switch Configuration and use factory defaults

SW2-4 Core Updump

See Section 3.6

ON = Core Updump Disabled

OFF = Core Updump Enabled via Recovery Switch (SW1)

SW2-5 SRAM Control ON = Retain values in SRAM during restarts

OFF = Force system to reinitialize SRAM

SW2-6 System Firmware

Load Control

ON = Enable remote downloading of System Firmware *

OFF = Disable remote downloading of System Firmware

SW2-7 N/A

SW2-8 Enable WINDIAG ON = Normal Operation (don’t allow WINDIAG to run test)

OFF = Disable boot project (allow WINDIAG to run test)

* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher

Pg. 10 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Table 3 – CW_30 CPU Board (Switch SW1) Assignments CPU/System

Recovery Mode/Local Mode Control (Note: SW1-4 not used)

Switch Function Setting

SW1-1/2 Recovery/Local Mode * Both ON or OFF = Recovery Mode

SW1 OFF & SW2 ON = Local Mode

SW1-3 Force Recovery Mode * ON = Force Recovery Mode (via CW Console)

OFF = Recovery Mode disabled

* = Note: Only the CPU Board Switch SW1 settings listed in this table have been tested.

Table 4 – CW_30 CPU Board Switch SW3/SW4 Assignments

RS-485 Loopback & Termination Control (COM5 = SW3 & COM6 = SW4)

Switch RS-485 Function

Switch ON Setting

SW3/4-1 TX+ to RX+ Loopback/2-Wire ON - Only for Diagnostics

SW3/4-2 TX− to RX− Loopback/2-Wire ON - Only for Diagnostics

SW3/4-3 100 Ohm RX+ Termination ON - End Nodes Only

SW3/4-4 100 Ohm RX− Termination ON - End Nodes Only

SW3/4-7 RX+ Bias (End Nodes/Node) ON - 4-Wire = Both End Nodes

ON - 2-Wire = One End Node Only

SW3/4-8 RX− Bias (End Nodes/Node) ON - 4-Wire = Both End Nodes

ON - 2-Wire = One End Node Only

3.1.6 CW_30 CPU Board LEDs

CW_30 CPU Boards are equipped with 15 LEDs. Table 5 provides CPU Board LED

assignments. Table 6 provides definitions for the six Status LEDS.

Table 5 – Assignment of CW_30 CPU Board LEDs

LED Ref. Function Color LED Ref. Function Color

CR2 Utility Port TX Red CR8 Status 2 Red

CR3 Utility Port RX Red CR9 Status 3 Red

CR4 - Top COM5 (BIP1) TX Red CR10 Status 4 Red

CR4 -

Bottom

COM5 (BIP1) RX Red CR11 Status 5 Red

CR5 - Top COM6 (BIP2)TX Red CR12 Status 6 Red

CR5 -

Bottom

COM6 (BIP2) RX Red CR13 Watchdog Red

CR6 Power Good Green CR14 Idle Red

CR7 Status 1 Red

Note: Optional Ethernet Port Jacks are equipped with two LEDs that function as

follows: Yellow = TX, Green = RX activity.

Two red LEDs provide for the following status conditions when lit: WD (CR13 - Indicates a

Watchdog condition has been detected) & IDLE (CR14 - Indicates that the CPU has free

time at the end of its execution cycle. Normally, it should be ON most of the time. When the

Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded). The

green Power Good LED (CR6) is on when power is within specification. Six status LEDs

provide run time status codes.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 11

Table 6

System Status Codes for Status LCDs CW_30 CPU Board (see Figure 6)

LED

CR12

LED

CR11

LED

CR10

LED

CR9

LED

CR8

LED

CR7

Status

Hex

Indication

Definition

0 0 0 0 0 0 00 Application Running

0 0 0 0 0 1 01 Unit in Diagnostic Mode

0 0 0 0 1 1 03 Unit Running Diagnostics

0 0 0 1 0 0 04 Flash XSUM Error

0 0 0 1 0 1 05 Error Initializing Application Device

0 0 0 1 1 1 07 Flash Programming Error

0 0 1 0 0 0 08 Using Factory Defaults *

0 0 1 0 0 1 09 Battery Failure Detected *

0 1 0 0 0 0 10 Waiting in Recovery Mode

0 0 1 0 1 0 0A Currently Loading the Boot Project

0 0 1 0 1 1 0B System Initialization in Progress

0 1 0 0 1 0 12 Error Testing SRAM

1 0 0 0 0 0 20 Application Loaded

1 0 1 0 0 0 28 Stopped at a Break Point

1 1 0 0 0 0 30 No Application Loaded

1 1 1 0 0 0 38 Running with Break Points

1 1 1 0 1 1 3B Waiting for Power-down (after NMI)

1 1 1 1 1 0 3E Waiting for Updump to be Performed

1 1 1 1 1 1 3F Unit Crashed (Watchdog Disabled)

* = Flashed at startup

Figure 6 – CW_30 CPU Status LED Hexi-decimal Codes

Pg. 12 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

3.2 CW_30 Communication Board (CB) Overview

CW_30 Communication Boards provide either four or two (depopulated version of Four Port

CB) communication ports which utilize 9-pin, D-Type, female connectors. Up to 2 CBs can

be installed in a CW_30. CB Board communication ports are labeled as follows:

First 4-Port CB contains Ports 1, 2, 7, & 8 (resides in Communication Socket #1).

Second 4-Port CB contains Ports 3, 4, 9 & 10 (resides in Communication Socket #2).

First 2-Port CB Contains Ports 1 & 2 (resides in Communication Socket #1).

Second 2-Port CB Contains Ports 3 & 4 (resides in Communication Socket #2).

Standard 9-Pin D-Type Connectors are used in the two port version of the CB and dual

stacked D-Type Connectors are used on four port versions. When the DPC contains two 4-

Port CBs, a maximum of ten ports are available (four on each CB and two on the CW_30

CPU Board). When two 2-Port CBs are installed in a CW_30 DPC, a maximum of six ports

are available (two on each CB assembly and two on the CW_30 CPU Board).

The communication ports can be configured for an RS-485 or RS-232 interface. The former

is required for BSAP network communications, while the latter is required for devices such

as a PC or printer. However; these ports can also be configured for other applications. For

example, port 1 can be configured to interface with a PC while ports 2, 3, 4, etc. can be

configured for use with options such as modems and printers. It should be noted that only 2-

Port CBs (Port 2) will support piggyback modems, and that RASCL "redundancy," and use

of a Hand Held Terminal aren’t supported.

3.2.1 Setting CB Board DIP Switches

The procedure for setting DIP switches is identical for the two different board versions

except that the 4-Port Communication Board contains four DIP switches while the 2-Port

CB contains two DIP switches. When an individual switch (toggle) is pressed to the right it

is set to its ON position (see Figure 7). Switches SW1 through SW4 control port

configuration and are assigned as follows:

SW1 - Controls Port 1/3

SW2 - Controls Port 7/9

SW3 - Controls Port 2/4

SW4 - Controls Port 8/10

Figure 7 - Enlarged View of SW1-SW4

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 13

Figure 8 - CW_30 - 2-Port CB Board Component Identification Diagram

Pg. 14 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 9 - CW_30 - 4-Port CB Board Component Identification Diagram

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 15

Switch functions are provided for RS-485 operation, in Table 7.

Table 7 – CB Board DIP Switches SW1 - SW4 - RS-485 Configuration Selections

SW1- SW4 Function Setting

1 TX+ to RX+ Loopback ON = Loopback Enabled, 2-Wire

OFF = Loopback Disabled, 4-Wire

2 TX− to RX− Loopback ON = Loopback Enabled, 2-Wire

OFF = Loopback Disabled, 4-Wire

3 RS-485 Termination ON = Termination Installed

OFF = No Termination

4 RS-485 Termination ON = Termination Installed

OFF = No Termination

5 OFF

6 OFF

7 RS-485 Bias Termination ON = Bias Enabled

OFF = No Bias

8 RS-485 Bias Termination ON = Bias Enabled

OFF = No Bias

Setting switches SW1 through SW4 does not complete the set-up configuration. The

jumpers listed in Table 7 must also be set to complete the procedure.

Note: When the DPC is specified with an internal 1200 bps Private Line (PL) Modem., 9600

bps Publicly Switched Telephone Network (PSTN) Modem, or a 1200 bps PL/PSTN Modem,

refer to the appropriate Customer Instruction Manual, i.e., CI-1200-PL, CI-9600 (PSTN), CI-

9600A (PSTN) or CI-1200 (PL/PSTN). For details on the Fiber Optic Interface, refer to

Appendix FA of Instruction Manual CI-3330.

3.2.2 Setting CB Board Configuration Jumpers

The 4-Port CB and 2-Port CB Boards contains up to twenty-one configuration jumpers to

set various communication parameters. The location of these jumpers is shown in Figures 8

and 9. The jumpers are set according to Table 8.

Table 8 – CB Board Configuration Jumper Settings

Jumper Description Setting Configuration

W1 Comm. Port Status LED

Control

1 to 2

2 to 3

Enable Comm. Status LEDs

Disable Comm. Status LEDs

W2 Port 1/3 Configuration 1 to 2

2 to 3

Port 1/3 = RS-232

Port 1/3 = RS-485

W3 Port 1/3 Configuration 1 to 2

2 to 3

Port 1/3 = RS-232

Port 1/3 = RS-485

W4 Port 1/3 Configuration 1 to 2

2 to 3

Port 1/3 = RS-232

Port 1/3 = RS-485

W5 Port 1/3 Configuration 1 to 2

2 to 3

Port 1/3 = RS-232

Port 1/3 = RS-485

W6 Port 1/3 RTS/CTS Control 1 to 2

2 to 3

Port 1/3 CTS Source is from Port A/C

Port 1/3 RTS to CTS Loopback

W7 Port 1/3 DSR/DTR Selection 1 to 2

2 to 3

Port 1/3 Pin 8 = DSR

Port 1/3 Pin 8 = DTR

Pg. 16 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Table 8 - CB Board Configuration Jumper Settings (Continued)

Jumper Description Setting Configuration

W8 Port 1/3 Configuration 1 to 2

2 to 3

Port 1/3 = RS-232

Port 1/3 = RS-485

W9 Port 2/4 Configuration 1 to 2

2 to 3

Port 2/4 = RS-232

Port 2/4 = RS-485

W10 Port 2/4 Configuration 1 to 2

2 to 3

Port 2/4 = RS-232

Port 2/4 = RS-485

W11 Port 2/4 Configuration 1 to 2

2 to 3

Port 2/4 = RS-232

Port 2/4 = RS-485

W12 Port 2/4 RTS/CTS Control 1 to 2

2 to 3

Port 2/4 CTS Source is from Port B/D

Port 2/4 RTS to CTS Loopback

W13 Port 2/4 DSR/DTR Selection 1 to 2

2 to 3

Port 2/4 Pin 8 = DSR

Port 2/4 Pin 8 = DTR

W14 Port 2/4 Configuration 1 to 2

2 to 3

Port 2/4 = RS-232

Port 2/4 = RS-485

W15 Port 2/4 Configuration 1 to 2

2 to 3

Port 2/4 = RS-232

Port 2/4 = RS-485

W16 Port 7/9 RS-XX/Modem

Control

1 to 2

2 to 3

Port 7/9 = RS-232 or RS-485

Port 7/9 = Modem

W17 Port 7/9 Configuration 1 to 2

2 to 3

Port 7/9 = RS-232

Port 7/9 = RS-485

W18 Port 7/9 Configuration 1 to 2

2 to 3

Port 7/9 = RS-232

Port 7/9 = RS-485

W19 Port 7/9 Configuration 1 to 2

2 to 3

Port 7/9 = RS-232

Port 7/9 = RS-485

W20 Port 7/9 Configuration 1 to 2

2 to 3

Port 7/9 = RS-232

Port 7/9 = RS-485

W21 Port 7/9 RTS/CTS Control 1 to 2

2 to 3

Port 7/9 CTS Source is from Port G/I

Port 7/9 RTS to CTS Loopback

W22 Port 7/9 DSR/DTR Selection 1 to 2

2 to 3

Port 7/9 Pin 8 = DSR

Port 7/9 Pin 8 = DTR

W23 Port 7/9 Configuration 1 to 2

2 to 3

Port 7/9 = RS-232

Port 7/9 = RS-485

W24 Port 8/10 Configuration 1 to 2

2 to 3

Port 8/10 = RS-232

Port 8/10 = RS-485

W25 Port 8/10 Configuration 1 to 2

2 to 3

Port 8/10 = RS-232

Port 8/10 = RS-485

W26 Port 8/10 Configuration 1 to 2

2 to 3

Port 8/10 = RS-232

Port 8/10 = RS-485

W27 Port 8/10 Configuration 1 to 2

2 to 3

Port 8/10 = RS-232

Port 8/10 = RS-485

W28 Port 8/10 RTS/CTS Control 1 to 2

2 to 3

Port 8/10 CTS Source is from Port H/J

Port 8/10 RTS to CTS Loopback

W29 Port 8/10 DSR/DTR Selection 1 to 2

2 to 3

Port 8/10 Pin 8 = DSR

Port 8/10 Pin 8 = DTR

W30 Port 8/10 Configuration 1 to 2

2 to 3

Port 8/10 = RS-232

Port 8/10 = RS-485

3.2.3 CB Board LED Indicators

The CB provide a TX and RX indicator for each communication channel. TX will light when

the channel is transmitting data and RX lights when the channel is receiving data.

Depending upon the data activity, the LEDs may blink or appear continuously lit during

communication activity. The LEDs will be out when there is no activity (see Figures 8 & 9).

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 17

3.2.4 CB Board Communication Port Information

CB Boards will have 2 or 4 serial communication ports that are supported by 9-pin female

D-type connectors that have pinouts the same as the DPC 3330 ECOM Boards (see Figures

8 and 9 and Table 10). All CB Board Comm. Ports can be individually user configured for

RS-232 or RS-485 operation.

The following information is provided to support use of CB Board Comm. Ports:

• When configured for RS-232 operation, CB Comm. Ports support RTS, DTR, CTS, DCD

and DSR modem control signals.

• RS-232 transceivers are enabled by the port’s DTR signal, i.e., when DTR goes high the

port becomes active.

• Each RS-232 transceiver has one active receiver while in the power-down mode

(disabled). DCD is connected to the active receiver.

• When configured for RS-485 operation, the CB Comm. Port receiver is enabled by DTR

while the driver is enabled by RTS.

• For RS-485 operation, an eight-position DIP switch (one per port) enables receiver

biasing and termination as well as two-wire and 4-wire selection.

• A 15-pin header (J4) supports the following CW_30 external communication device

options on 2-Port CB Board Comm. Port 2/4: Multipurpose Interface Board (MIB), Radio

Delay Interface (RDI), Transmitter Interface Board (TIB), 1200 Baud and 9600 Baud

Modems.

• Optional CW_30 Piggy-back modems are supported by ports 2/4 on 2-Port CBs only.

Table 9 - CB Board Connector J4 - Modem Option Header Pin Designations

Pin # Signal

2 GND

3 VCC5

4 +15V

5 -15V

6 TXD

7 RTS

8 DTR

9 RXD

10 CTS

11 DSR

12 DCD

Note: Pins 1, 13, 14 and 15 are unpopulated.

Table 10 - CB Board RS-232/RS-485 D-Type Connector Pin Assignments

Note: Identical to CW_30 CPU Bd. Ports 5 & 6 on Intf. Bd. Ass’y. 392574-01-2

Pin # Signal

RS-232

Description:

RS-232 Signals

Signal

RS-485

Description:

RS-485 Signals

1 DTR Data Terminal Ready Output TXD+ Transmit Data +

2 TXD Transmit Data Output TXD− Transmit Data −

3 RXD+ Receive Data +

4 RXD Receive Data Input RXD− Receive Data −

5 RTS Request To Send Output

6 CTS Clear To Send Input

Pg. 18 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Table 10 - CB Board RS-232/RS-485 D-Type Connector Pin Assignments

(Continued)

Note: Identical to CW_30 CPU Bd. Ports 5 & 6 on Intf. Bd. Ass’y. 392574-01-2

Pin # Signal

RS-232

Description:

RS-232 Signals

Signal

RS-485

Description:

RS-485 Signals

7 DCD Data Carrier Detect Input

8* DTR/DSR

Data Terminal Ready/

Data Set Ready Input

9 GND Ground GND Ground

* Jumper Configured, typically set for DTR on Pin-8

SECTION 4 - ControlWave_30 CONFIGURATION

There are seven (7) main steps required to configure a CW_30 DPC. This document

provides an overview of these steps with an emphasis on the installation and configuration

of the hardware. This section is also intended to serve as a reference for users who may

have already upgraded at least one CW_30 DPC.

4.1 Step 1 - Hardware Configuration

This involves unpacking the CW_30 upgrade hardware, setting switches and setting

jumpers on the new CW_30 boards, replacing the DPC 3330’s CPU and ECOM Boards with

the CW_30 boards, reconnecting any permanent communication cables, and connecting a

communications cable to a PC workstation to facilitate downloading the application load. To

upgrade the DPC 3330 to a CW_30, follow Hardware Configuration steps 1 through 5

below:

1. Remove the CW_30 boards from their carton. Remove all communication cables and the

CPU and ECOM Boards from the DPC 3330 being upgraded. (see Figures 2, 8 and 9 as

required). Note make sure the Comm. Cables are identified for proper

reinstallation.

2. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery

Jumper W3 on the CW_30 CPU should be installed across jumper posts 1 and 2.

Configure the CW_30 CPU Board’s DIP Switches and Jumpers. Figure 2 and Tables 2

through 4 provide information on Switch Settings. Jumper settings are provided in

Figure 2 and in section 3.1.5. Install the CPU Board into the CW_30.

3. Configure the DIP Switches and Jumpers on CB1 (and CB2 if provided) (see Figures 8

and 9). Section 3.2.1 and Table 7 provide information on CB Board DIP Switches.

Section 3.2.2 and Table 8 provide information on CB Board Jumpers. If required remove

the optional modem(s) from the ECOM Board(s) removed from the DPC 3330 in

Hardware Configuration step # 1 and reinstall the modem onto replacement CB

Board(s). Remember, only 2-Port CB Boards support TIBs, RDIs, MIBs or

Modems. Install the replacement CB Board(s) into the CW_30.

4. Connect the communication port cables removed in step 1. Connect the CW_30 CPU’s 3-

Wire Utility Port to a Communication Port of a PC (typically PC COMM. Port 1).

A CW_30 can be configured as a Master or Slave node on either a MODBUS network or

a BSAP network. A variety of communication schemes are available. Three com-

munication ports are contained on the CW_30 CPU Board. 2 or 4 communication ports

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 19

are contained on each CB Board. These communication ports are discussed in Section

3.1.2, 3.1.5 and 3.1.6 (CPU) and 3.2, 3.2.1, 3.2.2 and 3.2.4 (CB). Two (2) Ethernet

communication ports are available on the CPU Board (see Section 3.1.3). Serial RS-

232/485 communication ports are designated as follows:

CW_30 CPU Board:

COM5 - Port BIP1 (physically located on the Interface Board Assembly): (9-Pin Female

D-Type) RS-232 or RS-485 operation (Configured by CPU Jumpers W9 through

W15) (RS-485 operation utilizes CPU Switch SW3). Note: This port was

named BIP1 on original DPC 3330s. When set for factory defaults, COM5

defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer

protocol operation.

COM6 - Port BIP2 (physically located on the Interface Board Assembly): (9-Pin Female

D-Type) RS-232 or RS-485 operation (Configured by Jumpers W16 through

W22) (RS-485 operation utilizes Switch SW4). Note: This port was named

BIP2 on original DPC 3330s. When set for factory defaults, COM6 defaults

to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol

operation.

Utility Port - 3-Wire RS-232 (for FLASH Firmware and Core Updumps) (Utilizes CCPU

Switch SW1). The Utility Port operates at 115.2 Kbaud and utilizes the

1KXModem or Xmodem protocol.

CW_30 CB Boards:

COM1 - Port 1 on the 1st CCB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W2 through W8) (RS-485 operation utilizes CB

SW1). Note: This port was named A on original DPC 3330s. When set for

factory defaults, COM1 defaults to 115 Kbaud (RS-232), BSAP operation.

COM2 - Port 2 on the 1st CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W9 through W16) (RS-485 operation utilizes CB

SW3). Note: This port was named B on original DPC 3330s. When set for

factory defaults, COM2 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,

BSAP/ControlWave Designer protocol operation.

COM3 - Port 3 on the 2nd CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W2 through W8) (RS-485 operation utilizes CB

SW1). Note: This port was named C on original DPC 3330s. When set for

factory defaults, COM3 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,

BSAP/ControlWave Designer protocol operation.

COM4 - Port 4 on the 2nd CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W9 through W16) (RS-485 operation utilizes CB

Switch SW3). Note: This port was named D on original DPC 3330s. When

set for factory defaults, COM4 defaults to 9600 baud, 8-bits, no parity, 1 stop

bit, BSAP/ControlWave Designer protocol operation.

COM7 - Port 7 on the 1st CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W17 through W23) (RS-485 operation utilizes CB

SW2). Note: This port was named G on original DPC 3330s. When set for

factory defaults, COM7 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,

BSAP/ControlWave Designer protocol operation.

COM8 - Port 8 on the 1st CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W24 through W30) (RS-485 operation utilizes CB

SW4). Note: This port was named H on original DPC 3330s. When set for

factory defaults, COM8 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,

BSAP/ControlWave Designer protocol operation.

Pg. 20 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

COM9 - Port 9 on the 2nd CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W17 through W23) (RS-485 operation utilizes CB

SW2). Note: This port was named I on original DPC 3330s. When set for

factory defaults, COM9 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,

BSAP/ControlWave Designer protocol operation.

COM10 -Port 10 on the 2nd CB: (9-Pin Female D-Type) RS-232 or RS-485 operation

(Configured by CB Jumpers W24 through W30) (RS-485 operation utilizes CB

Switch SW4). Note: This port was named J on original DPC 3330s. When

set for factory defaults, COM10 defaults to 9600 baud, 8-bits, no parity, 1 stop

bit, BSAP/ControlWave Designer protocol operation.

4.1 Step 1 - Hardware Configuration (Continued)

Communication Ports COM1 through COM10 and the Utility Port support serial

asynchronous operation as listed above. Communication ports COM1 through COM10

can be configured for local communications, i.e., connected to a PC loaded with

ControlWave Designer and OpenBSI software. The Utility Port (J8 on the CW_30 CPU

Board) is used for FLASH firmware loads or Core Updumps. The pin labels for the

various RS-232/485 interface connectors are provided in Table 10 (see Figure 10 for RS-

232 wiring diagrams and CPU Port J8 Pin assignments).

RS-232 & RS-485 Interfaces

CW_30 DPC RS-232 & RS-485 communication schemes are discussed herein.

RS-232 Ports

An RS-232 interface supports Point to Point, half-duplex and full-duplex

communications (20 feet maximum, using data quality cable). Half-duplex com-

munications supported by the CW_30 utilize MODBUS or BSAP protocol, while full-

duplex is supported by the Point to Point (PPP) protocol. CW_30 RS-232 ports utilize

the cable shown in Figure 10A - Top) to interconnect with other devices such as a PC,

printer, another ControlWave series unit (other than a CW_10/30/35) when the CW_30

DPC is communicating using the full-duplex PPP protocol. The half-duplex cable of

Figure 10A (Bottom), is utilized when the CW_30 is connected to a ControlWave series

unit (other than a CW_10/30/35) and is running other than the PPP protocol. If

communicating with a Bristol series 3305, 3310, 3330, 3335 RTU/DPC or to another

CW_30//35/10 DPC/RTU, one of the cables shown in Figure 10B must be used.

CW_30 CPU Board’s Utility Port utilizes the cable shown in Figure 10C.

Note: The following facts regarding CW_30 RS-232 serial communication ports should

be observed when constructing communications cables:

• DCD must be high to transmit (except when dialing a modem)

• Each RS-232 transceiver has one active receiver while in powerdown mode

(disabled); the DCD signal is connected to the active receiver.

• CTS must be high to transmit.

• When port is set for full-duplex operation - RTS is always ON.

• DTR is always high (when port is active); DTR enables RS-232 Transceivers.

• When port is set for half-duplex operation - CTS must go low after RTS goes low.

• All RS-232 Comm. ports support RTS, DTR, CTS, DCD and DSR control signals.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 21

Figure 10 - Communication Port RS-232 Cable Wiring Diagram

RS-485 Ports

CW_30 DPCs can use an RS-485 communication port for local network communications to

multiple nodes up to 4000 feet away. Since this interface is intended for network

communications, Table 12 provides the appropriate connections for wiring the master, 1st

slave, and nth slave. Essentially, the master and the first slave transmit and receive data

on opposite lines; all slaves (from the first to the "nth") are paralleled (daisy chained) across

the same lines. The master node should be wired to one end of the RS-485 cable run. A 24-

Pg. 22 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

gauge paired conductor cable, such as Belden 9843 should be used. Note: Only half-duplex

RS-485 networks are supported.

Table 11 - RS-485 Port

Connector Pin Assignments (COM1 through COM10))

Signal

RS-485

Description:

RS-485 Signals

1 TXD+ Transmit Data + Output

2 TXD− Transmit Data − Output

3 RXD+ Receive Data + Input

4 RXD− Receive Date − Input

9 Power Ground Ground

Receiver biasing and termination as well as 2/4-wire selection are enabled by eight-

position DIP-Switches situated on the CW_30 CPU Board for COM5 and COM6 or on

CW_30 CCB Boards for COM 1 through COM 4 and COM7 through COM10 as follows:

COM1: CB Board #1 Switch SW1 (see Figures 8 & 9) (see Table 7)

COM2: CB Board #1 Switch SW3 (see Figures 8 & 9) (see Table 7)

COM3: CB Board #2 Switch SW1 (see Figures 8 & 9) (see Table 7)

COM4: CB Board #2 Switch SW3 (see Figures 8 & 9) (see Table 87

COM5: CPU Board Switch SW3 (see Figure 2) (see Table 4)

COM6: CPU Board Switch SW4 (see Figure 2) (see Table 4)

COM7: CB Board #1 Switch SW2 (see Figures 8 & 9) (see Table 7)

COM8: CB Board #1 Switch SW4 (see Figures 8 & 9) (see Table 7)

COM9: CB Board #2 Switch SW2 (see Figures 8 & 9) (see Table 7)

COM10: CB Board #2 Switch SW4 (see Figures 8 & 9) (see Table 7)

Table 11 provides the connector pin assignments for all CW_30 RS-485 communication

ports. Tables 4 & and 7 provide the RS-485 termination and loopback control Switch

Settings for the RS-485 Ports on the CPU and CB Boards (respectively).

To ensure that the “Receive Data” lines are in a proper state during inactive transmis-

sion periods, certain bias voltage levels must be maintained at the master and most dis-

tant slave units (end nodes). These end nodes also require the insertion of 100-Ohm

terminating resistors to properly balance the network. CPU and CB Board switches

must be configured at each node to establish proper network performance. This is ac-

complished by configuring the appropriate CPU/CB Board Switches so that the 100-

Ohm termination resistors and biasing networks are installed at the end nodes and are

removed at all other nodes on the network (see Table 4 for CPU Boards and Table 7 for

CB Boards).

Table 12 - RS-485 Network Connections

(see Table 11 for CW_30 RS-485 Port Pin # Assignments)

From

Master

To 1st

Slave

To nth

Slave

TXD+ RXD+ RXD+

TXD− RXD− RXD−

RXD+ TXD+ TXD+

RXD− TXD− TXD−

GND/ISOGND*

GND/ISOGND* GND/ISOGND*

* ISOGND with Isolated RS-485 Ports Only!

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 23

Note: Pins 1, 2, 3, 4 & 9 of Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm.

Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 = ISOGND.

4.1 Step 1 - Hardware Configuration (Continued)

5. Apply power to the CW_30 DPC. Continue with Steps 2 through 7 below (Sections 4.2

through 4.7 and 5.1) and the CW_30 will be ready for on line operation.

4.2 Step 2 - Software Installation on the PC Workstation

ControlWave Designer software must be installed on the PC. This is accomplished by

installing the ControlWave Designer Package from the Open BSI CD ROM.

You must install the Open BSI Network Edition. For information on minimum system

requirements and more details of the installation, see the installation procedure in Chapter

2 of the Open BSI Utilities Manual (document # D5081).

IMPORTANT:

When you start ControlWave Designer, you will be reminded to register the

software. Unregistered software can only be used for a maximum of 30 days. For

more information on the registration process, see Chapter 2 of the Open BSI

Utilities Manual (document# D5081).

4.3 Step 3 - Establish Communications using either LocalView or NetView,

and run the Flash Configuration Utility

Communications must be established with the CW_30 using either LocalView or NetView.

The CW_30 CPU Board ships from the factory with a default Flash configuration. Most

users will need to edit this configuration to set the IP address (if using Ethernet – default

IP address = 10.0.1.1 with IP Mask = 255.255.255.0), BSAP local address, user accounts,

and port parameters. This can be done in one of two ways:

• Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in

the Flash Configuration Utility, or in a text editor,

• or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash

Configuration Utility.

Detailed information on the Flash Configuration Utility and LocalView is included in

Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in

Chapter 6 of that same manual.

4.4 Step 4 - Create an Application-specific Control Strategy in Control-

Wave Designer

At this point, you can create your application-specific control strategy using ControlWave

Designer. If you are upgrading this unit from a DPC 3330 ACCOL II-based unit, you can

start by using the ACCOL Translator utility to take an existing ACCOL II load, and convert

it to a ControlWave Designer project. You will then need to examine the translated project,

and modify it, as necessary, to re-work logic that is unsupported in ControlWave Designer.

Pg. 24 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

If you don’t have a pre-existing ACCOL load to translate, you can create an all-new project

in ControlWave Designer. This involves opening a new project using the ‘ControlWave

MICRO’ template, defining I/O boards using the I/O Configurator, and creating a program

using one or more of the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL).

Some of these languages are text based, others use graphical diagrams. The choice is up to

you, depending upon your particular application.

The ControlWave MICRO Quick Setup Guide (document # D5124) includes a simple LD

example. Additional examples are included in the manual, Getting Started with

ControlWave Designer (document # D5085). More detailed information about

ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference

Manual (document # D5088).

The ACCOL3 Firmware Library, which is automatically accessible through the template

referenced above, includes a series of function blocks which perform a variety of process

control and communication functions. These can be included within your program to

perform various duties including PID control, alarming, calculations, etc. Detailed

information about each function block is included in the ControlWave Designer on-line

help files.

On the variables declaration page(s) in ControlWave Designer, you will need to mark any

variable you want to make accessible to external programs, such as Open BSI’s DataView

utility, as “PDD”. Similarly, any variables which should be collected into a database, or

exported using the OLE for Process Control (OPC) Server must be marked as “OPC”.

Variables marked as OPC can be built into a text file by the Open BSI Signal Extractor.

The text file can then be used in the creation of a database for human machine interface

(HMI) software such as OpenEnterprise, or Iconics’ Genesis. These HMI software packages

require that the "Datatype conversion enable" option be selected when generating the

file using Signal Extractor. Information about the Open BSI Signal Extractor is included in

Chapter 12 of the Open BSI Utilities Manual (document # D5081).

Once the program has been created, it is assigned to an executable task. The entire project

is then saved and compiled.

Debugging of your completed control strategy program can be performed using the built-in

debugger, and the I/O Simulator. Optionally, you can also use the I/O Simulator to simulate

the outputs on your I/O boards, as your project executes. Note, however, that the I/O

Simulator only supports the IPCxx resource; therefore, to use it, you will need to add a

second resource (IPCxx) to your project, and make copies of your tasks and global variable

worksheets under the new resource.

NOTE:

From this point on, the order of steps may be varied, somewhat,

depending upon the requirements of the user's application.

4.5 Step 5 – Create Application-specific Web Pages (OPTIONAL)

ControlWave series controllers, including the CW_30, can optionally export data to user-

created web pages.

A series of ActiveX controls for data collection and configuration are provided on the Open

BSI CD that can be included as part of these web pages (For information on the ActiveX

controls, see the Web_BSI Manual (document# D5087).

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 25

You can use whichever HTML creation package you want to create the pages, however, all

ControlWave web pages must be viewed within Microsoft® Internet Explorer.

The web pages may reside either on the PC workstation, or they can be downloaded into

FLASH memory at the CW_30. If stored at the CW_30, you must use the ControlView

utility to retrieve the page (using FTP) for viewing in Internet Explorer.

4.6 Step 6 – Create an Open BSI Network Containing the CW_30, or add the

CW_30 to an Existing Open BSI Network

In order for the CW_30 unit to function as part of a Bristol network, it is necessary to

include it in the Bristol network.

If no Bristol network exists:

You need to run Open BSI’s NetView software on the PC workstation in order to define

a Bristol network. A series of software wizards are used to define a Network Host PC, a

network, and the DPC/RTUs (controllers) assigned to the network. Finally, com-

munication lines must be specified which handle the address assigned to the CW_30.

Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081) include ‘quick

start’ examples for performing these steps. More detailed information is included in the

NetView chapter (Chapter 6) of D5081.

If a Bristol network already exists:

You will need to add the CW_30 to the existing network using NetView’s RTU Wizard.

Chapter 6 of the Open BSI Utilities Manual (document # D5081) includes different sub-

sections depending upon whether you are adding the unit to a BSAP network, or an IP

network.

4.7 Step 7 – Download the Application-specific Control Strategy into the

CW_30 DPC

Either ControlWave Designer or the Open BSI 1131 Downloader allows you to download

your completed control strategy (application load) file into the CW_30 DPC. Users

download the control strategy into the BOOT Project area of FLASH memory; this ensures

that if the CW_30 DPC is reset, or if there has been a failure of the backup battery, that the

control strategy can be restarted from the beginning, i.e., from the BOOT Project in FLASH

memory.

The Open BSI 1131 Downloader also allows the user to download files (such as user-created

web pages) into FLASH memory in the ControlWave_30 DPC. These can then be uploaded

to the PC using the ControlView utility. To download the application load, see Section 5.1

titled Downloading the Application Load.

SECTION 5 - OPERATIONAL DETAILS

CW_30 DPCs are shipped from the factory with firmware that allows the unit to be con-

figured in conjunction with an IEC 61131, application program. This section provides in-

formation as follows:

- Steps required to download the application load and place the unit into ‘Run’ mode.

- Steps required to download system firmware.

- Core Updumps

Pg. 26 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

5.1 Downloading the Application Load

Any CW_30 DPC must have a configured application load before it can be placed into

operation. For units being upgraded with the hardware discussed herein, this will require

connection of the CW_30 DPC to a PC running Windows NT (4.0 or higher), Windows 2000 or

Windows XP Professional and equipped with ControlWave Designer software & OpenBSI

software. Configuration of the application load must be performed by an individual familiar

with the various programming tools. The following software user documentation is referenced:

Getting Started with ControlWave Designer Manual - D5085

ControlWave Designer Reference Manual - D5088

Open BSI Utilities Manual - D5081

Web_BSI Manual - D5087

An application load download can be initiated, i.e., from ControlWave Designer, or from the

OpenBSI 1131 Downloader for CW_30 DPC Nodes.

1. Make sure that the CW_30 CPU’s Recovery Switch (SW1) is set in ‘Local Mode,’ i.e.,

SW1-1 set to the OFF position and SW1-2 set to the ON position.

Note:

From the factory, COM1 defaults to 115.2 Kbaud (RS-232) using the BSAP

Protocol. Don’t connect COM1 to a PC unless the PC’s RS-232 port in

question has been configured for BSAP operation.

2. Once the CW_30 DPC project has been defined, communications and configuration

parameters have been set, perform the download according to either ‘ControlWave

Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’ (see D5081 -

Chapter 7).

3. After the download has been completed leave the CPU Mode Switch (SW1) in the ‘Local

Mode’ position.

5.2 Upgrading CW_30 Firmware

CW_30 CPU Boards ship from the factory with system firmware already installed. If an

upgrade of the system firmware is required, use one of the procedures below to download

the new or replacement firmware from the PC. Upgrade of system firmware via LocalView

FLASH Mode requires OpenBSI 5.1 (or newer). If you have an older version of OpenBSI,

FLASH upgrades are to be performed via HyperTerminal. You will need a binary (*.BIN)

system firmware file that is read as follows: c_30450.bin (where c_3 is the product code and

0450 is the release number). Upgrade of an unattended CW_30 can be accomplished from a

remote PC. This capability is introduced in Section 5.2.3.

5.2.1 Using LocalView to Upgrade CW_30 Firmware

NOTE

Your CW_30 DPC must be set to Recovery Mode ENABLE (ON) prior to per-

forming the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after the

upgrade. On CW_30 DPCs this is accomplished via the CPU Board’s Recovery

Switch SW1. Set SW1-3 to the ON position for Recovery Mode. After setting SW1-3

to the ON position, turn power OFF and then ON again.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 27

A communication cable (see Figure 10C) must be connected to the Utility Port on the

CW_30 CPU Board and to any RS-232 port on the associated PC. The PC’s RS-232 port

used for this purpose must be set to run at 115.2 Kbaud. CW_30 CPU Switch SW1,

position, 3 must be set ON.

Start LocalView, Choose FLASH, Enter A Name, Click on [Create]

Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The

New View Mode dialog box will appear (see Figure 11).

Figure 11 - Local View - New View Mode Menu

"Mode"

Choose 'Flash' for the mode.

"Name"

Enter a name for the View Mode File in the "Name" field.

"Location"

If you want to store the View Mode File in a directory other than that shown in the

"Location" field, enter the new location there, or use the [Browse] push button to find

the directory.

When the "Mode", "Name", and "Location" have been specified, click on the [Create] push

button to activate the Communication Setup Wizard.

Step 1 - Communication Setup

Choose the communication port you want in the What port would you like to use: field.

Click on the [Next] pushbutton to activate the next wizard.

Step 2 - Flash RTU Setup

In the Flash RTU Setup Wizard, you need not set the RTU type or local address, since these

are unused in this mode. Click on the [Next] push button to activate the Flash Data Setup

Wizard.

Pg. 28 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 12 - Communication Setup: Step 1 Menu

CW_30

Figure 13 - Flash RTU Setup Menu

Step 3 - Flash Data Setup

Complete the following fields in the Flash Data Setup Wizard:

"Please enter the name of the binary file to Flash"

To upgrade system firmware, you must specify the path and name of a binary (*.BIN)

file on your hard disk containing the firmware.

Click on [Finish] to install the specified BIN file in FLASH memory at the DPC.

Once the Flash download has begun, you will NOT be allowed to shut down LocalView,

unless you cancel the download, or it has been completed.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 29

The progress of the Flash download will be displayed in the window. Any mismatch in file

versions, or if the type of .BIN file does not match the type of RTU/DPC, the download will

be aborted.

D:\OpenBSI\c_30450.bin

Figure 14 - Flash Data Setup Menu

Progress of the

flash download

Message area

‘Mod’ indicates

unsaved changes

to LVG file.

Total number of bytes in BIN file

Number of bytes

already downloaded

Path and filename of BIN file

If necessary, click here

to cancel the flash

wnl

oad

These fields do

NOT apply to

Controlwave-series

units.

D:\OpenBSI\c_30450.bin

Figure 15 - LocalView Downloading System Firmware Menu

Pg. 30 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Once the download has completed, set CPU Board Switch SW1-3 to the OFF position and

then turn power OFF and then ON again.

5.2.2 Using HyperTerminal to Upgrade CW_30 Firmware

A communication cable (see Figure 10C) must be connected to the CW_30 CPU Board’s

Utility Port and to any RS-232 port on the associated PC. The PC’s RS-232 port used for

this purpose must be set to run at 115.2 Kbaud. CW_30 CPU Board Switch SW1, position, 3

must be set to the ON position.

1. If not already running, apply power to the associated PC.

2. Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or

newer) application utility program. If using HyperTerminal for the first time, set the

communications properties (for the PC Port being utilized) via the Properties Menu as

follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop bits: = 1, and Flow

control: = None. After setting the communications properties, click OK.

3. Set the CW_30 CPU Board’s Recovery Switch (SW1) for ‘Recovery Mode,’ i.e., set CPU

Board Switch SW1-3 to the ON position.

4. Apply power to the CW_30 DPC. The resident BIOS will initialize and test the

hardware, this process is referred to as POST (Power On Self Test).

Unless there is a problem status code 10 (Status LED #5 ON) will be posted to the CPU

Board’s Status LEDs. Detection of a fault during POST will be posted on the Status

LEDs. When the Power On Self Test has completed, a system status code will be posted

to the Status LEDs (see Table 6 and Figure 6).

Figure 16 - HyperTerminal Recovery Mode Menu

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 31

From the HyperTerminal Recovery Mode menu (Figure 16), press the ‘F’ key to enter

FLASH download. A message will be displayed warning that the FLASH is about to be

erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices

are being erased; this could take a few minutes.

5. When the FLASH is ready for download the letter C will be displayed on the screen. In

the HyperTerminal command bar click on Transfer and then Send File (see Figure 17).

In the Send File Dialog Box (see Figure 18), select “1KXmodem” for the protocol, enter

the filename of the appropriate .bin file in the format “C_3xxxx.bin” (where xxxx varies

from release to release). Click on the Send button to start the download (see Figure 18).

When the HyperTerminal Recovery Mode Menu of Figure 16 appears, the download has

completed.

Figure 17 - HyperTerminal FLASH Download Menu

(Ready to Download) - (Transfer/Send File Selected)

Figure 18 - HyperTerminal Flash Download (Send File Dialog Box)

Pg. 32 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

6. Close the HyperTerminal program. The communication cable connected between the

CW_30 DPC and the PC can be removed if desired.

7. Set the CPU Board’s Recovery Switch (SW1) for ‘Local Mode,’ i.e., set SW1-1 OFF and

SW1-2 ON). Set SW1-3 OFF and then switch power OFF/ON.

Once the CW_30 DPC is running its application load, status codes will be posted to the six

Status LEDs on the CPU Board. These Status LED (Hex) Codes are listed in Table 6 (see

Figure 6).

Figure 19 - HyperTerminal FLASH Download (Download in Process)

5.2.3 Remote Upgrade of CW_30 Firmware

It is possible to download system firmware into an unattended remote CW_30 DPC. This

function can only be accomplished if CPU Board Switch SW2-6 (associated with the unit in

question) is set in the ON position (factory default). The procedure for performing a remote

download of system firmware is discussed in Appendix J of the Open BSI Utilities Manual

(document D5081). Note: Remote Upgrade of CW_30 Firmware requires Boot PROM

version 4.7 or higher and System PROM version 4.7 or higher.

5.3 Core Updump

In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for

evaluation by Bristol, Inc. engineers. This upload is referred to as a ‘Core Updump.’ A Core

Updump may be required if the CW_30 Distributed Process Controller repeatedly enters a

‘Watchdog State’ thus ill effecting system operation. A Watchdog State is entered when the

system crashes, i.e., a CPU timeout occurs due to improper software operation, a firmware

glitch, etc. In some cases the Watchdog State may reoccur but may not be logically

reproduced.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 33

‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in

CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block

Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash

Block files should be forwarded to Bristol, Inc. for evaluation. If additional information is

required to evaluate the condition, a Core Updump may be requested by Bristol. Once the

file generated by the Core Updump has been forwarded to Bristol, it will be evaluated and

the results will be provided to the user.

Follow the five steps below to perform a Core Updump.

1. Set CPU Board Switch SW2-1 OFF (Disable Watchdog Timer). If Switch SW2-4 is ON,

set it to OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is

OFF.

2. Wait for the error condition (typically 3F on CPU Board Status LEDs).

3. Connect CW_30 DPC’s Utility Port to a PC (see Figure 10C).

4. Set CPU Board Switch (SW1- Recovery) so that SW1-1 and SW1-2 are both in either the

ON position or the OFF position.

5. Start the PC’s HyperTerminal Program (at 115.2kbaud) and generate a file using the

1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to

Bristol, Inc. for evaluation.

When the Core Updump has been completed, set the CPU Board’s Recovery Switch as

follows: SW1-1 is in the OFF position & SW1-2 is in the ON position.

SECTION 6 - GENERAL SERVICE NOTES

Certain questions or situations frequently arise when servicing the CW_30 DPC. Some

items of interest are provided in Sections 6.1 through 6.3.

6.1 Extent of Field Repairs

Field repairs to a CW_30 DPC are strictly limited to the replacement of complete modules.

Component replacement on a CW_30 DPC Module constitutes tampering and will violate

the warranty. Defective CW_30 DPC components (printed circuit boards, LCD Displays,

etc.) must be returned to Bristol, Inc. for authorized service.

6.2 Disconnecting RAM Battery

The CW_30 DPC’s Lithium RAM battery cannot be replaced while power is on. Once the

RAM battery has been replaced, the unit will still execute its FLASH-based application load

(Boot Project) upon power-up, but all of the current process data will have been lost. Upon

power-up, the unit will act as though it had just been booted and it will revert back to the

initial values specified in its application load. The battery may be disabled by setting the

CW_30 CPU Board’s Battery Backup Board Jumper (W3) in position 2 to 3.

Pg. 34 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

6.3 Maintaining Backup Files

It is essential to maintain a backup disk of each application load file to guard against an

accidental loss of process configuration data. Without a backup record, it will be necessary

to reconfigure the entire application load; that can be a very time consuming procedure.

Always play it safe and keep backup copies of your operating system loads. A copy of the

application load can be loaded into CW_30 DPC FLASH memory and/or saved to a PC’s

Hard Drive as a ZIP file.

SECTION 7 - WINDIAG DIAGNOSTICS

Bristol’s WINDIAG Software is a diagnostic tool used for testing CW_30 DPC electronics

including, I/O circuitry, CPU memory, communications ports, etc., for proper performance.

The CW_30 DPC must be communicating with a PC equipped with the WINDIAG program.

CW_30 CPU Board configuration switch SW2-8 must be set to the OFF (Closed) position to

enable diagnostics. Communication between the CW_30 DPC (with/without application

loaded) and the PC can be made via a Local or Network Port with the following restrictions:

• CW_30 CPU Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting

SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into

diagnostic mode.

• The CW_30 communication port connected to the PC (running the WINDIAG program)

must match the speed of the PC. All serial communication ports (except COM1) can be

configured for 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer

protocol operation by setting CW_30 CPU Switch SW2-3 OFF This can also be

accomplished via user defined Soft Switches.

• Communication port COM1 is forced to 9600 baud operation when CW_30 CPU

Switches SW2-3 and SW2-8 have both been set OFF. COM1 can also be set to 9600 baud

operation via user defined Soft Switches.

To use the WINDIAG program place any critical process (associated with the CW_30 DPC

unit in question) under manual control. WINDIAG cannot be run while the CW_30 DPC

application is running. Set CW_30 CPU Board Switch SW2-8 to the OFF position. Perform

steps 1 through 6 below.

1. Start the OpenBSI NetView Program. A menu similar to Figure 20 will appear.

2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools,

then select Utilities Programs and then select Diagnostics.

3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 21 will appear.

4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG

will perform the diagnostics and display pass/fail results.

5. After all diagnostic testing has been performed, exit the WINDIAG program and then

exit the NetView Program if there aren’t any other CW_30 units to be tested.

When you close the NetView program you will be prompted as to whether or not you

want to close the OpenBSI program; select Yes.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 35

Figure 20 - NetView Startup Menu - Example with Multiple Networks

Figure 21 - WINDIAG Main Diagnostics Menu

6. Set CW_30 CPU Board Switch SW2-8 to the ON (Open) position and reboot the unit.

The CW_30 DPC should resume normal operation.

Pg. 36 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

7.1 Diagnostics Using WINDIAG

CW_30 electronics can be tested using the WINDIAG program. From WINDIAG’s Main

Diagnostics Menu (see Figure 18) the following diagnostic tests can be performed:

CPU & Peripherals Diagnostic: Checks the CPU Board [except for RAM & PROM

(FLASH)].

PROM/RAM Diagnostic: Checks the CPU Board’s RAM and PROM (FLASH)

hardware.

EEPROM Diagnostic: Checks I/O Module EEPROM on an I/O Module.

Communications Diagnostic: Checks all Comm. Ports - The External loop-back tests

require the use of a loop-back plug.

Ethernet Diagnostic: Checks Ethernet Port 1 and 2 on the CPU Board.

Analog Output Diagnostic: Checks AOs on various AO Modules.

Analog Input Diagnostic: Checks AIs on various AI Modules.

Low Level Analog Input Diag.: Checks AIs on the Low Level AI Module.

Discrete I/O Diagnostic: Checks DIs or DOs on various DI and DO Modules.

High Speed Counter Diagnostic: Checks HSCs on various High Speed Counter Modules.

Keyboard & Display Diagnostics Checks Keyboard/Keypad & Display hardware

Information on serial communication port loop-back testing is provided herein. For

additional information on WINDIAG tests, see document D4041A.

7.1.1 Communication Diagnostic Port Loop-back Tests

WINDIAG’s Communications Diagnostic Menu (see Figure 24) provides for selection of the

communication port to be tested. Depending on the type of network (RS-232 or RS-485) and

the port in question, a special loop-back plug is required as follows:

Ports 1 through 10 - RS-232: use a 9-pin male D-type loop-back plug or loop-back wires

(see Fig. 22).

Ports 1 through 10 - RS-485: use a 9-pin male D-type loop-back plug or loop-back wires

(see Fig. 23) or configure CW_30 CPU Switches (SW3 and

SW4) and/or CB Switches (SW1, SW2, SW3 and SW4) for

loopback operation (see Tables 4 & 7).

This group of tests verifies the correct operation of the Communication Interface. COM1,

through COM10 can be tested with this diagnostic. The CW_30 communication port that is

connected to the PC (local or network and used for running these tests) can’t be tested until

diagnostics has been established via one of the other ports, i.e., to test all CW_30 serial RS-

232/485 communication ports (via WINDIAG), communications with the PC will have to be

established twice (each time via a different port). It should be noted that the CW_30

communication port that is connected to the PC (RS-232, RS-485 or Ethernet) must be good

for WINDIAG to run the Communications Diagnostics

7.1.2 Serial Comm. Port External Loop-back Test Procedure

1. Connect an external loop-back plug or loop-back wires to the Communication Port to be

tested (see Figures 22 and 23). For RS-485 Loopback testing, CPU Switch SW3 and/or

SW4 can be configured for loopback operation (see Table 4).

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 37

9-Pin Male

“D” Connector

Loop-back Plug

(Looking from rear/wire side of Plug)

6 = CTS

7 = DCD

4 = RXD

2 = TXD

1 = DTR

5 = RTS

Figure 22 - RS-232 Loop-back Plug/Wires

9-Pin Male

“D” Connector

Loop-back Plug

(Looking from rear/wire side of Plug)

2 = TXD_

4 = RXD

3 = RXD+

1 = TXD+

Figure 23 - RS-485 Loop-back Wires

Figure 24 - WINDIAG’s Communications Diagnostic Menu

Pg. 38 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

2. Type "1," "2," "3," etc. (up to "10") for the port to test.

3. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5.

4. Click on RUN button next to External loop-back.

 Test responses:

a) Success - All sections of test passed

b) Failure - TXD RXD Failure

- CTS RTS Failure

 Execution time < 5 sec.

7.1.3 Ethernet Port Diagnostics

The Ethernet Diagnostic menu of Figure 25 is entered from the WINDIAG Main Diagnostic

Menu (Figure 21). This menu provides four poke points (three associated with Ethernet

circuitry test and one that provides the Return Hardware Address [which resides in

FLASH]). These tests verify the operation and integrity of the PCNET (Ethernet) Controller

and the Ethernet port hardware on the CPU Board and CB Board.

Figure 25 - Ethernet Diagnostic Menu

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 39

7.1.3.1 10/100Base-T (RJ-45 - Twisted Pair) Port Hardware Setup

The 10/100Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub.

To configure the system for the Loop-Back Out Twisted Pair diagnostic test either remove

the standard R-J45 cable from the CPU Board's R-J45 connector and replace it with an R-

J45 cable configured for loop-back, or remove the R-J45 cable associated with the port in

question from the hub and install the unterminated end into an RJ-45 Jack configured for

loop-back. Table 13 provides the pin identification and description for the RJ-45 port. Pin-1

(TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-)

for proper loop-back test configuration (see Figure 26).

If the "Loop-Back Out Twisted Pair" Test RUN button is selected while the port is attached

to an Ethernet Hub, a Failures Status will be posted.

Table 13 - Ethernet 10/100Base-T (RJ45) Connector Pin Assignments

Pin # Pneumonic Description

1 TX+ Transmit Data+

2 TX- Transmit Data-

3 RX+ Receive Data+

4 - Not Connected

5 - Not Connected

6 RX- Receive Data-

7 & 8 - Not Connected

Figure 26 - RJ-45 Ethernet Loop-back Plug

7.1.3.2 Ethernet Port Diagnostic Test Execution

There are four unique test buttons provided on the Ethernet Diagnostic Menu. Note: Only

the "RUN Loop-back out twisted pair" and "RUN Return hardware address" tests are

applicable to CW_30 units, i.e., the "RUN Chip internal loop-back" and "RUN Loop-back

out AUI port" tests aren’t applicable. The applicable tests are discussed below.

Pg. 40 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

7.1.3.3 Loop-back Out Twisted Pair Test RUN Button

Set the Number of Passes. Make sure that the port is properly configured with a cable or

jack for loop-back testing (see Section 7.1.3.1). Click on the "RUN Loop-back out twisted

pair" Test button. The test will proceed and return either 'Success' or one of the following

responses under the STATUS column:

Fail - No Hardware Present

- Loop-back Send Failed

- Loop-back Receive Failed

- Loop-back Compare Failed

- Error Information Returned

When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the

hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jack-

plug and reconnect the Ethernet cable to both the CW_30 Ethernet port and the Ethernet

Hub.

7.1.3.4 Return Hardware Address Test RUN Button

Set the Number of Passes. Click on the "Return hardware address" Test button. The test

will proceed and if successful the hardware address will be displayed. The hardware

address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all Bristol

Ethernet Comm. ports. The remainder of the hardware address is unique for each board

manufactured and is stored in EEPROM. If the error message "Error Information

Returned" is displayed instead of the hardware address, and the unit has been programmed

with a proper hardware address, the CPU Module should be replaced.

7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages

If either a "No Hardware Present" or "Error Information Returned" message is displayed,

ensure that the loop-back test requirements have been properly established (see Section

7.1.3.1). If test requirements have been met and the cable associated with the port test in

question is known to be good, the CPU Module should be replaced with a good unit.

In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare

Failed" message, check the cable in question. If the cable associated with the port test in

question is known to be good, the CPU Module should be replaced with a good unit.

SECTION 8 – DISPLAY/KEYPED ASSEMBLY OPERATION

CW_30s support Display/Keypad assemblies (local or remote) that were present prior to the

conversion to the ControlWave platform. Additionally, connector J6 on the CW_30’s CPU

Board accommodates connection to one of two unique remote Display/Keypad Assemblies;

one with a dual-button Keypad (see Figure 27) and one with a 25-button Keypad (see

Figure 2-28). Both Display/Keypad assemblies utilize identical 4 x 20 LCD Displays. Each

Display/Keypad assembly employs a unique microcontroller based Display/Keypad

Interface Circuitry (situated on the remote Display/Keypad assembly that drive the LCD

Display and interfaces the Keypad. Interface to the CW_30 is made via a cable equipped

with two plugs. This cable connects to the RJ-45 Display Jack (J3) on the CW_30

Expansion Board and RJ-45 Jack (J1) on the remote Display or Display/Keypad assembly.

A potentiometer is provided on the Display or Display/Keypad to set the contrast of the

LCD Display.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 41

Figure 2-27 provides mounting hardware information for the Dual-button Display/Keypad

Assembly. Operation of the Dual-button Display/Keypad Assembly is discussed in Section

2.4.5.1 of this document.

Figure 2-28 provides mounting hardware information for the 25-button Display/Keypad

Assembly. Information on configuring the ‘Display Function Block’ (required to configure

the Display associated with the 25-button Display/Keypad Assembly) is provided in

ControlWave Designer’s On-Line Help.

Note: Operation of the 25-button Display/Keypad Assembly is discussed in Ap-

pendix DKA of this document.

8.1 Operation of the Dual-button Display/Keypad Assembly

The Display will have a timeout of 20 minutes. If there has been no keypad activity for this

time the display will “logout,” i.e., the display will be turned off and scrolling stopped until

a key press occurs. When a key press occurs after a timeout the display will return to the

opening screen.

If a shorter timeout of the display is needed for power savings, another timeout may be

implemented. The processor connected to the display will control the timeout. When the

timeout occurs the display will be blanked, but communications between the CW_30 CPU

and display processor will still occur. The display processor will ignore posting the

messages to the screen when in the low power mode. When a key is pressed the display

processor will return to displaying information to the display.

Displays are organized into screens as follows:

Opening Screen: User defined strings

List Selection Screen: List Name

List Number

The List Selection screen is entered from the main opening screen by pressing the right

arrow. Once here the operator can select which list is to be viewed. The operator can

traverse though different list numbers by pressing the down arrow key. When the list to be

scrolled is shown on the display, pressing the right arrow key will bring the operator to the

Display Element screen.

Display Element Screen: <Blank Line>

Variable Name

The Display Element screen is entered from the list selection screen by pressing the right

arrow. Once here the operator can view the variables in the list. Once entered the first

element of the list is displayed and then next element will be displayed after the scroll

timeout occurs. The scrolling will continue displaying the next element in the list and then

wrapping around to the beginning of the list. The down arrow key will toggle the display

through hold and scroll mode. Pressing the right arrow key will bring the operator to the

list selection screen.

Pg. 42 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 27 - Dual-button Display/Keypad Assembly Installation Drawing

Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.

Automatic Mode

In Automatic mode a set of screens (based on the application load) are displayed. The

application programmer provides strings for the opening screen. From there the firmware is

responsible for displaying the screens and responding to key presses. Screens are fixed and

start off with an opening screen, which displays user information passed into the function

block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled

has been selected, the user can scroll through the list by pressing the down arrow key. List

elements will be displayed automatically, scrolling at a predetermined rate (determined by

iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing

the right arrow key again will cause the list to start scrolling again.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 43

The essence of Automatic mode is that the user can supply inputs into the function that will

determine which list can be displayed, but cannot change the menu or display. The user is

allowed to select a list and to start/stop scrolling.

Figure 2-28 - 25-Button Display/Keypad Assembly Installation Drawing

Manual Mode

In Manual Mode the programmer is responsible for creating each screen and displaying the

next desired screen, based on key inputs. The programmer has access to all lines of the

display and can provide any string that he/she desires to display. Special formats that must

be adhered to that allow the programmer to display what they want on the screen are

provided in the description of iaScrnSruct in the ACCOL 3 Display function block within

ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode

does not support reading Keypad key-presses. Note: Manual Mode operation requires

ControlWave Firmware 4.50 or newer.

Pg. 44 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

SECTION 9 - CW_30 SPECIFICATIONS

9.1 CW_30 CPU Board Specifications

Processor: Sharp’s LH7A400 32-bit System-on-Chip with 32-bit

ARM9TDMI RISC Core

Memory: 16 Mbytes of simultaneous read/write FLASH

1 Mbyte of on-board SRAM

512 Kbytes FLASH Boot/Downloader

4 Mbytes of SDRAM

Real Time Clock: A Semtech SH3000 support IC provides a full BCD clock

calender with programmable periodic/wakeup interrupt and

a programmable clock generator with adjustable spectrum

spreading.

Connectors: (see Table 14)

Table 14 - CPU Board Connector Summary

Ref. # Pins Function Notes

P2 62-pin Backplane Intf. CW_30 I/O Bus Interface

J2 8-Pin Ethernet Female Port # 1 10/100Base-T

J3 8-Pin Ethernet Female Port # 2 10/100Base-T

J5 21-pin Off-board Serial Comm. Port Intf.

Connector (RS-232/485)

Interfaced via a cable to COM5 and

COM6 on Interface Board Ass’y.

No. # 392574-01-2.

J8 3-pin RS-232 Utility Port 115.2 Kbaud to PC for Firmware

Flash and Core Updumps

9.1.1 CPU Board Communication Port Specifications

CPU Board Comm. Ports: J8: 3-pin In-line – Utility Port (RS-232)

J5: 21-pin Interface (Via cable) to Off-board serial Comm.

Ports BIP1/COM5 and BIP2/COM6 (which reside on

Interface Board Assembly 392574-01-2) COM5 & COM6

are individually configurable for RS-232 or RS-485

operation and utilize 9-Pin D-Type Female Connectors

J2: 8-pin 10/100Base-T (Female) Ethernet Port 1

J3: 8-pin 10/100Base-T (Female) Ethernet Port 1

Baud Rate: 300 to 115Kbps for RS-232 or RS-485

See Table 9 for connector pin assignments

9.1.2 CPU Board 3.3V Power Supply Specifications

Input: +5Vdc

Output Voltages: +3.3Vdc ±1%

Output Current: 0.6A Max. @ 3.3Vdc

Output Ripple P/P: +3.3V Output: 10mV

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 45

9.1.3 CPU Board Environmental Specifications

Temperature: Operating: -40 to +158 °F (-40 to +70 °C)

Storage: -40 to +185 °F (-40 to +85 °C)

Relative Humidity: 0-95% Non-condensing (Operating & Storage)

Vibration: 1g acceleration over 10 to 150 Hz

.5g acceleration over 150 to 2000 Hz

RFI/Emissions: In conformity with the following standards: ENV 50140

Radio-frequency electromagnetic field amplitude modulated

EMV

9.2 CW_30 Communication Board (CB) Specifications

9.2.1 CB Board Connectors

Table 15 – CB Board Connector Summary

Ref. # Pins Function Notes

J1 36-pin Backplane Intf. CW_30 I/O Bus Interface

Bottom

9-pin RS-232/485 Serial Comm. Port 1/3

(Bottom Left)

Female D-Type:

1 on CB#1, 3 on CB#2

Bottom

9-pin RS-232/485 Serial Comm. Port 2/4

(Bottom Right)

Female D-Type:

2 on CB#1, 4 on CB#2

Top

9-pin RS-232/485 Serial Comm. Port 7/9

(Top Left)

Female D-Type: 7 on CB#1, 9 on

CB#2 (Not On 2-Port CBs)

Top

9-pin RS-232/485 Serial Comm. Port 8/10

(Top Right)

Female D-Type 8 on CB#1, 10 on

CB#2 (Not on 2-Port CBs)

9.2.2 CB Board Communication Port Specifications

CB Board Comm. Ports: see Table 15

Baud Rate: 300 to 115Kbps for RS-232 or RS-485

See Table 10 for connector pin assignments

9.2.3 CB Board 3.3V Power Supply Specifications

Input: +5Vdc

Output Voltages: +3.3Vdc ±1%

Output Current: 0.6A Max. @ 3.3Vdc

Output Ripple P/P: +3.3V Output: 10mV

9.2.4 CB Board Environmental Specifications

Temperature: Operating: -40 to +158 °F (-40 to +70 °C)

Storage: -40 to +185 °F (-40 to +85 °C)

Pg. 46 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Relative Humidity: 0-95% Non-condensing (Operating & Storage)

Vibration: 1g acceleration over 10 to 150 Hz

.5g acceleration over 150 to 2000 Hz

www.EmersonProcess.com/Bristol

Product Information Package

PIP-CW_30 Upgrade Kit

Nov., 2006

30 Dis

/Ke

(

25 Ke

)

ControlWave_30 DISPLAY/KEYPAD

(with 25 Keys) ASSEMBLY GUIDE

Appendix DKA

PIP-CW_30 Upgrade Kit Appendix DKA – Display/Keypad Contents / 0 - 1

APPENDIX DKA

ControlWave_30 DISPLAY/KEYPAD

(with 25 Keys) Assembly Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

DKA1.1 OVERVIEW ..............................................................................................................DKA-1

DKA2.1 DISPLAY FUNCTION BLOCK DESCRIPTION....................................................DKA-2

DKA2.1.1 DISPLAY Function Block Parameters ....................................................................DKA-2

DKA3.1 PREPARING THE ControlWave PROJECT...........................................................DKA-3

DKA4.1 USING THE KEYPAD .............................................................................................DKA-4

DKA4.1.1 Scrolling.....................................................................................................................DKA-5

DKA4.1.2 Signing-On ................................................................................................................DKA-6

DKA4.1.3 Using the Clock Functions ....................................................................................... DLA-7

DKA4.1.3.1 Changing the Time ...................................................................................................DKA-8

DKA4.1.3.2 Changing the Date....................................................................................................DKA-8

DKA4.1.4 Choosing a Variable List from the List Menu.........................................................DKA-8

DKA4.1.5 Moving Through a Variable List..............................................................................DKA-9

DKA4.1.6 Changing Variable Parameters ...............................................................................DKA-9

DKA4.1.7 Signing-Off ..............................................................................................................DKA-12

DKA5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO....................................DKA-13

NOTE: The Dual-button Display/Keypad Assembly is discussed in Section 8.1 of

PIP-CW_30 Upgrade Kit.

PIP-CW_30 Upgrade Kit Appendix DKA - Display/Keypad / DKA-1

Appendix DKA

DISPLAY/KEYPAD ASSEMBLY GUIDE

DKA1.1 OVERVIEW

Bristol Display/Keypad assemblies provide a local, user interface for the ControlWave

3330 (CW_30) DPC. These assemblies allow an operator or engineer to view and modify

variable values and associated status information, via an ACCOL3 Function Block.

Variables can include inputs, process variables, calculated variables, constants, set-points,

tuning parameters and outputs used in a measurement or control application. Status bits

include alarm state, alarm acknowledge, control, manual, and questionable data.

Setting up the Display/Keypad is a simple matter of configuring a Display Function Block

in the ControlWave Designer project.

The Display/Keypad is comprised of a four line by twenty character liquid crystal display,

with adjustable LCD Contrast, and a 25 button membrane key matrix. Each key has a

microswitch for positive tactile feedback. This means that as you firmly depress the keys,

you will feel it click as it engages. In the case of the CW_30 DPC, the Display/Keypad is

located (typically panel or Enclosure Front Cover mounted) within the proximity of the

CW_30 and is installed in the field by field service personnel, user, integrator, contractor,

etc.

Figure 1 - Display/Keypad Assembly – 25 Button Keypad & 4 X 20 Display

DKA-2 / Appendix DKA - Display/5x5Keypad PIP-CW_30 Upgrade Kit

Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.

Automatic Mode

In Automatic Mode a set of screens (based on the application load) are displayed. The