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Emerson ControlWave EFM 3808 User Manual

Emerson ControlWave EFM 3808
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www.EmersonProcess.com/Remote
Instruction Manual
CI-ControlWave Express
Part: D301386X012
March, 2011
ControlWave Ex
p
ress
ControlWave Express
(Remote Terminal Unit)
Remote Automation Solution
s

Table of Contents

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Emerson ControlWave EFM 3808 Specifications

General IconGeneral
BrandEmerson
ModelControlWave EFM 3808
CategoryAutomobile Parts
LanguageEnglish

Summary

ControlWave Express Instruction Manual

Physical Description

Details the physical components of the ControlWave Express, including its enclosure, boards, and optional display.

CPU/System Controller Board

Describes the CPU/System Controller board, its microprocessor, memory, and communication ports.

Board Variations

Outlines the three basic variations of the CPU/System Controller board based on CPU, power, and I/O capabilities.

Power Options

Explains the different methods for powering the ControlWave Express, including solar, battery, and bulk power supplies.

I/O Options

Lists the standard I/O features and the available optional process I/O board configurations.

Software Tools

Details the software tools used for programming the ControlWave Express, including ControlWave Designer and OpenBSI Utilities.

Installation Guide

Site Considerations

Provides guidance on selecting an appropriate installation site and ensuring clearances for wiring and service.

Class I, Div 2 Installation Considerations

Outlines specific requirements for installing the ControlWave Express in hazardous locations according to NEC standards.

Installation Overview

Details the general steps involved in installing the ControlWave Express hardware and software.

Grounding the Housing

Explains the procedure for properly grounding the ControlWave Express enclosure for safety.

Configuring the CPU/System Controller Board

Provides instructions for setting switches and jumpers on the CPU/System Controller board for configuration.

Setting DIP Switches on the CPU/System Controller Board

Details the function and settings for DIP switches SW1, SW2, and SW3 on the CPU/System Controller board.

Setting Jumpers on the CPU/System Controller Board

Explains the configuration options for various jumpers (W1-W18) on the CPU/System Controller board.

General Wiring Guidelines

Offers best practices for making terminal connections and wiring the ControlWave Express.

Wiring Power to the CPU/System Controller Board

Provides detailed instructions for connecting power to the CPU/System Controller board using terminal blocks TB1 and TB2.

Connections to RS-232 Serial Port(s) on the CPU/System Controller Board

Details how to connect to the RS-232 serial ports (COM1, COM2) using different connector types.

Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller Board

Explains configuration and wiring for the COM3 port, supporting both RS-232 and RS-485 protocols.

Connections to the Ethernet Port on the CPU/System Controller Board

Describes how to connect to the 10/100Base-T Ethernet port for network communication.

Optional Display/Keypads

Details the available optional keypads and displays for the ControlWave Express.

I/O Configuration and Wiring

I/O Options

Lists the standard I/O capabilities and the configurations of optional process I/O boards.

Process I/O Board

Covers the configuration of the optional Process I/O board using jumpers and DIP switches.

Setting Jumpers on the Process I/O Board

Details the function and settings for jumpers (JP1, JP3-JP7) on the Process I/O board.

Setting DIP Switches on the Process I/O Board

Explains the configuration options for DIP switch SW1 on the Process I/O board.

I/O Wiring

Provides guidance on wiring I/O connections to the ControlWave Express, including shielding and grounding.

Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board

Describes the characteristics and wiring of non-isolated discrete inputs on TB2 and TB3.

Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board

Details the characteristics and wiring of non-isolated discrete outputs on TB3.

Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board

Explains the configuration and wiring for non-isolated analog inputs on TB6.

Non-Isolated Analog Output (AO) on TB7 of Process I/O Board

Covers the configuration and wiring for the non-isolated analog output on TB7.

Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Board

Describes the pulse counter/discrete inputs on TB5 of the CPU/System Controller board.

Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O Board

Details the high speed counter and discrete inputs on TB4 of the Process I/O board.

Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board

Explains how to connect and wire a 3-wire RTD to the CPU/System Controller board.

Connections to a Bristol Model 3808 Transmitter

Provides wiring diagrams for connecting a Bristol 3808 transmitter via RS-232 and RS-485.

Operation Procedures

Powering Up/Powering Down the ControlWave Express

Guides the user through the procedures for applying and removing power to the ControlWave Express.

Communicating with the ControlWave Express

Explains how to establish communication between a PC and the ControlWave Express.

Default Comm Port Settings

Lists the factory default communication port settings for COM1, COM2, COM3, and Ethernet.

Collecting Data from the ControlWave Express

Describes how to use OpenBSI utilities to collect real-time and historical data.

Creating and Downloading an Application (ControlWave Project)

Outlines the process of creating and downloading a ControlWave project using ControlWave Designer software.

Creating and Maintaining Backups

Emphasizes the importance of backing up ControlWave projects and configuration parameters.

Creating a Zipped Project File (*.ZWT) For Backup

Provides step-by-step instructions for creating a complete backup of a ControlWave project.

Saving Flash Configuration Parameters (*.FCP)

Explains how to save the ControlWave Express's flash configuration parameters using the Flash Configuration utility.

Backing up Data

Describes methods for backing up different types of data, such as tuning parameters and data arrays.

Service and Troubleshooting

Upgrading Firmware

Details methods for upgrading the ControlWave Express system firmware using various utilities.

Removing or Replacing Components

Provides procedures for accessing and replacing hardware components like boards and batteries.

Removing/Replacing the CPU/System Controller Board and the Process I/O Board

Step-by-step guide for removing and replacing the main CPU and optional Process I/O boards.

Removing/Replacing the Backup Battery

Instructions for safely removing and replacing the CPU/System Controller board's backup battery.

General Troubleshooting Procedures

Offers general guidance for troubleshooting issues with the ControlWave Express.

Checking LEDs

Explains the function of the LEDs on the ControlWave Express for diagnostic purposes.

WINDIAG Diagnostic Utility

Details how to use the WINDIAG software for testing system components like I/O and memory.

Available Diagnostics

Lists the diagnostic tests available within the WINDIAG utility for various components.

Core Updump

Explains how to perform a core updump to upload system memory contents for troubleshooting.

Special Instructions for Class I, Division 2 Hazardous Locations

Class I, Division 2 Hazardous Locations

Provides crucial safety and wiring instructions for installing the RTU in hazardous environments.

Module/Board Customer Wiring Connectors

Lists all customer wiring connectors for modules and boards with their associated wiring notes.