Instruction Manual

Doc Number CI-ControlWave EFM

Part Number D301383X012
December 2013

ControlWave® EFM
(Electronic Flow Meter)

Remote Automation Solutions

www.EmersonProcess.com/Remote
 IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.

These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions 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 information is required, the purchaser is advised to contact Remote Automation
Solutions.

RETURNED EQUIPMENT WARNING

When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions 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 Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions 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 instruments 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 for proper care and handling of ESD-sensitive components.
 ControlWave EFM Instruction Manual

Contents

Chapter 1 – Introduction 1-1

1.1 Scope of the Manual ...............................................................................................................1-2
1.2 Physical Description ...............................................................................................................1-3
1.3 Housings and Enclosure .......................................................................................................1-3
1.4 CPU Module .............................................................................................................................1-4
1.5 System Controller Module (SCM) ..........................................................................................1-6
1.6 Expansion Communications Modules ..................................................................................1-7
1.7 I/O Modules ..............................................................................................................................1-8
1.8 Software Tools.........................................................................................................................1-8
1.9 Overview of the Gas Flow Measurement Application .......................................................1-10

Chapter 2 – Installation 2-1

2.1 Site Considerations ................................................................................................................2-1
2.1.1 Class I, Div 2 Installation Considerations.................................................................2-2
2.2 Installation Overview ..............................................................................................................2-5
2.3 Unpacking Components .........................................................................................................2-6
2.4 Mounting the EFM Housing....................................................................................................2-7
2.4.1 Grounding the Housing ............................................................................................2-13
2.4.2 Connecting to the Multi-Variable Transducer (MVT) .............................................2-13
2.4.3 Process Pipeline Connection (Meter Runs without Cathodic Protection) ..........2-15
2.4.4 Process Pipeline Connection (Meter Runs with Cathodic Protection) ................2-15
2.5 System Controller Module (SCM) ........................................................................................2-17
2.5.1 General Information about the SCM ........................................................................2-17
2.5.2 SCM Installation Overview .......................................................................................2-19
2.5.3 Setting Jumpers on the SCM ...................................................................................2-19
2.5.4 Setting Mode Switch SW1 on the SCM ...................................................................2-19
2.5.5 General Wiring Guidelines .......................................................................................2-20
2.5.6 Wiring a Bulk DC Power Supply to the SCM ..........................................................2-21
2.6 Using a Solar Panel and Lead Acid Battery to Power the EFM ........................................2-22
2.6.1 Mounting the Solar Panel .........................................................................................2-22
2.6.2 Installing the Lead Acid Battery and Solar Panel Harness ...................................2-24
2.7 Power Distribution Board (Optional) ...................................................................................2-26
2.8 21V Power Supply (Optional) ...............................................................................................2-28
2.9 CPU Module ...........................................................................................................................2-29
2.9.1 Setting Jumpers on the CPU Module ......................................................................2-30
2.9.2 Setting DIP Switches on the CPU Module ..............................................................2-31
2.9.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules .......................2-34
2.9.4 Connections to RS-485 Serial Port(s) on CPU or ECOM Modules .......................2-39
2.9.5 Connections to Ethernet Port on the CPU Module ................................................2-42
2.10 Expanded Communications Module (ECOM) .....................................................................2-44
2.10.1 RS-232 Ports ..............................................................................................................2-45
2.10.2 RS-485 Ports ..............................................................................................................2-45
2.10.3 Modem Port (Type 1 ECOM only) ............................................................................2-46
2.11 Bezels .....................................................................................................................................2-49
2.12 Case Mounted Radio/Modem ...............................................................................................2-50
2.13 Optional Display/Keypads ....................................................................................................2-50

Chapter 3 – I/O Modules 3-1

3.1 Module Placement ...................................................................................................................3-2
3.2 Wiring .......................................................................................................................................3-3

Revised Dec-2013 Contents iii

ControlWave EFM Instruction Manual

3.2.1 Local Termination ....................................................................................................... 3-3

3.2.2 Shielding and Grounding ........................................................................................... 3-4
3.3 Non-isolated Digital Input/Output (DI/O) Module ................................................................. 3-5
3.4 Non-isolated Analog Input/Output & Analog Input Module ................................................ 3-7
3.5 Non-isolated High Speed Counter (HSC) Input Module .................................................... 3-10
3.6 Non-isolated Mixed I/O (MI/O) Module ................................................................................3-12
3.7 Resistance Temperature Device (RTD) Inputs on SCM .................................................... 3-16
3.8 Digital to Relay I/O Board Option ........................................................................................ 3-18
3.9 Connections to a Bristol Model 3808 Transmitter ............................................................. 3-20

Chapter 4 – Operation 4-1

4.1 Powering Up/Powering Down the ControlWave EFM.......................................................... 4-1
4.2 Communicating with the ControlWave EFM ........................................................................ 4-2
4.2.1 Default Comm Port...................................................................................................... 4-2
4.2.2 Changing Port Settings .............................................................................................. 4-3
4.2.3 Collecting Data from the ControlWave EFM ............................................................ 4-4
4.3 Creating and Downloading an Application (ControlWave Project) ................................... 4-4
4.4 Creating and Maintaining Backups ....................................................................................... 4-5
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup................................................. 4-5
4.4.2 Saving Flash Configuration Parameters (*.FCP) ..................................................... 4-7
4.4.3 Backing up Data .......................................................................................................... 4-8

Chapter 5 – Service and Troubleshooting 5-1

5.1 Upgrading Firmware ............................................................................................................... 5-2
5.2 Removing or Replacing Components ................................................................................... 5-5
5.2.1 Accessing Modules for Testing ................................................................................. 5-6
5.2.2 Removing/Replacing the Bezel.................................................................................. 5-6
5.2.3 Removing/Replacing the CPU Module ...................................................................... 5-6
5.2.4 Removing/Replacing the SCM ................................................................................... 5-7
5.2.5 Removing/Replacing an I/O Module .......................................................................... 5-7
5.2.6 Removal/Replacement of an Expansion Communication Module ......................... 5-8
5.2.7 Removal/Replacement of the Rechargeable Lead-acid Battery............................. 5-8
5.2.8 Removal/Replacement of a Power Distribution Board............................................ 5-9
5.2.9 Removal/Replacement of a 21V Power Supply Board ............................................ 5-9
5.2.10 Removal/Replacement of a Digital to Relay I/O Board .......................................... 5-10
5.2.11 Removal/Replacement of a Case-Mounted Radio/Modem.................................... 5-10
5.2.12 Removing/Replacing the Backup Battery .............................................................. 5-10
5.2.13 Enabling / Disabling the Backup Battery ................................................................ 5-12
5.3 General Troubleshooting Procedures ................................................................................ 5-12
5.3.1 Checking LEDs .......................................................................................................... 5-12
5.3.2 Checking Wiring/Signals .......................................................................................... 5-18
5.3.3 Calibration Checks.................................................................................................... 5-18
5.3.4 Common Communication Configuration Problems .............................................. 5-18
5.4 WINDIAG Diagnostic Utility .................................................................................................. 5-19
5.4.1 Available Diagnostics ............................................................................................... 5-22
5.5 Core Updump ........................................................................................................................ 5-26

Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1

Appendix D – Modem Installation D-1

Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1

iv Contents Revised Dec-2013

 ControlWave EFM Instruction Manual

Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Electronic Flow Meter (EFM) (called the “ControlWave EFM” or
“EFM” throughout the rest of this manual). For information about the
software used with the EFM, refer to Getting Started with ControlWave
Designer (D5085), the ControlWave Designer Programmer’s Handbook
(D5125), and the online help in ControlWave Designer. For information
on the flow measurement application used in the ControlWave EFM,
see the ControlWave Flow Measurement Applications Guide (D5137).
This chapter details the structure of this manual and provides an
overview of the ControlWave EFM and its components.

In This Chapter

1.1 Scope of the Manual ........................................................................1-2

1.2 Physical Description ........................................................................1-3
1.3 Housings and Enclosure .................................................................1-3
1.4 CPU Module ....................................................................................1-4
1.5 System Controller Module (SCM) ....................................................1-6
1.6 Expansion Communications Modules .............................................1-7
1.7 I/O Modules......................................................................................1-8
1.8 Software Tools .................................................................................1-8
1.9 Overview of the Gas Flow Measurement Application....................1-10

The ControlWave EFM measures differential pressure, static pressure,

and temperature and computes flow for both volume and energy for up
to four meter runs in accordance with API (American Petroleum
Institute) and AGA (American Gas Association) standards.
Features ControlWave EFMs have the following key features:
 Exceptional performance and low power consumption through use
of the ARM microprocessor
 Two CPU options (33 MHz or 150 MHz)
 Two RS-232 and one RS-485 asynchronous serial communication
ports
 Optional Ethernet port (150 MHz CPU only)
 Optional Expansion Communication modules (ECOMs) with
optional built-in modem and/or radio
 Wide operating temperature range: (–40 to +70C) (–40 to 158F)
 Variety of I/O modules (including mixed I/O)
 RTD input
 Lithium coin cell battery (located on the CPU module) provides
battery backup for the real-time clock and the system’s static RAM
(SRAM)
 Keypad /. Display for operator interaction.

Revised Dec-2013 Introduction 1-1

ControlWave EFM Instruction Manual

 Nonincendive Class I, Division 2 (Groups C and D) Hazardous

Location approvals

Figure 1-1. ControlWave EFM Enclosure (shown with 25-Button Display/Keypad Assembly and local
circular port)

1.1 Scope of the Manual

This manual contains the following chapters:
Chapter 1 Provides an overview of the hardware and
Introduction general specifications for the ControlWave EFM.
Chapter 2 Provides information on mounting the housing,
Installation wiring power, configuring the CPU module and
optional Expanded Communications module
(ECOM), and related peripherals such as the

1-2 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

optional keypad.
Chapter 3 Provides general information and wiring
I/O Modules diagrams for the I/O modules.
Chapter 4 Provides information on day-to-day operation of
Operation the ControlWave EFM.
Chapter 5 Service and Provides information on service and
Troubleshooting troubleshooting procedures.

1.2 Physical Description

ControlWave EFMs are furnished in a NEMA 3X rated Hoffman®
enclosure. The flow computer hardware comprises a backplane board
(mounted in a housing), a system controller module (SCM) and a CPU
module. Optional expansion communication module(s) may reside in
slots 3 and 4 of the housing in lieu of I/O modules. The CPU module
includes the communication ports and the system memory.
All system modules plug into the backplane (either 4-slot or 8-slot).
Each I/O module provides the circuitry and field interface hardware
necessary to interconnect the assigned field I/O circuits. Non-isolated
power is generated and regulated by the system controller module
(SCM) that provides +3.3Vdc for all logic and bulk power for I/O field
circuits from either a bulk 6Vdc or bulk 12Vdc source.

1.3 Housings and Enclosure

The ControlWave EFM housings are open-faced gold-irridite aluminum
which (whether base or expansion) are gold irridite-plated aluminum.
They house the printed circuit board (PCB) backplane and all
ControlWave EFM modules. The housing mounts to a fabrication panel
on the inner rear wall of the enclosure.
Two housings are available:
 4-slot backplane supports one system controller module (SCM), one
CPU, and two I/O modules.
 8-slot base housing supports one SCM, one CPU, and up to six I/O
modules. The 8-slot housing does not allow use of the internal
battery/solar panel option.
 You can substitute one or two expansion communication modules
(ECOMs) for I/O modules in slots 3 and 4.
The ControlWave EFM sits in a standard NEMA 3X Hoffman®
enclosure, which also houses the multivariable transducer, battery, and
communication equipment such as a radio or modem. The enclosure
consists of two pieces, the body and the front cover. A continuous
gasket seals the unit when you close the cover. A hinge on the left side
(facing the front of the unit) if formed by molded channels on the front
cover and the body that capture a stainless steel pin. Two latches on

Revised Dec-2013 Introduction 1-3

ControlWave EFM Instruction Manual

the enclosure’s right side secure the cover when you close it.
A weatherproof communication connector, either a 9-pin male D-type
connector or a circular 3-pin connector (the local port) mounts to the
bottom of the enclosure and connects internally to RS-232
communication port 1 for local communications.
The front cover includes a liquid crystal display (LCD) and keypad for
local operator access.

1.4 CPU Module

The CPU (central processing unit) module houses the multi-layer PCB,
which contains the CPU, I/O monitor/control, memory, and
communication functions.
The CPU module includes:
 Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core,
operating at 1.8V with a system clock speed of 33 MHz or 150
MHz.
 two RS-232 communication ports,
 one RS-485 communication port
 one 10/100baseT Ethernet ports (150 MHz units only)
 2 MB of battery backed Static RAM (SRAM),
 64MB of Synchronous Dynamic RAM (SDRAM),
 512KB boot/downloader Flash,
 16MB simultaneous read/write Flash memory
 transmit (TX) and receive (RX) LEDs for each communication port
 configuration DIP switches (described in Chapter 2.)

CPU Module The CPU module has two basic configurations, both of which have
Configurations an on-board backup battery and different combinations of
communications ports:
Table 1-1. CPU Module Configurations

Number of Number of Number of See Figure

RS-232 RS-485 Ethernet Ports
Ports Ports
2 1 0 left side of Figure 1-2
2 1 1 right side of Figure 1-2

Note: Do not confuse the CPU module (which has communication

components) with the Expansion Communication module
(ECOM), which does not have a CPU component or a battery
backup but does have additional communication components.

1-4 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 1-2. 33MHz CPU Module with Three Serial Ports (left), 150 MHz CPU Module with Three
Serial Ports and One Ethernet Port (right)

CPU Backup Battery CPU modules have a coin cell socket that accepts a lithium battery.
This battery provides backup power for the real-time clock and the
system’s Static RAM (SRAM).

CPU Memory There are several different types of memory used on the CPU module:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.

FLASH Memory
The CPU module contains 16 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.

System Memory (SRAM)

The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by a lithium backup battery). Critical system information that must be
Revised Dec-2013 Introduction 1-5
ControlWave EFM Instruction Manual

retained during power outages or when the system has been disabled for
maintenance is stored here. This includes the last states of all I/O points,
audit/archive historical data (if not stored in FLASH), the values of any
variables marked RETAIN, the values of any variables assigned to the
static memory area, and any pending alarm messages not yet reported.

SDRAM
The CPU module contains 64MB of synchronous dynamic random
access memory (SDRAM). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.

1.5 System Controller Module (SCM)

The System Controller Module (SCM) takes power from an external
bulk DC power supply (or an optional solar panel and lead acid battery
combination) and then provides +3.3Vdc power and GND through the
ControlWave EFM housing/backplane to all installed modules. The
SCM also supplies switched field power to I/O module slots.
Power Options The SCM operates with a nominal input of either 6V or 12V received
from a bulk supply connected to a pluggable terminal block, or from a
30 or 40 watt solar panel connected to a rechargeable lead acid battery.
If your EFM includes options such as the 21V power supply for external
transmitters, a case-mounted radio/modem, or a digital to relay I/O
board, you need a power distribution board as well.

1-6 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

1.6 Expansion Communications Modules

Expansion Comm. Modules provide two additional serial
communications ports and optionally the choice of a piggy-backed dial-
line modem or piggy-backed 900 MHz Spread Spectrum radio (or both).
The top port (labeled C1) supports RS-232 operation while the second
one (labeled C2) supports RS-485 operation. You can optionally order
the RS-485 port with isolation to 500Vdc. You can install up to two
expansion communication modules in backplane slots 3 and 4.

Figure 1-3. Expansion Communications (ECOM) Module

Revised Dec-2013 Introduction 1-7

ControlWave EFM Instruction Manual

1.7 I/O Modules

The ControlWave EFM supports factory-configured I/O modules
including analog I/O, analog input, digital I/O, high speed counter and
mixed I/O.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-4
shows a typical I/O module housing.
Configuration jumpers on I/O modules accommodate individual field
I/O user configuration. Terminations are pluggable and accept a
maximum wire size of #14 AWG. All I/O modules have surge
protection that meets C37.90-1978 and IEC 801-5 specifications. Each
I/O module connects to the backplane using a 36-pin male card-edge
connector. With the exception of the mixed I/O module, all I/O modules
are provided with two 10-point terminal block assemblies (for local
termination) or two 14-pin mass Termination headers (for remote
termination). Mixed I/O modules have two 10-point terminal blocks for
local termination only.

Figure 1-4. Two ControlWave EFM I/O Modules (with Bezel)

1.8 Software Tools

The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave.
Figure 1-5 graphically presents the programming environment.

1-8 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 1-5. ControlWave Programming Environment

The tools which make up the programming environment include:

 ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), and the ControlWave Designer
Programmer’s Handbook (document D5125).
 The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see the ControlWave Designer Programmer’s
Handbook (document D5125).
 The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see
the online help within ControlWave Designer.

Revised Dec-2013 Introduction 1-9

ControlWave EFM Instruction Manual

 OpenBSI Utilities provides a set of programs that allow you to

configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
 OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
 A series of web page controls are available for retrieval of real-time
data values and communication statistics. These 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. For
information on the ActiveX controls, see the Web_BSI Manual
(document D5087).
 User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
 Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).

Communication In addition to the Bristol Synchronous/Asynchronous Protocol

Protocols (BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.

1.9 Overview of the Gas Flow Measurement Application

Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave EFM with a pre-programmed flow
measurement application already loaded.

1-10 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

The ControlWave standard gas flow measurement application collects

static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline. The ControlWave EFM supports up to
four meter runs. Meter runs can use orifice, turbine, or ultrasonic
meters.
The application includes an auto-selector, PID/flow pressure control
algorithm per run or per station.
If you have the optional expansion communication module, you can
interface to a chromatograph to provide energy throughput as well as
composition information.
The application also supports a nomination function.

1.9.1 Data Acquisition – Static Pressure, Differential Pressure,

Temperature Variables
The application requires these process inputs for orifice measurement:
 static pressure (SP) collected once per second
 differential pressure (DP) collected once per second
 flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
 static pressure (SP) collected once per second
 frequency input collected once per second
 flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:
 Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
 Built-in multivariable transducer.
 External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.

1.9.2 Flow and Volume Calculations

Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
 AGA3-1985/NX-19

Revised Dec-2013 Introduction 1-11

ControlWave EFM Instruction Manual

 AGA3-1992 with selectable AGA8 Gross or AGA8 Detail

 AGA7/NX-19
 AGA7 with selectable AGA8 Gross or AGA8 Detail
 Auto-adjust AGA7/NX-19
 Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.

1.9.3 Flow Rate and Flow Time Calculations (AGA3)

For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low flow cutoff value, flow is
considered to be zero for that second. Hourly and daily flow time is
defined to be the number of seconds for which the differential pressure
exceeded the cutoff value for the period.
The values for static and differential pressure and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.

1.9.4 Flow Rate and Flow Time Calculations (AGA7)

When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate by applying the correction factor
computed by the AGA7 calculations to the frequency of the input
pulses. When the frequency drops below 1 Hz, the application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.

1.9.5 Extension Calculation and Analog Averaging

For orifice meters, the application calculates the flow extension every
second. The extension is the square root of the product of the absolute
upstream static pressure times the differential pressure. This extension is
used in the flow rate calculation. When there is no flow, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.

1-12 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

1.9.6 Energy Calculation

The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.

1.9.7 Volume and Energy Integration

The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.

1.9.8 Downstream Pressure Tap

The multivariable transducer typically measures static pressure from an
integral tap on the upstream, high-pressure leg of the differential
pressure connection. The transducer can also measure static pressure at
the downstream pressure tap, with the measurement taken from the low-
pressure side to the high-pressure side. In this installation, the
differential signal from the transducer is negative. If, while using the
integral smart multivariable transmitter (MVT) or an external MVT, you
select the downstream tap location during MVT configuration, the MVT
firmware changes the sign of the differential pressure to provide a
positive DP value.

1.9.9 Historical Data Storage (Audit Records/ Archive Files)

The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. Specifically, the averages of the process
variables stored in the data archive are for flowing periods, appropriate
to their usage in the equations, and any gas-related parameter designated
an event that is changed by an operator either remotely or locally causes
an entry in the audit log.
Audit Records The audit system maintains a history of alarms and certain events that
(Alarms and have an impact on the calculated and reported gas flow rates and
Events) volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the ControlWave stores alarms and events separately
to prevent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:

Revised Dec-2013 Introduction 1-13

ControlWave EFM Instruction Manual

 Any operator change to a configuration variable

 Any change in the state of an alarm variable
 A system restart
 Certain other system events
You can view audit records on-screen in the audit log.
See Appendix K of the OpenBSI Utilities Manual (D5081) for help on
interpreting audit records.
Archive Files Archive files store the value of process variables and other calculated
(Averages, variables at specified intervals along with the date and time of each
totals, and other entry. This includes flow rates, volumes and other calculated values.
values) When archive files fill up, new values overwrite the oldest entries in the
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.

Note: To prevent the system from creating several very short logs due
to a series of successive configuration changes, log breaks don’t
occur if a log contains less than 60 seconds (flowing or
otherwise) of data. This means that is a user enters 15
configuration changes over a two minute period, the log breaks
only twice. By default the log break feature is disabled.

Hourly Historical Data Log

Each meter run maintains an hourly data log that holds one record for
every contract hour. Hourly logs hold 840 entries or 35 days; this
ensures that the previous period of hourly data is always resident in
flash memory.
The hourly data log stores the following items:
 corrected volume
 uncorrected volume
 accumulated energy
 average static pressure
 average temperature
 average differential pressure
 average specific gravity
 average heating value
 flow time

1-14 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

 uncorrected count
ControlWave EFM maintains an hourly historical log for each of up to
four runs.

Daily Historical Data Log

Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour so the contract
gas day starts at some time other than midnight. The daily log holds 62
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
 corrected volume
 uncorrected volume
 accumulated energy
 average static pressure
 average temperature
 average differential pressure
 average specific gravity
 average heating value
 flow time
 uncorrected count
ControlWave EFM maintains a daily historical log for each of up to four
runs.

Periodic Historical Data Log

Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:
 flowing differential pressure
 flowing static pressure
 flowing temperature
 frequency
ControlWave EFM maintains a daily historical log for each of up to four
runs.

1.9.10 Run Switching

If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.

Revised Dec-2013 Introduction 1-15

ControlWave EFM Instruction Manual

1.9.11 Sampler and Odorizer

Samplers are external devices which measure the quality of the gas
stream. Because natural gas is odorless and colorless, devices called
odorizers inject an additive to the gas stream that allows people to
detect the presence of natural gas in the event of a gas leak.

1.9.12 Flow Rate Control – DCC (Jog Control) Using PID

To configure the EFM to perform flow rate control you wire the two
discrete outputs to the open and close inputs of a controller. The EFM
uses a proportional/integral/derivative (PID) algorithm to cause the
measured rate of flow to match a user-entered setpoint. When the flow
rate falls below the setpoint, the open output is pulsed. When the flow
rate rises above the setpoint, the close output is pulsed. The PID
equation calculates the duration of the open or close pulse; the
minimum pulse duration is 1.0 seconds. The user changeable parameters
are:
 Flow setpoint in MSCFH
 Deadband in % of setpoint
 Proportion gain
 Integral time in repeats/minute
 Derivative time in seconds
 Valve travel time (full close to full open)
 Process control limiting
 Pressure override limits
The flow control algorithm runs once per second.

1.9.13 Pulse Output for External Totalizer or Sampler

When you configure the EFM to provide a pulse output based on
volume, the operator provides a control volume and pulse duration.
After each calculation cycle, the application compares an internal
volume accumulator to the control volume. If the accumulator exceeds
the control volume then a pulse is output and the accumulator is reduced
by the volume represented by the pulse. You can use the pulse output to
drive an external totalizer, odorizer, gas sampler, or similar device.

1.9.14 Nominations
Nominations allow you to configure the EFM to allocate precise
amounts of gas flow (called nomination values) during specific time
periods, called nomination periods. When the nomination value is
reached, the system performs an action (such as opening or closing a
valve). Prior to reaching the nomination value, the application compares
the volume/energy to a configured alarm level and generates an alarm
when the volume/energy meets or exceeds that alarm level.

1-16 Introduction Revised Dec-2013

 ControlWave EFM Instruction Manual

Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
EFM, considerations for installation, and instructions for setting
switches and jumpers on the CPU, SCM, and ECOM modules.
In This Chapter

2.1 Site Considerations..........................................................................2-1

2.1.1 Class I, Div 2 Installation Considerations .............................2-2
2.2 Installation Overview........................................................................2-5
2.3 Unpacking Components ..................................................................2-6
2.4 Mounting the EFM Housing .............................................................2-7
2.4.1 Grounding the Housing ......................................................2-13
2.4.2 Connecting to the Multi-Variable Transducer (MVT)..........2-13
2.4.3 Process Pipeline Connection (Meter Runs without Cathodic
Protection) ........................................................................2-15
2.4.4 Process Pipeline Connection (Meter Runs with Cathodic
Protection) ........................................................................2-15
2.5 System Controller Module (SCM) ..................................................2-17
2.5.1 General Information about the SCM ..................................2-17
2.5.2 SCM Installation Overview .................................................2-19
2.5.3 Setting Jumpers on the SCM .............................................2-19
2.5.4 Setting Mode Switch SW1 on the SCM..............................2-19
2.5.5 General Wiring Guidelines .................................................2-20
2.5.6 Wiring a Bulk DC Power Supply to the SCM .....................2-21
2.6 Using a Solar Panel and Lead Acid Battery to Power the EFM ....2-22
2.6.1 Mounting the Solar Panel ...................................................2-22
2.6.2 Installing the Lead Acid Battery and Solar Panel Harness 2-24
2.7 Power Distribution Board (Optional) ..............................................2-26
2.8 21V Power Supply (Optional) ........................................................2-28
2.9 CPU Module ..................................................................................2-29
2.9.1 Setting Jumpers on the CPU Module .................................2-30
2.9.2 Setting DIP Switches on the CPU Module .........................2-31
2.9.3 Connections to RS-232 Port(s) on CPU or ECOM ............2-34
2.9.4 Connections to RS-485 Port(s) on CPU or ECOM ............2-39
2.9.5 Connections to Ethernet Port on the CPU Module ............2-42
2.10 Expanded Communications Module (ECOM) ...............................2-44
2.10.1 RS-232 Ports ......................................................................2-45
2.10.2 RS-485 Ports ......................................................................2-45
2.10.3 Modem Port (Type 1 ECOM only) ......................................2-46
2.11 Bezels ............................................................................................2-49
2.12 Case Mounted Radio/Modem ........................................................2-50
2.13 Optional Display/Keypads..............................................................2-50

2.1 Site Considerations

When choosing an installation site, check all clearances. Ensure that the
ControlWave EFM front cover (hinged on the left side) can be opened
for wiring and service and that the LCD/keypad is visible and accessible
to the on-site operator.

Revised Dec-2013 Installation 2-1

ControlWave EFM Instruction Manual

To ensure safe use of this product, please review and follow the
Caution instructions in the following supplemental documentation:
 Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
 ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
Specifications See document 1660DS-5i available on our website for detailed
for Temperature, technical specifications for temperature, humidity, and vibration for
Humidity and the ControlWave EFM. This document is available on our website at
Vibration www.emersonprocess.com/remote.
 Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
 Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave EFM is not
exposed to a level of vibration that exceeds that provided in the
technical specifications.

2.1.1 Class I, Div 2 Installation Considerations

Underwriters Laboratories (UL) lists the ControlWave EFM as non-
incendive and suitable only for use in Class I, Division 2, Group C, and
D hazardous locations and non-hazardous locations. Read this chapter
and Appendix A carefully before you install a ControlWave EFM in a
hazardous location.
Perform all power and I/O wiring for unrated circuits in accordance
with Class I, Division 2 wiring methods as defined in Article 501-4 (b)
of the National Electrical Code, NFPA 70 (for installations within the
United States) or as specified in Section 18-152 of the Canadian
Electrical Code (for installation in Canada).

WARNING EXPLOSION HAZARD

Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not connect or disconnect equipment unless the power is switched
off and the area is known to be non-hazardous.

2-2 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-1. 4-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with
D-Type Local Port)

Revised Dec-2013 Installation 2-3

ControlWave EFM Instruction Manual

Figure 2-2. 8-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with
Circular Local Port)

2-4 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.2 Installation Overview

Installing a ControlWave EFM involves several general steps:
1. Unpack, mount and ground the unit. (See Section 2.3 and Section
2.4.)
2. Remove the System Controller Module (SCM) and configure
jumpers and mode switch as needed, then re-install it in chassis slot
1. (See Section 2.5.)
3. Remove the CPU, enable the backup battery jumper and set
switches as needed then re-install it in chassis slot 2. (See Section
2.9.)
4. Configure/connect the communication port to a PC or other
devices. (See Section 2.9.3 to Section 2.10.3.
5. Install I/O wiring to each I/O module, connect a cable to a Bristol
3808 transmitter (if required). (See Chapter 3).
6. Install the bezels to protect the I/O modules (see Section 2.11.)
7. If required, install the RTD probe (see Section 3.7.)
8. Install the rechargeable lead acid battery and solar panel (if
provided). (See Section 2.6.)
9. Connect DC power wiring and apply power. (See Section 2.5.6.)
10. Install PC-based software (ControlWave Designer and/or
OpenBSI/TechView)
11. Establish communications
12. Create an application-specific control strategy (ControlWave
project).
13. Create application-specific web pages (optional)
14. Add the ControlWave EFM to an OpenBSI network
15. Download the application-specific ControlWave project into the
ControlWave EFM.
Notes:
 If you purchased the ControlWave EFM with the standard
application already loaded, you do not need to create an application,
or web pages, and the application is already downloaded for you.
ControlWave Designer would only be necessary if you also
purchased application source code and wanted to edit it.
 Steps 10 through 15 require that you install and use ControlWave
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and configuration
is beyond the scope of this manual.

Revised Dec-2013 Installation 2-5

ControlWave EFM Instruction Manual

2.3 Unpacking Components

Packaging The ControlWave EFM ships from the factory fully assembled with all
components installed except for the unit’s solar panel and battery (if
provided); these items ship separately.
If you ever need to re-install modules into the housing, follow these
guidelines:
Notes:
 Do not install modules in the housing until you mount and ground
the housing at the designated installation site.
 The SCM module must reside in slot #1 of the housing.
 The CPU module must reside in slot #2 of the housing.
 The first ECOM module (if you have one) must reside in slot #3 of
the housing (the first I/O slot); a second ECOM module (if you have
one) must reside in slot #4 of the housing (the second I/O slot).

Housing The housing (or chassis) for the ControlWave EFM is an open-faced
gold irridite coated aluminum assembly. The eight slot housing has six
I/O slots; the four slot housing has two I/O slots. You can substitute one
or two expansion communication modules for I/O modules in the first
two I/O slots.
Keyed cutouts in the housing’s rear wall permit wall or panel mounting.
The housing is mounted to the fabricated panel on the inner rear wall of
the enclosure and has the following components:
 Built-in guides on the top and bottom of the housing permit easy
installation and removal of modules
 Built-in ground lug (on bottom of unit)
 Backplane provides seating and electrical interface to all modules.
 Internal mounting brackets support the various system components
in the enclosure such as the battery and ControlWave EFM base
assembly. The battery and EFM base assembly mount to the
fabrication panel which secures to the inner rear wall of the
enclosure. If you have a radio/modem it mounts using the
radio/modem mounting bracket beneath the battery mounting
bracket on units with a 4-slot chassis.

2-6 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-3. 8/4-Slot ControlWave EFM Housing - The 4-Slot Chassis is shown with ECOMs in Slots 3
& 4)

2.4 Mounting the EFM Housing

 You must position the ControlWave EFM vertically with the
transducer (MVT) at its base. Make sure clearances are adequate so
that you can open the door, and ensure the front of the assembly is
visible and accessible for service, installation, and for operator
access to the LCD display/keypad.

Revised Dec-2013 Installation 2-7

ControlWave EFM Instruction Manual

 You can mount the unit to a wall, or to a vertical 2 inch pipe

clamped at the rear of the unit with two clamps and four bolts. You
must anchor the pipe in cement deep enough to conform to local
building codes associated with frost considerations.
 If your unit requires a solar panel, make sure there is sufficient
clearance. You can mount the solar panel to the same 2” pipe that
secures the unit.
 You mount the MVT to a process manifold which then mounts to
the main (meter run) directly or via two pipes. (See Figure 2-9,
Figure 2-10, and Figure 2-11).
 Only connect power wiring after the unit is mounted and properly
grounded.
 I/O, power, RTD, antenna and communication port cabling enters
the bottom of the unit through conduit or special function fittings.

(1) 1” NPT Conduit Hub (2) Local Port D-Type Jack Male D-Type Jack or
Circular Female Jack
(3) RTD Cable Assembly or Sealing Plug (4) Battery Ventilation Assembly
(5) 5” Liquid Tight Conduit Fitting or Plug (6) Ant. Cable Fitting, Polyphaser,
(7) Solderless Ground Lug (8) Multivariable Transducer

Figure 2-4. ControlWave EFM Bottom View

2-8 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-5. Side View of ControlWave EFM Mounted to a 2” Pipe

Revised Dec-2013 Installation 2-9

ControlWave EFM Instruction Manual

Figure 2-6. 4-Slot ControlWave EFM

2-10 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-7. 8-Slot ControlWave EFM - Base Chassis Assembly Dimensions

Revised Dec-2013 Installation 2-11

ControlWave EFM Instruction Manual

Figure 2-8. ControlWave EFM NEMA 3X Enclosure Dimensions

2-12 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.4.1 Grounding the Housing

The ControlWave EFM enclosure includes a ground lug. Once you have
installed the unit, run a ground wire (#4 AWG max wire size) between
the ground lug (see Figure 2-4) and a known good earth ground. As an
added precaution, run a #14 AWG wire from SCM power connector
TB1-3 (chassis ground) to the same known good earth ground. For more
information on grounding see the ControlWave Grounding Supplement
(S1400CW):
Additional grounding guidelines include:
 Use stranded copper wire (#4 AWG) to earth ground, and keep the
length as short as possible.
 Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
 Using a high-wattage soldering iron, tin the wire ends with solder
before you insert them into the chassis ground lug.
 Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.

2.4.2 Connecting to the Multi-Variable Transducer (MVT)

The ControlWave EFM’s multivariable transducer (MVT) secures to the
bottom of the enclosure. The MVT pressure assembly connects to the
process manifold either directly or by tubing. Within the body of the
transducer, metal diaphragms are exposed to the gas. Solid-state strain
gauge sensors in the neck of the transducer measure the pressure applied
to the diaphragms and produce proportional electrical signals.
The neck of the transducer extends into the bottom of the enclosure,
with the body of the transducer outside the enclosure. The MVT cable
connector is factory mated with System Controller module connector
P2.
The MVT provides connection ports on the process flange as the
standard arrangement. Optional manifold blocks may also be specified.
Figure 2-9 details MVT process flange and optional manifold block
connector mounting dimensions.
Standard Process Flange for MVT – Two process flanges containing
the connection ports are assembled to the transmitter. Port designations
(L and H) are stamped on the body of the flanges. Ports accept ¼-18
NPT pipe connections to 2-1/8 in. centers for connection to orifice taps
or a standard three-valve manifold. These process flange connections
are illustrated at the top of Figure 2-9.

Revised Dec-2013 Installation 2-13

ControlWave EFM Instruction Manual

Four bolts and nuts hold the two process flange assemblies in place.
When you remove the bolts, you can reposition the flanges so that the
connections can emanate from the front, rear or bottom of the
transducer. Take care not to damage the sensor module assembly during
this procedure. Once you position the flange, tighten the bolts in an
alternating sequence to about 20-30 foot-pounds of torque.
Optional Process Manifold Blocks – Process manifold blocks may be
installed on the transducers to permit the use of connector assemblies
having different connection centers. The manifold blocks, which are
oval in appearance, mate with the transmitter’s process flange. The
blocks may be installed in several positions to achieve different
connection centers as shown in Figure 2-9.

Figure 2-9. Process Flange and Optional Manifold Block Connectors

2-14 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.4.3 Process Pipeline Connection (Meter Runs without Cathodic

Protection)
You can mount the ControlWave EFM directly on the pipeline or
remotely on a vertical stand-alone two-inch pipe or on a wall. The Earth
ground cable must run between the EFM’s ground lug and Earth ground
(rod or bed) even though the ControlWave EFM’s multivariable
transducer (MVT) may be grounded to the pipeline. If any pressure
transmitters or pulse transducers are remotely mounted, connect their
chassis grounds to the pipeline or Earth ground.

Note: For installation of the unit without cathodic protection, a direct

mount installation is similar to Figure 2-10 and a remote
installation is similar to Figure 2-11. The main difference is that
without cathodic protection, whether you’re mounting directly
or remotely, you do not use the transducer to manifold dielectric
isolation kit.

2.4.4 Process Pipeline Connection (Meter Runs with Cathodic

Protection)
You can mount the ControlWave EFM directly on the pipeline (using a
manifold block) or remotely on a vertical stand-alone two-inch pipe or
on a wall.
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.

Transducer to Manifold
Dielectric Isolation Kit

Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Bottom Washers (4)
Mounting Bolts (4)

AWG 4 Ground Wire

Ground Rod or System

Figure 2-10. ControlWave EFM Direct Mount Installation with Cathodic Protection

Revised Dec-2013 Installation 2-15

ControlWave EFM Instruction Manual

Transducer to Manifold
Dielectric Isolation Kit

Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
AWG 4 Ground Wire Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Isolating
Bottom Washers (4)
Fittings
Mounting Bolts (4)

2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.

Clamp(s)
Ground Rod or System

Figure 2-11. ControlWave EFM Remote Installation with Cathodic Protection

Dielectric isolators are available and are always recommended as an

added measure in isolating the ControlWave EFM from the pipeline
even though the enclosure does provide some galvanic isolation from
the pipeline and should not be affected by the cathodic protection or
other EMF on the pipeline.
It is recommended that isolation fitting always be used in remotely
mounted meter systems.
Install isolation fittings or gaskets between the following connections:
 All conductive tubing that runs between the pipeline and mounting
valve manifold and/or the unit’s multivariable transducer (MVT).
 All conductive connections or tubing runs between the ControlWave
EFM and a turbine meter, pulse transducer, or any other I/O device
that is mounted on the pipeline.
 Any temperature transducer, pressure transmitter, etc. and their
mount/interface to the pipeline.
In remote installations, the ground conductor connects between the
ControlWave EFM’s chassis ground lug and a known earth ground.
Connect the cases of temperature transducers, pressure transmitters, etc.
to the known good earth ground. If the mounting 2-inch pipe (when
used) is in continuity with the pipeline you must electrically isolate it

2-16 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

from the EFM. Use a strong heat-shrink material such as RAYCHEM

WCSM 68/22 EU 3140. This black tubing easily slips over the 2-inch
pipe and then after uniform heating (with a rosebud torch) it electrically
insulates and increases the strength of the pipe stand. See F1670SS-0a
for information on PGI direct mount systems and manifolds.

2.5 System Controller Module (SCM)

Before we actually configure the SCM and install it in the housing,
we’re going to discuss some general information about how it works.

2.5.1 General Information about the SCM

DC power from a bulk DC supply (nominally +6 Vdc or +12 Vdc)
connects to the System Controller Module (SCM) on connector TB1.
The SCM converts, regulates, and filters the power to provide +3.3 Vdc
to modules in the backplane.
The SCM plugs into slot #1 (first slot from the left) on the ControlWave
EFM’s backplane using connector P1, a 44-pin female non-keyed
header (see Figure 2-12).

Revised Dec-2013 Installation 2-17

ControlWave EFM Instruction Manual

WATCHDOG LED JP5, JP6, JP7, JP8 & JP9

(Red) 1-to-2 Installed = 12V Bulk System
CR27 2-to-3 Installed = 6V Bulk System
IDLE LED
(Red)
CR26 1
JP6
JP7
Staus LEDs CR25 1
(Red) 1
CR24 JP5
JP8 JP9
1 1

SW1 = Mode Switch

J2 2
J2
Display Intf.
RJ-45
Connector

TB1
1A
Input Power
Connector P1
TB2
RTD Interface
Connector

P2 (+4.5/4.9Vdc to +16.0Vdc for +6V supply)

MVT Interface TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
Connector
TB1-3 Chassis Ground (CHASSIS)

JP7 - 1.2V Reference Source Current Selection

JP1 - Factory Configured 1-to-2 Installed = 12V Bulk System
(Not Shown) 2-to-3 Installed = 6V Bulk System

JP5 - Power Fail Trip Point Selection JP8 - Supply Shutdown Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System 1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System 2-to-3 Installed = 6V Bulk System

JP6 - Supply Shutdown Trip Point Selection JP9- Power Fail Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System 1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System 2-to-3 Installed = 6V Bulk System

Figure 2-12. System Controller Module Component Identification Diagram

Another connector (TB2-future) provides an RTD connection, and an

RJ-45 connector provides the interface to the display/keypad.
Two red LEDs on the SCM’s front panel enable you to monitor the
status of the watchdog (WD) and Idle (IDLE) circuits.

Note: The Idle LED is usually on, indicating when the CPU has free
time at the end of its execution cycle. If the LED is off, it
indicates the CPU has no free time and may be overloading.
Six additional LEDs provide system status codes (see Chapter 5).
Board Fuse The SCM is fused to protect the entire system using a 5x20mm slow
blow fuse F1 rated at 1 Amp.

2-18 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.5.2 SCM Installation Overview

There are several steps you need to follow when you install the SCM.
1. Identify the carton holding the SCM and remove it from that carton.
See Section 2.3.
2. Set jumpers on the SCM based on whether your external DC bulk
power supply provides +12V or +6V. See Section 2.5.3.
3. If your SCM includes a mode switch (SW1) set it according to
Section 2.5.4.
4. Slide the SCM into slot #1 of the housing.
5. Unplug terminal block connector TB1 from the SCM and wire it to
an external bulk DC power supply. See Section 2.5.6.
6. If you want to use the RTD connector TB2, unplug it from the SCM
and wire it to an RTD according to instructions in Section 3.7.
7. After you configure and install the CPU module in slot #2 re-connect
terminal blocks to their connectors to apply power to the unit.

2.5.3 Setting Jumpers on the SCM

The SCM has five jumpers (JP5, JP6, JP7, JP8, JP9) which you set
based on whether your bulk DC power supply will provide +12V or
+6V. See Figure 2-12 to locate the jumpers on your version of the
SCM.
 JP5, JP6, JP7, JP8 and JP9: Three-position bulk power system
selection Jumper:
o 1-to-2 Installed = Choose this to select +12V Bulk System
o 2-to-3 Installed = Choose this to select +6V Bulk System

2.5.4 Setting Mode Switch SW1 on the SCM

The SCM has a DIP switch that controls whether the SCM operates in
Local Mode or Recovery Mode.
Local Mode is the normal operating mode for the ControlWave EFM,
and is the factory default. We recommend you use the factory default
unless you have a reason to use Recovery Mode.
Only use Recovery Mode during system firmware upgrades or core
updumps. See Chapter 5 for more information on these subjects.
Table 2-1 lists the SW1 settings:

Revised Dec-2013 Installation 2-19

ControlWave EFM Instruction Manual

Table 2-1. SCM Switch SW1

Switch position Mode

Both switches set to right (Open) or Activates Recovery mode, used for
both switches set to left (Closed) firmware upgrades or core updumps.
Upper switch (SW-1) set to right Activates Local mode, used for
(Open) and lower switch (SW-2) set to normal operation. (This is the factory
left (Closed) default)

Note: Only the SCM SW1 switch settings listed in the table have been
tested.

2.5.5 General Wiring Guidelines

 ControlWave EFMs use compression-type terminals that
accommodate up to #14 AWG wire.
 When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the wire.
 To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
 Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.

2-20 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.5.6 Wiring a Bulk DC Power Supply to the SCM

Caution At this time you can also connect power wiring. However; for safety
reasons and to prevent accidental damage to the your bulk DC power
supply, do not connect the pluggable terminal block connectors TB1 to
the SCM until after you install, wire, and configure the CPU module.
Follow the instructions in Section 2.5.5 General Wiring Guidelines when
wiring connections.

You can connect one bulk DC power supply (nominally either +12 Vdc
or +6 Vdc) to the SCM using connector TB1.
Use the following formula to determine the maximum current required:
Bulk + 6/12 Vdc Supply Current = CPU + Sum of all ECOM modules and I/O modules, optional boards
and optional case-mounted modem/radio

Notes:
 This summation accommodates steady state current draw.
 Table 2-2 provides detailed steady state power current requirements
for each ControlWave EFM base assembly module. Current
consumption in this table is based on the standard EFM application
(ControlWave project).
 In the case of a case-mounted modem or radio, the unit’s
manufacturer
 Power requirements for the optional digital to relay I/O board, 21V
power supply board, and the battery charger power manager board
are provided in the ControlWave EFM product data sheet.
Refer to Table 2-2 for ControlWave EFM bulk power requirements.

Table 2-2. Bulk Power Requirements

Bulk 12 Vdc Bulk 6 Vdc

Component Power Supply Power Supply
CPU + SCM and backplane 8.6 mA 14 mA
Non-isolated AI/AO Module 2.8 mA + (47.2 mA – VEXT) 5.6 mA + (47.2 mA – VEXT)
Non-isolated DI/O Module 12 mA 24 mA
Non-isolated HSC Module 5 mA 10 mA
Non-isolated Mixed I/O module 16.67 mA + (24.3 mA – VEXT) 34 mA + (24.3 mA – VEXT)
(with optional AO board)
ECOM without modem/radio 22 mA 45 mA
ECOM with MultiTech modem 56 mA 112 mA
ECOM with MDS radio 277 mA 555 mA
ECOM with modem & MDS radio 311 mA 622 mA
ECOM with FreeWave radio 272 mA 545 mA
ECOM with modem and FreeWave 306 mA 612 mA
radio

Revised Dec-2013 Installation 2-21

ControlWave EFM Instruction Manual

Terminal Block Unplug removable connector TB1 from the SCM and wire DC power to
Connector TB1 the connector. We recommend you do not plug the connector back into
the SCM until the CPU module is already installed in the housing.
TB1 provides three input connections for bulk DC power:
 TB1-1: (+VIN) (+4.5V/4.9V to +16V dc for +6V supply)
(+9.6/10.3V to +16V dc for +12V supply)
 TB1-2 = (-VIN) (Supply Ground)
 TB1-3 = Chassis Ground - CHASSIS ( )

Figure 2-13 shows the typical wiring at the SCM’s TB1 block.

Figure 2-13. SCM TB1 Wiring

Note: As an added precaution, we recommend that you run a #14

AWG wire from the TB1-3 power connection (Ground) to the
same known good earth ground used for the base housing.

2.6 Using a Solar Panel and Lead Acid Battery to Power the EFM
Instead of an external bulk DC power supply, you can use a solar panel
and rechargeable lead acid battery combination to power the EFM.
You can order this option with a 30W/40W solar panel with a built-in
regulator and a 12V, 33AH lead acid battery.

2.6.1 Mounting the Solar Panel

You can mount the solar panel to a 2” to 2-3/8” pipe using muffler
(pipe) clamps. You secure the pipe clamps using four ¼-20 nuts and
washers. See Figure 2-14.
Allow sufficient clearance so that you can swivel the solar panel for
optimum alignment with the sun, and so you can adjust the tilt angle for
maximum performance to accommodate the latitude of the installation
site. Solar panel wires enter the unit through a liquid tight conduit fitting
on the bottom of the enclosure.

2-22 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

A B
A

B
D
E C

Note 2: Item D slots

accommodate Tilt
Angle Adjustment.

A
A A
NOTE 1: To Attach item C to item D: B
Slide two bolts (A) through the top and bottom A
Solar Panel (Centered) Channel Holes. Affix item
B
C to item D via 2 sets of item A hardware as C D
E
follows: Flat Washer, Lock Washer & Hex Nut
(Max. Torque = 120 Inch-Pounds).
Adjustable
Tilt Angle

E
Vertical
Pole

A - 6 places consists of
the following hardware:
5/16-18 x .75 Hex Hd. Bolt
A D 5/16 Flat Washer
5/16 Spring Lock Washer
A B 5/16-18 Hex Nut
A
B - 2 places:
A C 2-3/8 U-Clamp Assembly
C - Adjustable Angle Bracket
(Attaches to Solar Panel)
D - Pole Mounting Bracket
E - 30 or 40 Watt Solar Panel

Figure 2-14. 30/40 Watt Solar Panel Mounting Diagram

Swivel and Tilt You must swivel the solar panel for optimum alignment with the sun. In
Angle the northern hemisphere, face the panel due south (not magnetic south).
In the southern hemisphere, face the panel due north (not magnetic
north).
30/40 watt solar panel systems have adjustable tilt angles. Adjust the tilt
angle for maximum performance to accommodate the latitude of your
installation site. Table 2-3 shows the angle (from horizontal) at which
you should install the solar panel to maximize annual energy output. At
most latitudes, performance can be improved by less of an angle during
the summer and more of an angle during winter.

Revised Dec-2013 Installation 2-23

ControlWave EFM Instruction Manual

Table 2-3. Solar Panel Tilt Angle

Latitude Tilt Angle

0-4° 10° from Horizontal
5-20° Add 5° to the Local Latitude
21-45° Add 10° to the Local Latitude
46-65° Add 15° to the Local Latitude
66-75° 80° from Horizontal

Connecting the Internally, you connect the solar panel wires directly to the rechargeable
Solar Panel to lead acid battery:
the Lead Acid PWR (red wire) terminal
Battery
GND (black wire) terminal
See Section 2.6.2 for more information on these connections.

2.6.2 Installing the Lead Acid Battery and Solar Panel Harness
Remove the rechargeable sealed lead-acid battery from its shipping
carton and install it on its mounting bracket within the enclosure as
illustrated in Figure 2-15.
1. Remove connector TB1 from the system controller module (SCM)
and remove the battery/power harness from the battery
charger/power manager board.
2. Remove the lead-acid battery from its shipping carton.
3. Install the lead-acid battery (on end) as illustrated in Figure 2-15.

Note: Before you install it, make sure the lead-acid battery is fully
charged.
4. Route the solar panel power wiring harness into the enclosure
through the solar power conduit fitting (see Item 5 of Figure 2-4).
5. Connect the solar panel harness to the internal battery (red =
positive & black = negative).
6. Secure the battery using the battery clamp.
7. When you are ready to apply power, connect the battery power
harness to either the power distribution board (if present) or to TB1
on the SCM.

2-24 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-15. Enclosure with Sealed Lead-acid Battery Installed

Revised Dec-2013 Installation 2-25

ControlWave EFM Instruction Manual

2.7 Power Distribution Board (Optional)

If your ControlWave EFM includes any of the following optional
components, it also requires the power distribution board.
 21V Power Supply Board for external transmitters
 Digital to Relay I/O Board
 Case-mounted radio or modem
The power distribution board, as well as the 21V power supply board
and the digital to relay I/O board mount inside the enclosure using a
Snap Track and dual PCB mounting bracket.

Figure 2-16. Power Distribution Board

Power distribution boards include six terminal block connectors:

TB1 Primary Power Input: (three-conductor) (from user supplied bulk
power source)
 TB1-1 = Power+ (Pos. input)
 TB1-2 = Power– (Neg. input)
 TB1-3 = Chassis (GND)
TB2 - Main Power Output 1: (two-conductor) (to SCM Power
Connector TB1)
 TB2-1 = PWR1+ to TB1-1 on SCM (+VIN)
 TB2-2 = PWR1– to TB1-2 on SCM (–VIN)
TB3 - Main Power Output 2: (two-conductor) (to 21V PS Board
Connector TB1)
 TB3-1 = PWR2+ to TB1-1 on 21VPS (+VIN)
 TB3-2 = PWR2– to TB1-2 on 21VPS (GND)
TB4 - Fused Power Output 1: (two-conductor) (to Digital to Relay I/O
Board Connector J1)
 TB4-1 = FPWR1+ to J1-10 on D-to-R I/O Bd. (PWR+)

2-26 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

 TB4-2 = FPWR1– to J1-9 on D-to-R I/O Bd. (PWR GND)

TB5 - Fused Power Output 2: (two-conductor) (to External
Modem/Radio Pwr. Connector)
 TB5-1 = FPWR2+ to Radio/Modem Power+
 TB5-2 = FPWR2– to Radio/Modem Power– (PWR GND)
TB6 - Fused Power Output 3: (two-conductor) (optional use - similar
to TB5)
 TB6-1 = FPWR3+ to Radio/Modem Power+
 TB6-2 = FPWR3– to Radio/Modem Power– (PWR GND)
Note: Fuse F1 is rated at 1.5A and protects the solar panel regulator
circuitry. Fuse F3 is rated at .5A and protects fused power output
1. F1 and F3 are provided for Class I, Div. 1 hazardous location
use only, which does not apply to the ControlWave EFM.

Figure 2-17. Power Distribution Board and Other Options - Snap Track Mounting

Revised Dec-2013 Installation 2-27

ControlWave EFM Instruction Manual

2.8 21V Power Supply (Optional)

The 21V power supply is typically used to provide power to
temperature and pressure transmitters (such as the Bristol 3508) that
require higher than +12V but lower than +21.4V (± .8V) to operate.
The 21V power supply has two terminal blocks that accommodate
power connections between the EFM and the remote transmitters. TB1
is a three-position terminal block that provides input power from the
power distribution board (see Section 2.7). Four-position terminal block
(TB2) provides +21V power and ground to the remote transmitters. See
Table 2-4 and Figure 2-18 for details on these connections.

Figure 2-18. 21V Power Supply Board

Table 2-4 - 21V Power Supply Board Terminal Designations

21VPS 21VPS TB Connection to Connection to
TB# Name Power Dist. Bd. XMTR
TB1-1 +12VIN TB3-1 N/A
TB1-2 12VGND TB3-2 N/A
TB1-3 CHASSISGND N/A N/A
TB2-1 +21V N/A XMTR1+
TB2-2 21VGND N/A XMTR1-
TB2-3 +21V N/A XMTR2+
TB2-4 21VGND N/A XMTR2-

2-28 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

2.9 CPU Module

The CPU module, which controls the ControlWave EFM and handles
memory and communication functions, can only be installed in Slot #2
of the backplane.

Note: Do not confuse the CPU module (which has communication

components) with the Expansion Communication module
(ECOM), which does not have a CPU component or a battery
backup but does have additional communication components.
Identify the carton holding the CPU module and remove it from that
carton. The CPU module has two basic configurations, each of which
have on-board communications components:
 CPU with two RS-232 serial ports, and one RS-485 serial port (see
Figure 2-19)
 CPU with two RS-232 serial ports, one RS-485 serial port, and one
Ethernet port (see Figure 2-20). The Ethernet option is only
available for 150 MHz CPU.

Figure 2-19. CPU Module with Three Serial Ports

Revised Dec-2013 Installation 2-29

ControlWave EFM Instruction Manual

Figure 2-20. CPU Module with Three Serial Ports and One Ethernet Port

2.9.1 Setting Jumpers on the CPU Module

Each CPU module contains a number of jumpers (labeled with JPn)
when n in the jumper number. See Figure 2-19 or Figure 2-20 to locate
the jumpers.

Note: When present, jumpers 1, 2, 3, 5, 6, and 9 (JP1, JP2, JP3, JP5,

JP6, and JP9) are reserved for factory use only. Do not alter
these jumpers from their factory settings.

 Jumper 4 (JP4) enables the Idle and Status LEDs on the SCM. It
comes enabled from the factory. (We recommend you leave these
LEDs enabled during initial installation and setup. If power
conservation is an issue, you can disable these LEDs by removing
the jumper.)
 Jumper 7 (JP7) enables the Communication Port Status LEDs on the
CPU module. It comes enabled from the factory. We recommend
you leave these LEDs enabled during initial installation and setup. If

2-30 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

power conservation is an issue, you can disable these LEDs by

removing the jumper.

Note: For maximum shelf life, the CPU module ships from the
factory with the installed lithium backup battery disabled.
You must enable it when you install the CPU module by
placing JP8 on pins 1-2.
 Jumper 8 (JP8) enables/disables the lithium backup battery on the
CPU module.
Pins 1-2: Enables the CPU module’s backup battery.
Pins 2-3: Disables the CPU module’s backup battery (Factory
default)
 Jumper 10 (JP10) specifies how COM1 is enabled.
Pins 1-2: Enables COM1 whenever DCD is active. (Factory
default)
Pins 2-3: Enables COM1 whenever you connect a cable to the
port.
 Jumper 11 (JP11) when present, specifies how COM2 is enabled.
Pins 1-2: Enables COM2 whenever DTR is ON. (Factory
default)
Pins 2-3: Port is always enabled. This setting can be used to
control external radios that feature DTR sleep modes.

2.9.2 Setting DIP Switches on the CPU Module

Before you install the CPU module, you must determine the settings for
three banks of DIP switches. Refer to Figure 2-19 or Figure 2-20 for
the location of the DIP switch banks on each CPU module. Refer to
Tables 2-5 through 2-7 for DIP switch setting values.

Note: Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF.

Table 2-5. CPU Module Switch SW1

SW1 Setting Function Mode

1 N/A Not currently used.
2 N/A Not currently used.
3 Force Enables recovery mode. Values are:
Recovery ON (enables recovery mode)
Mode OFF (disables recovery mode). – This is the factory
default.
4 N/A Not currently used.

Revised Dec-2013 Installation 2-31

ControlWave EFM Instruction Manual

Table 2-6. CPU Module Switch SW2

SW2 Setting Function Mode
1 Watchdog Controls whether the system enters a watchdog state
Enable when a crash or system hangup occurs and automatically
restarts. Values are:
ON (Enables watchdog circuit; factory default)
OFF (Disables watchdog circuit and prevents automatic
restart)
2 Lock/Unlock Controls the ability to modify soft switches, other
Soft Switches configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)
3 Use/Ignore Controls the use of soft switches. Values are:
Soft Switches ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
4 Core Updump Causes the ControlWave EFM to perform a core updump,
provided you have set the SCM mode switch to Recovery
mode. Values are:
ON (Disables core updump; factory default)
OFF (Core updump via SCM mode switch SW1)
5 SRAM Control Manages SRAM contents following a low power situation
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory
default)
OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start.
6 System Allows a remote download of system firmware (on units
Firmware equipped with boot PROM version 4.7 or higher and
system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory
default)
OFF (Disable remote download of system firmware)
7 N/A Not currently used.
8 Enable Suspends normal operation and allows diagnostic
WINDIAG routines. Values are:
ON (Permits normal system operation, including the boot
project, and disables the WINDIAG diagnostics from
running; factory default)
OFF (Allow WINDIAG to run test; disable boot project and
normal system operation.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all communication ports to 9600 bps operation.
All serial communication ports must be set at 9600
bps before WINDIAG can perform communication
tests.

2-32 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Notes:
 Table 2-7 describes switch settings for the RS-485 port. You may
want to review Section 2.9.4 Connections to RS-485 Serial Port(s)
before you set these switches.
 Table 2-7 applies to the following switches:
o SW3 on CPU Module – controls COM3
o SW1 on Type 1 ECOM Module – controls COM5/COM9
o SW1 on Type 2 ECOM Module – controls COM6/COM10
o SW2 on Type 2 ECOM Module – controls COM7/COM11

Table 2-7. RS-485 Configuration Switch

SW3 Setting Function Mode

1 TX+ to RX+ Loopback ON (only for diagnostics or 2-wire)
2 TX- to RX- Loopback ON (only for diagnostics or 2-wire)
3 100 Ohm RX+ Termination ON (End nodes only)
4 100 Ohm RX- Termination ON (End nodes only)
5 N/A Not currently used
6 Slew Rate (ISO485 Only) ON (Slow rate enabled)
OFF (Fast rate enabled)
Note: On CPU module, not currently used.

7 RX+ Bias (End Node) ON (End nodes only)

8 RX- Bias (End Node) ON (End nodes only)

After you configure the jumpers and DIP switches, slide the CPU
module into slot #2 (the second slot from the left) of the housing (see
Figure 2-6 or Figure 2-7).

Revised Dec-2013 Installation 2-33

ControlWave EFM Instruction Manual

2.9.3 Connections to RS-232 Serial Port(s) on CPU or ECOM

Modules
An RS-232 port provides point-to-point, half-duplex and full-duplex
communications (for a maximum of 20 feet using data quality cable).
Your CPU module includes two RS-232 ports.
If you require additional RS-232 ports, you can purchase an optional
expansion communication module that can include either one (ECOM
Type 1) or two (ECOM Type 2) RS-232 ports. The ControlWave EFM
can support up to two expansion communication modules, for a total of
up to four additional RS-232 ports beyond those on the CPU module.
Expansion communication modules reside in slot #3 and slot #4.

RS-232 COM RS-232 COM ports are assigned names based on their location in the
Port Names and ControlWave EFM.
Connectors
 The CPU module RS-232 ports are COM1 and COM2.
Table 2-8. RS-232 Connectors on CPU

Connector Name # Pins Function Notes

J3 COM1 9-pin 9-pin male D-sub (RS-232). See Figure 2-19, Figure 2-20,
Also supports circular 3-pin Figure 2-21 & Table 2-8
female connector (local port)
at the bottom of the enclosure.
J4 COM2 9-pin 9-pin male D-sub (RS-232) See Figure 2-19, Figure 2-20
Figure 2-21 & Table 2-8
 If you have an ECOM module with one RS-232 port, this is COM4
if the module is in slot #3 or COM8 if the module is in slot #4.
 If you have an ECOM module with two RS-232 ports, those ports
are COM4 and COM5, respectively, if the ECOM module is in slot
#3, or COM8 and COM9, respectively, if the ECOM module is in
slot #4.
Table 2-9. RS-232 Connectors on Expansion Communications Modules

Connector Name # Function Notes

Pins
J4 COM4 (when in slot 3) 9-pin 9-pin male D-sub (RS- See Figure 2-21, Figure 2-31,
COM8 (when in slot 4) 232) Figure 2-32 & Table 2-10
J5 COM5 (when in slot 3) 9-pin 9-pin male D-sub (RS- See Figure 2-21, Figure 2-32 &
COM9 (when in slot 4) 232) Table 2-10
Only available on ECOM Type
2 models.

2-34 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

RS-232 COM For the ControlWave EFM, half-duplex communications use Modbus or
Port Cables BSAP protocol, while full-duplex communications use point-to-point
protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 2-
22) to connect with other devices (such as a PC, a printer, another
ControlWave [except the CW_10/30/35]) when the ControlWave EFM
uses the full-duplex PPP protocol.

Note: You can configure the ControlWave EFM as either a master or

slave node on a Modbus or BSAP network.
Figure 2-21 illustrates the CPU module’s male 9-pin D-type connector.
Use the content provided in Table 2-8 to determine pin assignments for
the COM1 and COM2 ports and the expansion communication ports
COM4/5 and COM8/9.

Figure 2-21. Male DB9 9-Pin Connector

Table 2-10. RS-232 Port Connector Pin Assignment

RS-232
Pin Signal RS-232 Description
1 DCD Data Carrier Detect Input
2 RXD Receive Data Input
3 TXD Transmit Data Output
4 DTR Data Terminal Ready Output
5 GND Signal/Power Ground
6 DSR Data Set Ready Input
7 RTS Request to Send Output
8 CTS Clear to Send Input
9 N/A

Use the “null modem” cable for full-duplex (PPP protocol)

communications when connecting a ControlWave EFM to a PC. (See
top part of Figure 2-22.)

Revised Dec-2013 Installation 2-35

ControlWave EFM Instruction Manual

Figure 2-22. Full-duplex and Half-duplex Cable

Use the half-duplex cable (shown in the bottom part of Figure 2-22)
when connecting the ControlWave EFM to another ControlWave series
unit (again, with the exception of the CW_10/30/35).
When communicating with a Network 3000 series RTU 3305, RTU
3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of
the cables shown in Figure 2-23.

Figure 2-23. Full-duplex and Half-duplex Cable

When connecting the ControlWave EFM to an external (case-mounted)

modem or radio, use the cable shown in

2-36 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-24. Communication Interface Cable for Connection to Case-Mounted (External) Radio or
Modem

When interfacing to the COM3 port of a ControlWave, or the COM5 or

COM6 port a ControlWaveEXP unit, use the cable presented in Figure
2-25 along with the cable shown in Figure 2-22 or Figure 2-23.

Figure 2-25. Full-duplex and Half-duplex Cable

If you use the local port circular connector see Figure 2-26, Figure 2-27
and Table 2-11.

Figure 2-26. PC Connected to ControlWave EFM via D-Type Local Port (use Null Modem Cable P/N
392843-01-3)

Revised Dec-2013 Installation 2-37

ControlWave EFM Instruction Manual

Figure 2-27. PC Connected to ControlWave EFM via Circular Local Port (use Cable P/N 395402-01-
8 [10 foot cable] or P/N 395402-02-6 [25 foot cable])

Table 2-11. RS-232 Port (COM1) Connector Pin Assignment (COM1 Connectors – Circular Local
Port & D-Type “C1” Connector on CPU)

RS-232 Wire Local Port

COM1 Pin Signal RS-232 Description Color RS-232
Pin
1 DCD Data Carrier Detect Green 1
Input
2 RXD Receive Data Input White 7
3 TXD Transmit Data Output Red 2
4 DTR Data Terminal Ready Brown 4
Output
5 GND Signal/Power Ground Black 6
6 DSR Data Set Ready Input
7* RTS Request to Send
Output
8* CTS Clear to Send Input
* RTS connected to CTS

RS-232 Cable Observe the following guidelines when constructing RS-232

Guidelines communication cables:
 Ensure that DCD is high to transmit (except when dialing a modem)

2-38 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

 Verify that each RS-232 transceiver has one active receiver while
disabled (in power down mode); connect the DCD signal to the
active receiver.
 Set CTS to high to transmit.
 If the port is set for full-duplex operation, RTS is always ON.
 Ensure that DTR is always high when port is active; DTR enables
RS-232 transceivers.

Note: Control DTR using the PORTCONTROL function block and

the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.
 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.
 All RS-232 comm port I/O signals are protected by surge protectors.

2.9.4 Connections to RS-485 Serial Port(s) on CPU or ECOM

Modules
The RS-485 port supports local network communications to multiple
nodes up to 4000 feet away.
Your CPU module includes one RS-485 port.
If you require additional RS-485 ports, you can purchase an optional
expansion communication module that includes one or two RS-485
ports. The ControlWave EFM can support up to two expansion
communication modules, for a total of up to four additional RS-485
ports beyond the one on the CPU module. Expansion communication
modules reside in slot #3 and slot #4.
RS-485 COM RS-485 COM ports are assigned names based on their location in the
Port Names and ControlWave EFM.
Connectors
 The CPU module’s RS-485 port is COM3.
 If you have a Type 1 ECOM module in slot #3, its RS-485 port is
COM5. If you have a Type 1 ECOM module in slot #4, its RS-485
port is COM9.
 If you have a Type 2 ECOM module in slot #3, its RS-485 ports are
COM6 and COM7. If you have a Type 2 ECOM module in slot #4,
its RS-485 ports are COM10 and COM11.
Table 2-12 provides the connector assignments for CPU port COM3;
Table 2-13 shows the assignments for ECOM1 port COM5/9; and Table
2-14 shows assignments for ECOM2 ports COM6/10 and 7/11.

Revised Dec-2013 Installation 2-39

ControlWave EFM Instruction Manual

Table 2-12. RS-485 Connectors on CPU

Connector Name # Pins Function Notes

J5 COM3 9-pin 9-pin male D-sub (RS-485) See Figure 2-19 and Figure 2-
20.
Table 2-13. RS-485 Connectors on Type 1 Expansion Communications Modules

Connector Name # Pins Function Notes

J5 COM5 (when in slot 3) 9-pin 9-pin male D-sub See Figure 2-31 & Table 2-14
COM9 (when in slot 4) (RS-485) Only available on ECOM Type
2 models.

Table 2-14. RS-485 Connectors on Type 2 Expansion Communications Modules

Connector Name # Pins Function Notes

J6 COM6 (when in slot 3) 9-pin 9-pin male D-sub See Figure 2-32 & Table 2-14
COM10 (when in slot (RS-485)
4)
J7 COM7 (when in slot 3) 9-pin 9-pin male D-sub See Figure 2-32 & Table 2-14
COM11 (when in slot (RS-485)
4)

RS-485 COM Figure 2-21 illustrates the CPU module’s male 9-pin D-type connector.
Port Cables Use the content provided in Table 2-15 to determine pin assignments for
the COM3 port on the CPU (CPU switch SW3), and COM5/9,
COM6/10, and COM7/11 expansion communication ports (ECOM
switches SW1 and SW2).

Table 2-15. RS-485 Port Connector Pin Assignment

Pin RS-485 Signal RS-485 Description

1 N/A
2 RXD– Receive Data – Input
3 TXD– Transmit Data – Output
4 TXD+ Transmit Data + Output
5 GND/ Ground/Isolated Ground
ISOGND
6 RXD+ Receive Data + Input
7 N/A
8 N/A
9 N/A

2-40 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Since the RS-485 port is intended for network communications, refer to

Table 2-16 for the appropriate connections for wiring the master, first
slave, and nth slave.
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisy-
chained) across the same lines. Wire the master node to one end of the
RS-485 cable run using a 24-gauge paired conductor cable (such as a
Belden 9843).

Note: ControlWave EFMs support only half-duplex RS-485 networks.

Table 2-16. RS-485 Network Connections

From Master To First 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.
To ensure that the “Receive Data” lines are in a proper state during
inactive transmission periods, you must maintain certain bias voltage
levels at the master and most distant slave units (end nodes). These end
nodes also require the insertion of 100Ω terminating resistors to
properly balance the network.
You must also configure switches at each node to establish proper
network performance. Accomplish this by configuring switches listed so
that the 100Ω termination resistors and biasing networks are installed at
the end nodes and are removed at all other nodes on the network. You
enable receiver biasing and termination (as well as 2-wire or 4-wire
selection) using an 8-position DIP switch located on the CPU and
ECOM modules. See Table 2-5 in Section 2.9.2 Setting DIP Switches on
the CPU Modules for information on RS-485 termination and loopback
control switch settings.

Revised Dec-2013 Installation 2-41

ControlWave EFM Instruction Manual

2.9.5 Connections to Ethernet Port on the CPU Module

Caution The RJ45 Ethernet port is located on the CPU module (150 MHz version
only). The SCM also has one RJ45 port for the optional Display/Keypad.
Never connect Ethernet to the Display/Keypad port or damage to the SCM
will result.

ControlWave EFMs can support up to two Ethernet ports. These use a

10/100Base-T RJ-45 modular connector that provides a shielded
twisted pair interface to an Ethernet hub. Two LEDs per port provide
transmit and receive status indications:
Port assignments are:
 Ethernet Port 1: CPU Bd. J6, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
 Ethernet Port 2: CPU Bd. J5, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with
port 8 having the capability to link either to another hub or to an
Ethernet communications port). Both ends of the Ethernet twisted pair
cable are equipped with modular RJ-45 connectors.
1 8

Looking into
receptacle

Figure 2-28. RJ-45 Ethernet Connector

These cables have a one-to-one wiring configuration as shown in Figure

2-29. Table 2-17 provides the assignment and definitions of the 8-pin
10/100Base-T connectors.

Figure 2-29. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)

2-42 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Table 2-17. Ethernet 10/100Base-T CPU Module Pin Assignments

Pin Description
1 Transmit Data+ (Output)
2 Transmit Data– (Output)
3 Receive Data+ (Input)
4 Not connected
5 Not connected
6 Receive Data– (Input)
7 Not connected
8 Not connected

Note: You can swap TX and RX at the hub.

You can connect two nodes in a point-to-point configuration without

using a hub. However, you must configure the cable so that the TX+/-
Data pins connect to the RX+/- Data pins (swapped) at the opposite
ends of the cable (see Figure 2-30).

Figure 2-30. Point-to-Point 10/100Base T Ethernet Cable

The maximum length of one segment (CPU to hub) is 100 meters (328
feet). The use of Category 5 shielded cable is recommended.

Revised Dec-2013 Installation 2-43

ControlWave EFM Instruction Manual

2.10 Expanded Communications Module (ECOM)

ControlWave EFM can support up to two optional expanded
communications modules (ECOMs) which you can install only in slots
#3 or #4 (in place of I/O modules). ECOMSs do not have a CPU
component.
Two Types of There are two types of ECOM module:
ECOM Modules
 Type 1 Expansion Communications Module (ECOM1) with one RS-
232 port, one RS-485 serial port, and an optional modem port (see
Figure 2-31)
 Type 2 Expansion Communications Module (ECOM2) with two
RS-232 serial ports and two RS-485 serial ports (see Figure 2-32)
Identify the carton holding the ECOM module(s) and remove the
module from that carton.

Figure 2-31. Type 1 ECOM with Two Serial Ports and a Modem

2-44 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Receive LEDs Transmit LEDs

Comm. Port 4/8
CR1 W1
1-2 Installed = LEDs Enabled
2-3 installed = LEDs Disabled
1

W1 W2 for Comm. Port 4/8

1 2
Comm. Port 4/8
RS-232
J4 W2
&
1-2 Installed = Loopback Disabled
2-3 installed = RTS/CTS Loopback
W3

Comm. Port 5/9

CR2
W3 for Comm. Port 5/9 P1
1
J2 - for Factory Use ONLY

Comm. Port 5/9

RS-232 J5

Comm. Port 6/10

CR3
T1

Comm. Port 6/10 O N

RS-485 J6 1 2 3 4 5 6 7 8

SW1
Comm. Port 6/10 Isolation
RS-485 Network Transformers
Comm. Port 7/11 Configuration for
Isolated RS-485
CR4
T2

Comm. Port 7/11 O N

RS-485 J7 1 2 3 4 5 6 7 8

SW2
Comm. Port 7/11
RS-485 Network
Configuration

If In Slot #3 - Comm. Port Assignments = 4, 5, 6 & 7

If in Slot #4 - Comm. Port Assignments = 8, 9, 10 & 11

Figure 2-32. Type 2 ECOM with Two RS-232 and Two RS-485 Ports

Detailed Technical For detailed technical specifications, please see document

Specifications CWMICRO:COM available on our website
http://www.emersonprocess.com/remote/D301673X012.pdf.

2.10.1 RS-232 Ports

Type 1 ECOMs include one RS-232 port. Type 2 ECOMs include two
RS-232 ports. For information on connecting to these ports, including
cabling information, see Section 2.9.3.

2.10.2 RS-485 Ports

Type 1 ECOMs include one RS-485 port. Type 2 ECOMs include two
RS-485 ports. For information on connecting to these ports, including
cabling information, see Section 2.9.4.

Revised Dec-2013 Installation 2-45

ControlWave EFM Instruction Manual

When connecting a ControlWave EFM to an external (case-mounted)

modem, use the cable configuration in Figure 2-33.

Figure 2-33. Full-duplex and Half-duplex Cable

Figure 2-34. ECOM Modem Installation

2.10.3 Modem Port (Type 1 ECOM only)

You can mount an optional 56Kb PSTN Hayes-type modem on a Type
1 ECOM (see Figure 2-34).
The ControlWave EFM then assigns the modem COM7 (if in slot #3) or
COM11 (if in slot #4).
You can configure the MultiTech model MT9234SMI modem module
for publicly switched telephone network (PSTN) operation. You can

2-46 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

also clock DTE/DCE serial data into (transmit) or out of (receive) the
modem at rates up to 115.2 kHz.
The factory supplies the modem pre-installed or in kit form with all
required hardware. You install it on the ECOM1 module and then use
the Ports page in the Flash Configuration utility (in NetView,
LocalView, or TechView) to assign ports. Configure a profile for the
modem using AT commands submitted using a terminal emulation
program (such as HyperTerminal). Users typically use AT commands
only when checking the modem’s active or stored profile or when
reconfiguring a modem (to turn auto answer on or off, etc.).
Prior to shipment from the factory, the MultiTech modems are pre-
configured using the following steps:
1. Connect pin Enable modem setup by setting jumper JP2 on the
ECOM to 2-3.
2. Connect via HyperTerminal (Parameters = 9600, 8, N, 1, None)
to ECOM port C1 using the null modem cable (see Figure 2-22).
3. Send Factory Default = AT&F0
4. Disable Flow Control = AT&K0
5. Set baud rate using AT Command: AT$SB9600, or whatever
baud rate you require.
6. Write to Memory. = AT&W
7. Disable setup mode. Park JP2 (no connection)

Note: You can reconfigure the modem using AT commands and a

terminal program (like HyperTerminal). Connect pins 2 and 3 of
JP2 with a suitcase jumper, and use a null modem cable (see
Figure 2-22) to connect the PC to the modem (COM4 or
COM8).
PSTN Figure 2-35 shows a publicly switched telephone network (PSTN)
Connections using a single master and three remote ControlWave EFMs (equivalent
to EFMs for this application) each equipped with a PSTN modem.
This application requires only one remote connection.
Use a cable with standard telephone connectors (RJ11s) on each end.
Plug one end of the cable into the RJ11 connector jack on the ECOM
and the end into a RJ11 wall jack. The telephone company provides the
necessary subscriber loops at its central system along with the phone
numbers for each destination.

Caution Connect only one modem on each drop. If you attempt to parallel two or
more modems across a single drop, an impedance mismatch occurs,
adversely affecting the signal. Modems cannot provide reliable
communications under these conditions.

Revised Dec-2013 Installation 2-47

ControlWave EFM Instruction Manual

Figure 2-35. PTSN Field Connections for ControlWave Micros (and EFMs)

Figure 2-36. Phone Cord Wiring

The 56K PSTN modem is FCC-approved for use with public telephone
lines. However, before you place a modem in operation, check the
following items to make sure you meet all FCC requirements:
 Connections to party line service are subject to state tariffs.
 Connections to telephone company-provided coin service (central
office implemented systems) are prohibited.
 The equipment compliance information is summarized as follows:
o Complies with Part 68 FCC Rules.
o Contains device with FCC Registration Number: AU7-USA-
25814-M5-E

2-48 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

o Ringer Equivalence Number (REN): 0.3B

Note: The sum of all the RENs on your telephone lines should
be less than five in order to assure proper service from
the telephone company. In some cases, a sum of five may
not be usable on a given line.
 Make any direct connections to PSTN lines through standard plugs
and jacks as specified in the FCC rules. The PSTN line connector
plugs into J1 on the modem. Notify your telephone company that the
jack (connector) required for your device is one of the following:
o USOC: RJ11C or
o USOC: RJ11W

Note: The jack provided on the Modem (J1) is a 6-pin TELCO RJ-
11. The connections to the modem are pin 3 PSTN-Tip, and
pin 4 PSTN-Ring.
 After the telephone company has installed the above jack, connect
the modem to your equipment by inserting the appropriate
equipment interface RJ11 plug into the modem and wall connector.

2.11 Bezels
Bezels are blue plastic covers (see Figure 2-37) that protect an adjacent
pair of I/O modules and provide an easy way for you to route wiring.
The factory provides bezels with each order. Install bezels over I/O
modules whenever the ControlWave EFM is operational; remove the
bezels for maintenance procedures.
Bezels attach to the module covers of two adjacent I/O modules. Hooks
on the bezels (see Figure 2-37) attach to notches in the upper and lower
portions of the module covers. Align the hooks on the bezel with the
notches on the I/O module covers and slide the bezel down. To remove
the bezel, grasp its sides and gently squeeze them, and pull up and then
away from the I/O modules.

Revised Dec-2013 Installation 2-49

ControlWave EFM Instruction Manual

Figure 2-37. Bezel Assembly

2.12 Case Mounted Radio/Modem

An alternative to using a Type 1 ECOM module with an integrated
modem/radio is to order a case-mounted modem/radio. In this
configuration, the ControlWave EFM ships from the factory with a user
selected radio or modem installed within the enclosure (beneath the
battery mounting bracket) or as a radio-ready unit, in other words, ready
for field installation of a factory-supplied radio. The installer must
ensure that the remote antenna (associated with a case mounted radio) is
properly installed and connected.
 See the ControlWave Radio-Ready Installation Guide (D5138) for
information on installing factory-supplied radios in the field.
 See the ControlWave PSTN Modem Installation Guide
(D301734X012) for information on installing the 9600 bps PSTN
modem.

2.13 Optional Display/Keypads

The ControlWave EFM supports two optional display/keypads:
 A 2-button keypad (shown in the left of Figure 2-38)
 A 25-button keypad (shown in the right Figure 2-38)

2-50 Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 2-38. Optional 2-Button and 25-Button Keypads

Both keypads use the same 4-line by 20-character LCD displays. You
connect the keypad to the ControlWave EFM using a cable, one end of
which has an RJ-45 jack (connected into the RJ-45 equipped with two
plugs). This cable connects between the RJ-45 display jack (J2) on the
SCM module and RJ-45 jack (J1) on the remote Display/Keypad
assembly. A potentiometer, provided on the keypad, allows you to set
the contrast of the LCD display.

Note: For further information on the installation and use of the

optional keypads, refer to the ControlWave Display/Keypad
Manual (D5135).

Revised Dec-2013 Installation 2-51

This page is intentionally left blank
 ControlWave EFM Instruction Manual

Chapter 3 – I/O Modules

This chapter discusses the placement and wiring for I/O modules for the
ControlWave EFM. The chapter begins with some general instructions
on module installation that are common to most I/O modules. The
balance of the chapter includes specific details for configuring and
wiring each type of I/O module.
In This Chapter

3.1 Module Placement ...........................................................................3-2

3.2 Wiring ...............................................................................................3-3
3.2.1 Local Termination .................................................................3-3
3.2.2 Shielding and Grounding ......................................................3-4
3.3 Non-isolated Digital Input/Output (DI/O) Module .............................3-5
3.4 Non-isolated Analog Input/Output & Analog Input Module ..............3-7
3.5 Non-isolated High Speed Counter (HSC) Input Module ................3-10
3.6 Non-isolated Mixed I/O (MI/O) Module ..........................................3-12
3.7 Resistance Temperature Device (RTD) Inputs on SCM ...............3-16
3.8 Digital to Relay I/O Board Option ..................................................3-18
3.9 Connections to a Bristol Model 3808 Transmitter .........................3-20

Installation Installing any I/O module in the ControlWave EFM involves the same
basic steps:
1. Remove the I/O module and associated I/O module cover from the
shipping carton. The cover snaps on or off to provide access to the
unit’s I/O connectors.
Notes:
 I/O modules for the ControlWave EFM use local termination where
field wiring connects directly to the I/O module’s removable
terminal blocks.
 You can use the ControlWave Loop Power Supply to provide
regulated and isolated 24Vdc field power for externally powered
non-isolated I/O. See PIP-ControlWaveLS.
 Modules normally ship from the factory completely assembled.
2. When installing wiring in conjunction with the I/O modules, install
the field wiring between the I/O module’s removable terminal
blocks and field devices. (See Section 3.2 Wiring.)
3. Align the I/O module with its intended slot on the base housing and
slide the module into the housing. Make sure the module I/O module
cover snaps into the appropriate securing notches on the housing.
4. Plug the local cable assemblies into the appropriate I/O module
connectors

Revised Dec-2013 I/O Modules 3-1

ControlWave EFM Instruction Manual

5. After installing and wiring two I/O modules into adjacent slots in
the housing, cover the modules with a protective bezel. The bezels
snap on and off for maintenance.
6. Using a PC running the ControlWave Designer and OpenBSI
software, configure the ControlWave EFM to accept the new I/O
modules and download the revised ControlWave project.

Note: This step is beyond the scope of this manual and is only
required if you are not using the base flow measurement
application which has I/O already defined. Refer to the
ControlWave Designer Programmer’s Handbook (D5125)
for further instructions.

Caution Power down the ControlWave EFM before you install or remove any I/O
module. Shut down any processes the ControlWave EFM may be
managing (or switch them over manually or handle with another
controller). Perform any hardware configuration (wiring, jumper
configuration, and installation) only when the ControlWave EFM is
powered down.

Before any I/O modules can become operational, you must use
ControlWave Designer to configure and then download the application
(project). The exception to this is if the application is already configured
for you.

Do not install any modules in the housing until you have mounted and
grounded the housing at its designated installation site.
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:
 Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
 ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)

3.1 Module Placement

You can place I/O modules in the housing:
 4-slot housing: supports up to two I/O modules in slots 3 and 4.
 8-slot housing: supports up to six I/O modules in slots 3 through 8.
 Optionally you can install an expansion communication module in
slot 3, slot 4, or both, instead of an I/O module.
Note: Some modules have placement restrictions. Note these in the
individual descriptions.

3-2 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 3-1. ControlWave EFM Slot Assignments

3.2 Wiring
I/O modules support local termination where field wiring connects
directly to the module’s removable terminal blocks.
ControlWave EFM I/O modules use compression-type terminals that
accommodate up to #14 AWG wire. Consult with the field device
manufacturer for recommendations if using smaller wire sizes. Insert the
wire’s bared end (approx. ¼” max) into the clamp beneath the screw
and secure the wire. To prevent shorts, ensure that no bare wire is
exposed. If using standard wire, tin the bare end with solder to prevent
flattening and improve conductivity. Allow some slack in the wires
when making terminal connections. Slack makes the wires more
manageable and helps minimize mechanical strain on the terminal
blocks.

3.2.1 Local Termination

For I/O modules equipped with local terminal blocks, install the field
wiring between the I/O module’s removable terminal block connectors
and field devices (see Figure 3-1). Use AWG 14 or smaller wire
(consult with the field device manufacturer for recommendations).
Leave some slack and plan for wire routing, identification, and
maintenance. Route the bundled wires out through the bottom of the I/O
Revised Dec-2013 I/O Modules 3-3
ControlWave EFM Instruction Manual

module assembly between the terminal block and the terminal housing.
All I/O wiring should be routed in/out of the enclosure through the 1”
NPT conduit hub.

Figure 3-2. Module Wiring: Local Termination

3.2.2 Shielding and Grounding

Use twisted-pair, shielded and insulated cable for I/O signal wiring to
minimize signal errors caused by electromagnetic interference (EMI),
radio frequency interference (RFI), and transients. When using shielded
cable, ground all shields at only one point in the appropriate system.
This prevents circulating ground current loops that can cause signal
errors.

3-4 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

3.3 Non-isolated Digital Input/Output (DI/O) Module

Non-isolated DI/O modules consist of a digital input/output PCB with
two 10-point terminal block assemblies for local termination. The DI/O
module also includes 14 configuration jumpers, an LED board with 16
status LEDs (one for each point), and a cover assembly. The DI/O
module connects with the backplane using a 36-pin gold-plated card-
edge connector.
Non-isolated DI/O modules contain field interface circuitry for up to 12
digital inputs and four digital outputs.
Table 3-1. Non-Isolated DI/DO Module General Characteristics
Type Number Characteristics
Supported
Digital 12 Each DI supports/ includes:
Inputs (DI)  Internally sourced DI operation for dry
contacts pulled internally to 3.3Vdc when
field input is open.
 Surge suppressor
 Signal conditioning
 Filter time of 15 ms
 Jumper to configure source current for either
2 mA or 60 uA
 Dedicated LED on module turns ON when
DI is ON.
Digital 4 Each DO supports/ includes:
Outputs  Open drain MOSFET provides 100mA at
(DO) 30Vdc to an externally powered device.
 Surge suppressor
 Current sink to ground of DI/DO module
 Dedicated LED on module turns ON when
DO is ON.

Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.

Setting Jumpers DI/O modules provide 12 individually field configurable DIs and 4
non-configurable externally powered DOs.
Using configuration jumpers W1 through W12, you can set each DI
individually to provide either a 2 mA or 60 uA source current. Table 3-2
details jumper settings.

Table 3-2. Jumper Assignments: Non-isolated DI/O Module

Jumper Purpose Description
W1-W12 Configures DI1 through DI12 Pins 1-2 installed = 2mA Source Current
(respectively) Pins 2-3 installed = 60uA Source Current
W13 Enables LEDs Pins 1-2 installed = allows manual enabling of LEDs

Revised Dec-2013 I/O Modules 3-5

ControlWave EFM Instruction Manual

Jumper Purpose Description

Pins 2-3 installed = allows software enabling of LEDs
W14 Programs Serial EEPROM Reserved for factory use only

Wiring the Module Figure 3-3 shows the terminal block assignments for the locally
terminated DI/O module.

Figure 3-3. Non-isolated DI/O Module (Local Termination)

Software Configuration To use data from a non-isolated DI/O module you must add a
CWM_MD board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

3-6 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

3.4 Non-isolated Analog Input/Output & Analog Input Module

Non-isolated Analog Input/Output (AI/O) modules support six
externally sourced 4–20mA or 1–5 Vdc single-ended analog inputs and
optionally, two independently configurable 4–20 mA or 1–5 Vdc analog
outputs. Non-isolated Analog Input (AI) modules are identical to
AI/O modules but have a depopulated AO section.
AI/O modules consist of an AI/O PCB with two 10-point terminal block
assemblies for local termination, 12 configuration jumpers, and a cover
assembly. The AI/O module connects with the backplane using a 36-pin
gold-plated card-edge connector.
Table 3-3. Non-Isolated AI/O and AI Module General Characteristics
Type Number Characteristics
Supported
Analog Inputs 6 on AI/O Each AI supports/includes:
(AI) Module  Jumper to configure input for either 4–
20mA or 1–5 Vdc
6 on AI  Signal conditioning that provides 2 Hz
Module low pass filter
 Transorb for surge suppression
 Analog to Digital converter
Analog Outputs 2 on AI/O Each AO supports/includes:
(AO) Module  Jumper to configure output for either 4–
20mA or 1–5 Vdc
None on AI  maximum external load to the 4–20mA
Module output of either 250 ohms with an
external 11V power source or 650
ohms with an external 24V power
source.
 maximum external load current to the
1–5 Vdc output is 5 mA with an
external 11-30 V power source.
 AO operation requires an 11–30Vdc
power source connected to the VEXT
terminal of the AI/O module.

Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.

Configurations Each non-isolated AI/O module (general part number 396568-01-7)

consists of a PCB with six AIs, 2 AOs, and comes with a module
cover.
Each non-isolated AI module (general part number 396569-01-3)
consists of a PCB with six AIs and comes with a module cover.
Cable Shields Connect cable shields associated with AI wiring to the ControlWave
EFM’s housing ground. Multiple shield terminations require that you
supply a copper ground bus (up to a #4 AWG wire size) and connect it
Revised Dec-2013 I/O Modules 3-7
ControlWave EFM Instruction Manual

to the housing’s ground lug.

This ground bus must accommodate a connection to a known good earth
ground (in lieu of a direct connection from the ground lug) and to all AI
cable shields. Shield wires should use an appropriate terminal lug.
Secure them to the copper bus using industry rugged hardware
(screw/bolt, lock washer, and nuts).
Setting Jumpers AI/O and AI modules have jumpers you can use to configure each of
the six AIs. You can individually configure AIs for 1–5 Vdc or 4–20
mA operation. See Table 3-4.
Table 3-4. Jumper Assignments: Non-isolated AI/O and AI Module
Jumper Purpose Description
JP1-JP6 Configures AI1 through AI6 Pins 1-2 installed = 4-20 mA AI
(respectively) Pins 2-3 installed = 1-5 V AI
JP71 AO1 Field Output Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5 V AO
JP81 AO2 Field Output Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5 V AO
JP91 AO1 Output Type Pins 1-2 installed = 1-5 V AO
Pins 2-3 installed = 4-20 mA AO
JP101 AO2 Output Type Pins 1-2 installed = 1-5 V AO
Pins 2-3 installed = 4-20 mA AO
JP1 Configures ISP Connector Reserved for factory use only
W1 Programs Serial EEPROM Reserved for factory use only
1 Configuration for JP7 and JP9 must match (that is, both 1-5 V or 4-20mA)
Configuration for JP8 and JP10 must match (that is, both 1-5 V or 4-20mA)

Wiring the Module Figure 3-4 shows field wiring assignments associated with the locally
terminated AI/O and AI modules.

3-8 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 3-4. Non-isolated AI/O and AI Module Configuration (Local Termination)

Software Configuration To use data from a non-isolated AI/O module you must add a
CWM_MA board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for these modules.

Revised Dec-2013 I/O Modules 3-9

ControlWave EFM Instruction Manual

3.5 Non-isolated High Speed Counter (HSC) Input Module

Non-isolated High Speed Counter (HSC) Input modules provide up to
four inputs. You can individually configure HSC module inputs for
either a 10 KHz (high speed) or 300 Hz (low speed) input, and as a 16-
bit high speed counter
HSC modules consist of a HSC PCB with two 10-point terminal block
assemblies for local termination, 14 configuration jumpers, an LED
daughter board with four status LEDs (one for each point), and a cover
assembly. The HSC PCM connects with the backplane using a 36-pin
gold-plated card-edge connector.
Table 3-5. High Speed Counter Module General Characteristics
Type Number Characteristics
Supported
High Speed 4 Each HSC supports/includes:
Counter Inputs  Jumper to configure point as either a
(HSC) low speed input (300 Hz) or a high
speed input (10 KHz).
 Jumper to configure HSC current.
 Bandwidth limiting
 Surge suppression
 Field inputs can be driven by signals or
relay contacts.
 LED status indicator

Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.

Setting Jumpers HSC modules support up to four HSC inputs. Configure the HSC
jumpers (W1 through W14) according to Table 3-6.
Table 3-6. Jumper Assignments: Non-isolated HSC Module
Jumper Purpose Description
W1 – W4 Configures HSC1 through Pins 1-2 installed = Enables 300 Hz (low speed input)
HSC4 (respectively) Pins 2-3 installed = Enables 10 KHz (high speed input)
W5 Programs Serial EEPROM Reserved for factory use only
W6 Enables LEDs Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
W7 & W8 Controls HSC1 Current Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
W9 & W10 Controls HSC2 Current Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
W11 & W12 Control HSC3 Current Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
W13 & W14 Controls HSC4 Current Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load

3-10 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Wiring the Module Figure 3-5 shows field wiring assignments for the locally terminated
HSC module.

Figure 3-5. Non-isolated HSC Module (Local Termination)

Software Configuration To use data from a high speed counter module you must add a
CWM_HSC4 board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

Revised Dec-2013 I/O Modules 3-11

ControlWave EFM Instruction Manual

3.6 Non-isolated Mixed I/O (MI/O) Module

Non-isolated Mixed I/O (MI/O) modules provide up to six individually
field configurable DI/Os, four AIs, two HSC Inputs and, optionally, one
AO.
MI/O modules consist of an MI/O PCB with two 10-point terminal
block assemblies (TB1 and TB2) for local termination, 28 configuration
jumpers, and a module cover. The MI/O PCB connects to the backplane
using a 36-pin gold-plated card-edge connector.

Note: Unless otherwise noted, I/O circuitry is identical to circuitry

used on corresponding I/O modules in earlier sections of this
chapter.
The high speed counters support surge suppression, bandwidth limiting,
and 20 µs (50 kHz) filtering. You can individually field configure the
HSC inputs to enable/disable contact debounce circuitry and for 2 mA
or 200µA (low power) operation. The maximum frequency of an HSC
input signal is 15 kHz.
Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.

Optional AO Optionally, certain configurations of MI/O modules can also support

one externally powered (VEXT = 11–30 Vdc) analog output.
AO circuitry consists of a 12-bit resolution Digital-to-Analog Converter
(DAC).
Configurations The non-isolated Mixed I/O (MI/O) module (general part number
396630-XX-X) has the following configurations:
Table 3-7. Mixed I/O Module Configurations

Part Number I/O Included Termination Notes

Connector
396897-01-0 4AI, 2HSC, 6DI/DO local includes LED daughterboard
396897-02-9 4AI, 2HSC, 6DI/DO local includes LED daughterboard
& 1AO (on daughterboard)

Setting Jumpers MI/O modules have 28 jumpers you can use to configure each input or
output. See Table 3-8. See Figure 3-7 for jumper locations.

3-12 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Table 3-8. Jumper Assignments: Non-isolated MI/O Module

Jumper Purpose Description
1
W1 Configures optional AO for Pins 1-2 installed = Sets AO for current output
voltage or current output Pins 2-3 installed = Sets AO for voltage output
W2 Configures optional AO for Pins 1-2 installed = Sets AO for voltage output
voltage or current output Pins 2-3 installed = Sets AO for current output
W3 Enables DI/DO status LEDs Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
W4 Enables HSC status LEDs Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
W5 & W6 Controls HSC1 Current Pins 1-2 installed = Permits additional 2 mA load
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
W7 & W8 Controls HSC2 Current Pins 1-2 installed = Permits additional 2 mA load
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
W9 & W10 Configures HSC1 and HSC2 Pins 1-2 installed = Enables HSC debounce
debounce (respectively) Pins 2-3 installed = Disabled HSC debounce
W11-W16 Configures DI1 through DI6 Pins 1-2 installed = Sets 2 mA source current
current (respectively) Pins 2-3 installed = Sets 60 uA source current
W17-W22 Select DI/O1 through DI/O6 Pins 1-2 installed = Sets digital input operation
points (respectively) Pins 2-3 installed = Sets digital output operation
W23-W26 Configures AI1 through AI4 Pins 1-2 installed = 4–20 mA AI (250Ω resistor in)
(respectively) Pins 2-3 installed = 1–5 Vdc AI
W272 Selects AO Voltage Pins 1-2 installed = N/A
Pins 2-3 installed = External Field Voltage (TB2-9)
W28 Enables HSC Circuitry Pins 1-2 installed = Enable (power) HSC circuit
Pins 2-3 installed = Disable HSC circuit
1 W1 jumper located on optional AO daughterboard.
2 Set W27 always to pins 2-3.
Wiring the Module Figure 3-6 shows field wiring assignments for a locally terminated
MI/O module. See Figure 3-7 for jumper locations and terminal
blocks.

Revised Dec-2013 I/O Modules 3-13

ControlWave EFM Instruction Manual

Figure 3-6. Mixed I/O Module Wiring Diagram

3-14 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 3-7. Non Isolated Mixed I/O Module Configuration Diagram

Software Configuration To use data from a mixed I/O module you must add a CWM_MIX
board in ControlWave Designer’s I/O Configurator, and then configure
it. See the ControlWave Designer Programmer's Handbook (D5125)
for more information. That same manual includes an I/O Mapping
section that describes, for advanced users, the I/O map for this module.

Revised Dec-2013 I/O Modules 3-15

ControlWave EFM Instruction Manual

3.7 Resistance Temperature Device (RTD) Inputs on SCM

System controller module connector TB2 provides connection to a 3-
wire 100 ohm platinum bulb RTD (using the DIN 43760 curve).
Wire the RTD according to Table 3-9, Figure 3-8 and Figure 3-9. In
this configuration, the return lead connects to the RTD- terminal and the
two junction leads (Sense and Excitation) connect to the RTD+ and
RTD EXC terminals.
Never ground the RTD cable shield at both ends or allow it to come in
Caution contact with metallic/conductive conduit because multiple ground paths
can cause RTD input errors.

Table 3-9. RTD Connections to System Controller Module Connector

TB2
TB2 Pin Signal Function
1 RTD EXC Excitation
2 RTD+ Sense
3 RTD- Return

Figure 3-8. 3-Wire RTD Temperature Input Wiring

3-16 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Installing the RTD To install the RTD probe, screw the fitting body into the thermowell
Probe with a 7/8” open-end wrench. While you apply pressure against the
sheath to force the tip of the RTD probe into the bottom of the
thermowell (so that the probe tip is in contact with the bottom of the
thermowell), tighten the 9/16” nut using an open-end wrench against
the 7/8” fitting body.

Figure 3-9. RTD Probe Installation/Removal Diagram

Software Configuration To use data from the RTD your ControlWave project must include a
CWM_ECPU which you set up using ControlWave Designer’s I/O
Configurator. See the ControlWave Designer Programmer's Handbook
(D5125) for more information. That same manual includes an I/O
Mapping section that describes, for advanced users, the I/O map for
this module.

Revised Dec-2013 I/O Modules 3-17

ControlWave EFM Instruction Manual

3.8 Digital to Relay I/O Board Option

Digital to relay I/O boards accept up to two discrete input signals from
an open drain MOSFET device and convert them to Form C relay
output signals using solid state relay (SSR) logic. The minimum current
load will be 100mA. Figure 3-10 provides a component view of the
Digital to Relay I/O Board.
Each ControlWave EFM discrete output is converted to a Form C relay
output signal which can be configured for opposite or identical state
conditions, i.e., both Normally Open (NO) or Normally Closed (NC) or
one Normally open with the other Normally Closed.

Figure 3-10. Digital to Relay I/O Board

Digital to Relay I/O The Digital to Relay I/O Board contains ten (10) Jumpers which allow
Board Jumper Settings you to configure contacts for Normally Open/Normally Closed states.
You can configure contacts associated with each of the Form C Relays
for identical or opposite states.

Note: Jumper Pairs W3/W5, W4/W6, W7/W9 and W8/W10 must be set
in opposite states.

3-18 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

You can optionally tie the commons associated with each form C relay
(R0COM and R1COM) to the ControlWave EFM power ground or to a
floating ground. Jumper W1 is associated with Outputs R0A and R0B
and W2 is associated with outputs R1A and R1B. When you install
jumper W1, it ties the common (C) associated with outputs R0A and
R0B to ControlWave EFM power ground; when jumper W1 is not
installed, the common is floating. When you install jumper W2 it ties
the common (C) associated with outputs R1A and R1B to ControlWave
EFM power ground; when jumper W2 is not installed, the common will
be floating.
Table 3-10 provides the relationship between Jumper settings and Form
C Relay Outputs.

Table 3-10 Jumper Settings versus Form C Relay Output States

Jumpers R0A Jumpers R0B Jumpers R1A Jumpers R1B

W3/W5 State W4/W6 State W7/W9 State W7/W9 State
IN/OUT NO IN/OUT NO IN/OUT NO IN/OUT NO
OUT/IN NC OUT/IN NC OUT/IN NC OUT/IN NC
NO = Normally Open; NC = Normally Closed

Table 3-11 - Digital to Relay I/O Board Connections to J1/P1

J1 Pin Signal Function Wiring Connections

1 R1B Relay 1 Output B To field
2 R1A Relay 1 Output A To field
3 R1COM Relay 1 Common To field (see W2)
4 Chassis GND Chassis Ground Chassis ground lug
5 R0COM Relay 0 Common To field (jumper W1)
6 R0B Relay 0 Output B To field
7 R0A Relay 0 Output A To field
8
9 Power GND Power ground Power distribution board TB4 pin 2 (black
wire)
10 Power – DC Power – 6/12 V dc Power distribution board TB4 pin 1 (red
wire)
11 DOut0 Discrete Output 0 DI/O module TB 2-5 through TB 2-8 or
mixed I/O module TB1-1 through TB1-6
(yellow wire)
12 DOut1 Discrete Output 1 DI/O module TB 2-6 through TB 2-8 or
mixed I/O module TB1-2 through TB1-6
(orange wire)

Revised Dec-2013 I/O Modules 3-19

ControlWave EFM Instruction Manual

The DI/DO module (Section 3.3) and the mixed I/O module (Section
3.6) provide independent firmware controlled open drain outputs, which
can be used for control or signaling functions (DI/DO Modules provide
up to four DO while the mixed I/O module provides up to 6 DO). Each
output is wired to the source terminal of an N Channel MOSFET
capable of switching up to 16 Volts at up to 100mA. When closed, the
FET shorts the output to ground with resistance of .5 Ohms or less.
These outputs are protected by 16V Transorbs.
Since these outputs are not isolated, exercise care to ensure that the
Caution load current does not affect operation of the ControlWave EFM or related
devices
You can wire two of these outputs to field circuitry via the Digital to
Relay I/O Board option (see Figure 3-11). Table 3-11 provides the
wiring connections for the DI/O module or the mixed I/O module and
the Digital to Relay I/O Board.

Figure 3-11. Digital to Relay I/O Board Wiring Diagram

3.9 Connections to a Bristol Model 3808 Transmitter

You can connect a Bristol 3808 transmitter (digital) to the ControlWave
EFM through either an RS-232 or RS-485 port. Communication
schemes and cable lengths determine the type of communication port
you need to use. In general RS-232 communications require that you
place the 3808 transmitter within 25 feet of the ControlWave EFM
(local communications). You can use RS-485 communications to reach
transmitters up to 4000 feet away (remote communications).
Figure 3-12 details RS-232 wiring connections required between the
ControlWave EFM and the 3808 transmitter.

3-20 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 3-12. 3808 Transmitter to ControlWave EFM RS-232 Comm. Cable Diagram
Figure 3-13 details RS-485 wiring connections required between the
ControlWave EFM and the 3808 transmitter.

Note: For loopback and termination control use switch SW3 on the
CPU module to configure COM3. Use switch SW1 on the
ECOM module to configure COM5 or COM9.

Figure 3-13. 3808 Transmitter to ControlWave EFM RS-485 Comm. Cable

Revised Dec-2013 I/O Modules 3-21

ControlWave EFM Instruction Manual

You can connect up to eight (8) Bristol 3808 transmitters to a

ControlWave EFM using a half-duplex RS-485 network. See Figure 3-
14 for an illustration of this type of network.

Figure 3-14. ControlWave EFM to 3808s - RS-485 Network Diagram

3-22 I/O Modules Revised Dec-2013

 ControlWave EFM Instruction Manual

Chapter 4 – Operation
This chapter provides general operational details for using the
ControlWave EFM.
In This Chapter

4.1 Powering Up/Powering Down the ControlWave EFM .....................4-1

4.2 Communicating with the ControlWave EFM ....................................4-2
4.2.1 Default Comm Port ...............................................................4-2
4.2.2 Changing Port Settings ........................................................4-3
4.2.3 Collecting Data from the ControlWave EFM ........................4-4
4.3 Creating and Downloading an Application (ControlWave Project) ..4-4
4.4 Creating and Maintaining Backups ..................................................4-5
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ............4-5
4.4.2 Saving Flash Configuration Parameters (*.FCP) .................4-7
4.4.3 Backing up Data ...................................................................4-8

WARNING EXPLOSION HAZARD

Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.

4.1 Powering Up/Powering Down the ControlWave EFM

The ControlWave EFM receives power from either an external bulk
power or a rechargeable lead acid battery and solar panel combination.
Power connects to connector TB1 on the SCM. Chapter 2 includes
instructions for wiring power supply to the ControlWave EFM.
To apply power to the ControlWave EFM, plug the power supply into
connector TB1 on the SCM.
To remove power from the ControlWave EFM, unplug the power
supply from connector TB1 on the SCM.

Mode Switch The mode switch (SW1) is a two-position piano type DIP switch that
allows you to configure the mode for firmware upgrades, core
updumps, or normal running operations (see Figure 4-1).
 Set both DIP switches to either the Open position (to the right) or
the Closed position (to the left) to place the ControlWave EFM in

Revised Dec-2013 Operation 4-1

ControlWave EFM Instruction Manual

Recovery mode. Use Recovery mode for a firmware upgrade or a

core updump (see Chapter 5).
 Set SW1-1 (the upper DIP switch) to the Open (right) position and
SW1-2 (the lower DIP switch) to the Closed (left) position to place
the ControlWave EFM in Local mode, which is used for normal
running operations.

Figure 4-1. Mode Switch

4.2 Communicating with the ControlWave EFM

You communicate to the ControlWave EFM by connecting a cable
between a port on your PC workstation and one of the ControlWave
EFM ports.
The port at the PC workstation must match the configuration of the
ControlWave EFM port.

4.2.1 Default Comm Port As delivered from the factory, ControlWave EFM
communication ports have default settings. Table 4-1 details these
defaults.

Table 4-1. Default Comm Port Settings (by PCB)

Port PCB Default Configuration

COM1 CPU Ships from factory at RS-232; 115.2 Kbps using BSAP. Once
the default switch is OFF, a factory default of IP Point-to-Point
protocol (PPP) at 115,200 applies.
COM2 CPU RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM3 CPU RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM4 ECOM Type 1 or Type RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
2 ControlWave Designer protocol
COM5 ECOM Type 1 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 2 RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM6 ECOM Type 1 Not applicable
ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM7 ECOM Type 1 Not applicable
ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol

4-2 Operation Revised Dec-2013

 ControlWave EFM Instruction Manual

Port PCB Default Configuration

COM8 ECOM Type 1 or Type RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
2 ControlWave Designer protocol
COM9 ECOM Type 1 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 2 RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM10 ECOM Type 1 Radio port
ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM11 ECOM Type 1 Modem port
ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol

Notes:
 You can re-enable the factory default comm. settings at any time by
setting switch SW2-3 on the CPU module to “OFF.”
 If you set both SW2-3 and SW2-8 to “OFF” all serial ports
(including COM1) become 9600 baud/BSAP. This is used for
diagnostics mode.
 For information on communication cables see Chapter2.

Ethernet Using an optional Ethernet port (located on the CPU module), you can
connect either directly or through a network to a PC equipped with an
Ethernet port.
The Ethernet port is only available for the 150 MHz CPU. If the
Ethernet port is present, the factory pre-configures its initial IP address
and mask, as follows:
ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.0
Because each unit that ships from the factory has this address initially
pre-programmed, you should only use this address for “bench” testing
and configuration. You must change this address before putting the
ControlWave unit on an actual network, since an address conflict
would exist as soon as you place the second ControlWave unit online.

4.2.2 Changing Port Settings

You change port settings (baud rate, port type, IP address, and so on)
using the Flash Configuration utility.
You must establish communications with the ControlWave EFM using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.

Revised Dec-2013 Operation 4-3

ControlWave EFM Instruction Manual

Note: For detailed information on using the Flash Configuration utility,

see Chapter 5 of the OpenBSI Utilities Manual (D5081).

Caution When you change the baud rate for a port, the baud rate changes as
soon as you write the flash file changes to the RTU, and do not require
a reset. For this reason, you should not change baud rate for the active
port on which you are communicating, or communications will
immediately stop due to the baud rate mismatch between the PC port
and the controller port. If this happens accidentally, you can use CPU
switch settings as discussed in the notes in Section 4.2.1 to restore
defaults and re-establish communications.

4.2.3 Collecting Data from the ControlWave EFM

OpenBSI utilities such as DataView, Data Array Save/Restore and
Harvester allow you to collect real time data (values of variables, array
values, alarm messages) and historical data (audit records, archive files)
from the ControlWave. See the OpenBSI Utilities Manual (D5081) for
details. SCADA software such as OpenEnterprise can then present this
data to an operator in the form of graphical displays and reports.

4.3 Creating and Downloading an Application (ControlWave Project)

Your ControlWave executes an application called a ControlWave
project. Certain standard projects are available for purchase, or you can
purchase PC-based ControlWave Designer software and create your
own project. Instructions for creating a ControlWave project are beyond
the scope of this manual. Please refer to the following sources for
information:
 Getting Started with ControlWave Designer (D5085)
 ControlWave Designer Programmer’s Handbook (D5125)
 ControlWave Designer online help
You must connect the EFM to a PC running ControlWave Designer
software and OpenBSI software.

Note: You can download an application either from ControlWave

Designer or from the OpenBSI 1131 Downloader.
o Set the SCM’s Mode switch to local mode (that is, SW1-1 to
Open [right] and SW1-2 to Closed [left]).

Note: COM1 has a factory default of 115.2 Kps (RS-232) using the
Internet Point-to-Point Protocol (PPP). Do not connect COM1 to
a PC unless you configure that PC’s RS-232 port for PPP.
1. Define the EFM project, setting communication and
configuration parameters.

4-4 Operation Revised Dec-2013

 ControlWave EFM Instruction Manual

2. Download the project according to instructions in the

Downloading section of the ControlWave Designer
Programmer's Manual (D5125).
3. After the download completes successfully, leave Mode switch
(SW1) in local mode.

4.4 Creating and Maintaining Backups

You should always maintain a current backup of each ControlWave
project and keep it in a safe place, preferably in a location physically
separate from the controller.
The reason we recommend you keep a backup files is that if a disaster
occurs that damages or destroys your ControlWave hardware (flood,
lightning strike, etc.) you don’t want to also lose its control strategy
software programs. Otherwise, when the unit is repaired or replaced,
you’d have to create a new ControlWave project from scratch, which
might take a lot longer than replacing a few damaged modules.

Caution Always maintain a backup copy of your ControlWave project in a safe

place.

Anytime you modify your ControlWave project, be sure to create a new

backup of the new project.

Notes:
 You may find it useful to maintain more than one backup copy in
case the backup media itself fails, for example, a CD-ROM becomes
unreadable because it melted in the sun or a thumb drive fails
because someone spilled coffee on it.
 If you don’t keep more than one backup copy, it’s a good idea to
periodically test your backup copy to verify that the media has not
failed.

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

Note: The .zwt file is a complete backup of your entire project
including code, comments and graphics. It may be stored on your
PC or removable storage media. It may also be downloaded and
archived to ControlWave Flash memory where it may be
uploaded at a later time for editing.
With your current ControlWave project open in ControlWave Designer,
perform the following steps:
1. Click File > Save Project As / Zip Project As.

Revised Dec-2013 Operation 4-5

ControlWave EFM Instruction Manual

Figure 4-2. Saving a Backup of Your Project

2. In the “Save/Zip project as” dialog box, specify a project name in

the File name field. In Figure 4-2 we chose the name mynewproj.
3. In the Save as type field, choose Zipped Project Files (*.zwt).
4. In the Zip Options area, select which additional files you want to
include in the zwt file. Other than increasing the file size of the zwt,
it doesn’t hurt to check any or all of these options.
Zip Option Description
Zip User-Libraries If you created your own user-defined
functions or function blocks, you must
select this to preserve them.
Zip Frontend-Code If you selected Zip User-Libraries you
should also select this option to include
compiled code for libraries in your zip file.
Otherwise, you need to re-compile your
user libraries with the project when you
unzip the zwt.
Zip FW-Libraries This includes firmware libraries, such as
ACCOL3.FWL in your zwt.
Zip Pagelayouts This includes pagelayout information for
printing your project, as well as graphical
elements used in certain 1131 languages.

5. Click Zip and a progress bar displays the percent complete of the
zipping process.
6. When the zip process completes, you’ll see a message box reporting
successful completion. Click OK.

4-6 Operation Revised Dec-2013

 ControlWave EFM Instruction Manual

7. Copy the resulting zwt file to backup media (CD-ROM, thumb

drive, etc.) If you ever need to restore the project, just open the zwt
file in ControlWave Designer, load libraries as needed, then compile
the project and download it into the ControlWave.

4.4.2 Saving Flash Configuration Parameters (*.FCP)

You must establish communications with the ControlWave using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.

Note: For detailed information on using the Flash Configuration utility,

see Chapter 5 of the OpenBSI Utilities Manual (D5081).
1. Start the Flash Configuration utility. To do this in NetView or
LocalView, right-click on the icon for this ControlWave and
choose RTU > RTU Configuration Parameters.

To do this in TechView, click Operations > Access Flash

Parameters or click the Access Flash icon .

2. Depending upon how your system is configured, the Flash

Configuration – Loading Options dialog box may open. If it
does, choose Load from device and wait for the utility to
retrieve all parameters from the ControlWave, then skip to step
4, otherwise, just proceed to step 3.

3. Click and wait for the utility to retrieve all

parameters from the ControlWave.

4. Click and specify a name for your FCP file,

then click Save. When the status line indicates successful
completion, your FCP file in done.

Revised Dec-2013 Operation 4-7

ControlWave EFM Instruction Manual

5. Copy the resulting FCP file to backup media (CD-ROM, thumb

drive, etc.) If you ever need to restore the FCP parameters to the
controller, establish communications with the unit, start the
Flash Configuration utility, and load the FCP file using the Read
from FCP button, then choose the Write to RTU button.

4.4.3 Backing up Data

You can back up certain types of data and restore it if needed. There are
other types of data that you can only collect, but you cannot restore.
 If you have certain variables that represent tuning parameters
(setpoints, for example) you can use tools such as the OpenBSI
DataView recipe feature to save those values to a recipe file on the
PC, and then restore them at a later time. See Chapter 8 of the
OpenBSI Utilities Manual (D5081).
 You can store the contents of read/write data arrays using the
OpenBSI Data Array Save/Restore utility. See Chapter 13 of the
OpenBSI Utilities Manual (D5081).
 You can collect alarms, and historical data (audit records, archive
files) but you cannot restore alarms or historical data.

4-8 Operation Revised Dec-2013

 ControlWave EFM Instruction Manual

Chapter 5 – Service and Troubleshooting

This chapter provides general diagnostic and test information for the
ControlWave EFM.
In This Chapter

5.1 Upgrading Firmware ........................................................................5-2

5.2 Removing or Replacing Components ..............................................5-5
5.2.1 Accessing Modules for Testing ............................................5-6
5.2.2 Removing/Replacing the Bezel ............................................5-6
5.2.3 Removing/Replacing the CPU Module.................................5-6
5.2.4 Removing/Replacing the SCM .............................................5-7
5.2.5 Removing/Replacing an I/O Module ....................................5-7
5.2.6 Removal/Replacement of an ECOM Module .......................5-8
5.2.7 Removal/Replacement of the Lead-acid Battery .................5-8
5.2.8 Removal/Replacement of a Power Distribution Board .........5-9
5.2.9 Removal/Replacement of a 21V Power Supply Board ........5-9
5.2.10 Removal/Replacement of a Digital to Relay I/O Board ......5-10
5.2.11 Removal/Replacement of Case-Mounted Radio/Modem ..5-10
5.2.12 Removing/Replacing the Backup Battery ..........................5-10
5.2.13 Enabling / Disabling the Backup Battery ............................5-12
5.3 General Troubleshooting Procedures ...........................................5-12
5.3.1 Checking LEDs...................................................................5-12
5.3.2 Checking Wiring/Signals ....................................................5-18
5.3.3 Calibration Checks .............................................................5-18
5.3.4 Common Communication Configuration Problems ............5-18
5.4 WINDIAG Diagnostic Utility ...........................................................5-19
5.4.1 Available Diagnostics .........................................................5-22
5.5 Core Updump ................................................................................5-26

Equipment You need the following equipment to perform the procedures described
in this chapter:
To run diagnostics software:
 PC with WINDIAG software, and either OpenBSI LocalView,
NetView, or TechView for communications.
 Null modem interface cable
 Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 5-12)
 Loop-back plug, 9-pin female D-Sub (for RS-485) (see Figure 5-13)
 Loop-back plug, 8-pin RJ-45 male (for twisted pair Ethernet) (see
Figure 5-15)
To perform firmware upgrades:
 Null modem interface cable
 PC with the following software:
o OpenBSI LocalView
o OpenBSI System Firmware Downloader and either NetView,
LocalView, or TechView for communications.
o HyperTerminal (included in Windows®)
To replace the SRAM backup battery:

Revised Dec-2013 Service & Troubleshooting 5-1

ControlWave EFM Instruction Manual

 Depending on the type of battery holder, either a small flat head

screwdriver, or tweezers/needle nose pliers.

Note: When you service a ControlWave EFM on site, we recommend

that you close down (or place under manual control) any
associated processes. This precaution prevents any processes
from accidentally running out of control when you conduct tests.

Caution Harmful electrical potentials may still exist at the field wiring terminals
even though the ControlWave EFM’s power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or
perform any wiring operations until you verify that all associated power
supply sources are turned off and/or disconnected.
Always turn off any external supply sources for externally powered I.O
circuits before you change any modules.

WARNING EXPLOSION HAZARD

Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.

See Appendix A for details on Class I Division 2 usage of this device.

5.1 Upgrading Firmware

The ControlWave EFM CPU ships from the factory with system
firmware already installed. If you need to upgrade the system firmware
(stored in Flash memory) to acquire new functionality or restore
firmware, you can use one of several methods.
System Use this tool to download system firmware to an unattended remote
Firmware ControlWave EFM. To use this utility, you must set CPU module
Downloader switch SW2-6 ON (the factory default position).

Note: For further information and detailed use instructions, refer to

Appendix J of the OpenBSI Utilities Manual (D5081).

LocalView One of the standard OpenBSI utilities, LocalView requires OpenBSI

version 5.1 (or newer). If you have an older version of OpenBSI, use
HyperTerminal.

5-2 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Note: For further information and detailed use instructions, refer to the
Flash Mode section of Chapter 5 of the OpenBSI Utilities
Manual (D5081).

HyperTerminal HyperTerminal is a communications utility program included with

Microsoft® Windows® XP.
Notes:
 If you are using a version of OpenBSI older than 5.1, or do not have
OpenBSI software, you can only perform a firmware upgrade using
HyperTerminal.
 While HyperTerminal is included in Microsoft® Window® XP,
some newer versions of Windows® do not include it.
 HyperTerminal requires *.BIN files; newer ControlWave firmware
upgrade files use *.CAB files. In cases such as those, you should use
the Remote System Firmware Downloader.
1. Connect a null modem cable between COM1 of the
ControlWave EFM and any RS-232 port on the associated PC.
2. Click Start > Programs > Accessories > Communications >
HyperTerminal
3. If using HyperTerminal for the first time, set the communication
properties (for the PC port) via the Properties Menu as follows:
Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop
bits: = 1, and Flow control: = None and then click OK.
4. Either set the SCM’s mode switch (SW1) for Recovery Mode,
that is, set both switches in the OPEN or CLOSED position or
set CPU Switch SW1-3 ON (ON = Force Recovery).
5. Apply power; to the ControlWave EFM. The resident BIOS
initializes and tests the hardware, this process is referred to as
POST (Power On Self Test). Unless there is a problem, SCM
status LEDS show status code 10 (LED #5 ON). If you see a
different status code, see Section 5.3.1
6. From the HyperTerminal Mode menu (Figure 5-1), press the F
key to enter FLASH download. A message warns that the
FLASH is about to be erased; press the Y key at the prompt. The
screen displays dots as the system erases the flash memory; this
could take a few minutes.

Revised Dec-2013 Service & Troubleshooting 5-3

ControlWave EFM Instruction Manual

Figure 5-1. HyperTerminal Mode Menu

7. When the FLASH is ready for download, HyperTerminal

repeatedly displays the letter C on the screen. In the
HyperTerminal menu bar click Transfer > Send File (see
Figure 5-2).

Figure 5-2. HyperTerminal (Ready to Download)

8. In the Send File dialog box (see Figure 5-3), select 1KXmodem
for the protocol, enter the filename of the appropriate .bin file in
the format “CWExxxxx.bin” (where xxxxx varies from release to
release) and click Send to start the flash upgrade (see Figure 5-
4). When you see the HyperTerminal Mode Menu again, it
means the download has completed.

5-4 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 5-3. Send File dialog box

9. Exit HyperTerminal and power down the ControlWave EFM. If
desired, you can disconnect the null modem cable between the
ControlWave EFM and the PC.
10. Set the SCM’s mode switch (SW1) for Local Mode, i.e., SW1-1 in
the OPEN (Right) position and SW1-2 in the CLOSED (Left)
position or if CPU Module Switch SW1-3 was set for Recovery
Mode, set it to the OFF position (OFF = Recovery Mode
Disabled).
11. Restore power to the ControlWave EFM.

Figure 5-4. HyperTerminal (Download in Process)

5.2 Removing or Replacing Components

This section provides information on accessing EFM modules for
testing, as well as removal/replacement procedures.

Revised Dec-2013 Service & Troubleshooting 5-5

ControlWave EFM Instruction Manual

Field repairs to ControlWave EFMs are strictly limited to the

Caution replacement of complete modules. Replacing module components
constitutes tampering and violates the product warranty. Return
defective modules or housings to the factory for authorized service.

5.2.1 Accessing Modules for Testing

Only technically qualified personnel should test and/or replace EFM
modules. Read completely the disassembly and test procedures
described in this manual before starting. Any damage to the
ControlWave EFM resulting from improper handling or incorrect
service procedures is not covered under the product warranty
agreement. If you cannot properly perform these procedures, obtain
authorization and then return the device to the factory for evaluation and
repairs.

5.2.2 Removing/Replacing the Bezel

1. Grasp the sides of the bezel assembly and gently lift it up and then
off its associated I/O module covers.
2. To replace the bezel, align the latches (left and right, top and
bottom) with the associated notches in the I/O module cover. Press
the bezel in so that the notches capture its latches and slide it
downward until it securely seats.

5.2.3 Removing/Replacing the CPU Module

Use this procedure to remove or replace the CPU module.
1. If the EFM is running, place any critical control processes under
manual control.
2. Shut down the EFM by disconnecting power from the system
controller module (SCM).
3. Disconnect any CPU module communication cables. Label or
otherwise identify them so you can easily return them to their
assigned communication ports. .
4. Press down on the cover’s built-in top latch (with one hand) and
up on the cover’s built-in bottom latch (with the other hand).
5. Carefully slide the CPU module out of the front of the housing.
If any binding occurs, gently rock the module up and down to
free it.
6. To replace a CPU module, power must be off. Carefully align
the CPU module with the guides for slot 2 in the EFM and insert
the module into the housing. When the module correctly seats,
its cover should latch to the housing.

5-6 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

7. Replace any communication cables, apply power, and test the

module.

5.2.4 Removing/Replacing the SCM

Use this procedure to remove or replace the System Controller Module
(SCM).
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Unplug the SCM’s modular connectors.
3. Press down on the cover’s built-in top latch (with one hand) and
up on the cover’s built-in bottom latch (with the other hand).
4. Carefully slide the SCM out of the front of the housing. If binding
occurs, gently rock the module up and down to free it.
5. To replace an SCM, power must be off. Carefully align the SCM
with the guides for slot 1 in the EFM and insert the module into
the housing. When the module correctly seats, its cover should
latch to the housing.
6. Replace power and watchdog cables and then apply power and test
the unit.

5.2.5 Removing/Replacing an I/O Module

Use this procedure to remove or replace an I/O module.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Remove the applicable bezel (see Section 5.2.2).
3. Unplug local termination cable headers from I/O module
connectors TB1 and TB2 and set the cables aside. Label or
otherwise identify these cables so you can easily return them to
their assigned connectors.
4. Press down on the cover’s built-in top latch (with one hand) and
up on the cover’s built-in bottom latch (with the other hand).
5. Carefully slide the I/O module out of the front of the housing. If
binding occurs, gently rock the I/O module up and down to free
it.
6. To replace an I/O module, power must be off. Carefully align the
I/O module with the applicable I/O slot and insert the unit into
the housing. When the module correctly seats, its cover should
latch to the housing.
7. Connect local termination cables to I/O module connectors.

Revised Dec-2013 Service & Troubleshooting 5-7

ControlWave EFM Instruction Manual

8. Apply power and test the unit.

5.2.6 Removal/Replacement of an Expansion Communication Module

Use this procedure to remove or replace an expansion communication
(ECOM) module.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Disconnect any ECOM module communication cables. Label or
otherwise identify them so you can easily return them to their
assigned communication ports. .
3. Press down on the cover’s built-in top latch (with one hand) and
up on the cover’s built-in bottom latch (with the other hand).
4. Carefully slide the ECOM module out of the front of the
housing. If binding occurs, gently rock the ECOM module up
and down to free it.
5. To replace an ECOM module, power must be off. Carefully
align the ECOM module with the appropriate slot (3 or 4) and
insert the unit into the housing. When the module correctly seats,
its cover should latch to the housing.
6. Connect communication cables to ECOM module connectors.
7. Apply power and test the unit.

5.2.7 Removal/Replacement of the Rechargeable Lead-acid Battery

Use this procedure to remove or replace the rechargeable lead acid
battery.

1. If the EFM is running, place any critical control processes under

manual control and shut down the unit by disconnecting power
from the SCM.
2. Disconnect the power cables from the battery terminals (remove
screw and nut on each terminal).
3. Loosen the two 11/32” nuts on the ends of the battery clamp.
Lift the battery clamp and rotate it rearward.
4. Carefully lift up and remove the rechargeable lead-acid battery.

Note: Make sure your replacement lead acid battery is fully charged
before you install it.

5-8 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

5. To replace the battery, align the unit so that the negative battery
terminal is oriented to the top and right as illustrated in Figure 2-
15 and place the battery into the battery mounting bracket
(battery clamp must be in the released position.
6. Raise the battery clamp and rotate it forward until you can lower
it to secure the rechargeable lead-acid battery. Tighten the two
11/32” nuts on the ends of the battery clamp.
7. Replace the power cables to the battery terminals (black/NEG,
Red/POS).
8. Apply power and test the unit.

5.2.8 Removal/Replacement of a Power Distribution Board

Use this procedure to remove or replace the optional power distribution
board.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Unplug wiring harnesses from power distribution board
connectors TB1 through TB6. Label or otherwise identify them
so you can easily re-connect them later.
3. Slide the power distribution board toward the front of the unit
and remove it from its snap track holder.
4. To replace the power distribution board, slide it into its snap
track holder. Replace wiring harness connectors TB1 through
TB6.
5. Apply power and test the unit.

5.2.9 Removal/Replacement of a 21V Power Supply Board

Use this procedure to remove or replace the optional 21V power supply
board.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Unplug wiring harnesses from 21V power supply board
connectors TB1 and TB2.
3. Slide the 21V power supply board toward the front of the unit and
remove it from its snap track holder.
4. To replace the 21V power supply board, slide it into its snap track
holder. Replace wiring harness connectors TB1 and TB2.
5. Apply power and test the unit.

Revised Dec-2013 Service & Troubleshooting 5-9

ControlWave EFM Instruction Manual

5.2.10 Removal/Replacement of a Digital to Relay I/O Board

Use this procedure to remove or replace the optional digital to relay I/O
board.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Unplug wiring harnesses from digital to relay I/O board
connector J1.
3. Slide the digital to relay I/O board toward the front of the unit
and remove it from its snap track holder.
4. To replace the digital to relay I/O board, slide it into its snap
track holder. Replace wiring harness connector J1/P1.
5. Apply power and test the unit.

5.2.11 Removal/Replacement of a Case-Mounted Radio/Modem

Use this procedure to remove or replace a case-mounted radio or
modem.
1. If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2. Remove the removable lead-acid battery (if present) (see Section
5.2.7).
3. Disconnect (unplug) all connectors (power and interface) from
the radio/modem.
4. Remove the mounting screws from the bottom (inside) of the
battery mounting bracket and remove the radio/modem (with
mounting plate if present).
5. Replace the radio/modem in the reverse order from which it was
removed.
6. Apply power and test the unit.

5.2.12 Removing/Replacing the Backup Battery

Note: The CPU module draws power from the battery only if the
module loses power. For a ControlWave EFM containing 2MB
of SRAM, a worst-case current draw of 42 uA allows a battery
life of approximately 5238 hours. This means you should not
need to replace a battery until the ControlWave EFM has been in
service for an extended period (normally many years).

5-10 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

The CPU module accommodates a lithium coin cell backup battery

housed in a coin-cell socket (S1). A supervisory circuit on the CPU
switches to battery power when the regulated 3.3 Vdc falls out of
specification. The battery then provides backup power for the real-time
clock (RTC) and the system SRAM on the CPU module.

Caution You lose SRAM contents when you remove the backup battery.

If you replace a backup battery, wait at least one minute before re-
powering the system. This enables the SRAM to completely discharge.

After you install the new battery, ensure that you have placed jumper
JP8 on pins 1-2 (to enable the battery).

The procedure for replacing the battery varies slightly depending upon
the type of battery holder – snap type or clip type.
Removing / 1. If the EFM is running, place any critical control processes under
Replacing the manual control.
Battery – Snap 2. Remove power from the ControlWave EFM.
Type Holder
3. Remove the CPU module from the housing.
Battery Part
Numbers: 4. To remove the lithium battery, insert the tip of a small flat head
CR2032 screw driver into the gap between the battery and the holder. (The
DL2032 gap is on the side of the holder that doesn’t have the inner clip
against the battery.) Gently push the screwdriver at an angle
underneath the battery and it will pop out of the holder.
Inner clip
5. To install the replacement battery, press one side of the battery
against the inner clip of the holder then press the battery down into
the slot so it snaps in.
6. Replace the CPU module in slot 2 of the housing.
7. Re-connect power to the ControlWave EFM.
Gap between
battery and holder 8. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the EFM acts as though it
had just been booted and reverts back to the initial values specified
in its application.

Revised Dec-2013 Service & Troubleshooting 5-11

ControlWave EFM Instruction Manual

Removing / 1. If the EFM is running, place any critical control processes under
Replacing the manual control.
Battery – Clip 2. Remove power from the ControlWave EFM.
Type Holder
3. Remove the CPU module from the housing.
Battery Part
Numbers: 4. To remove the lithium battery, gently pry up the tab holding the
battery in the coin cell socket and remove the battery with a pair of
BR2330, tweezers or needle-nosed pliers. Install the replacement battery.
BR2335,
BR2335-B 5. Replace the CPU module in slot 2 of the housing.
6. Re-connect power to the ControlWave EFM.
7. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the EFM acts as though it
had just been booted and reverts back to the initial values specified
in its application.

5.2.13 Enabling / Disabling the Backup Battery

For maximum shelf life, the CPU module ships from the factory
with the installed lithium backup battery disabled. You must enable
it when you install the CPU module.
Enabling To enable the battery, install jumper JP8 on pins 1-2.

Disabling For maximum shelf life, you can isolate the battery from the circuit by
placing jumper JP8 on pins 2-3.

5.3 General Troubleshooting Procedures

This section presents some procedures to troubleshoot problems with
the EFM.

5.3.1 Checking LEDs

Most EFM modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions.
Table 5-1 shows LED assignments on EFM modules.

Table 5-1. LED Assignments on Modules

Module LED Name LED Color Function

SCM IDLE Red ON = Idle
SCM WD Red ON = Watchdog condition
OFF = Normal

5-12 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Module LED Name LED Color Function

SCM 6 STATUS Red See Table 5-2 and Figure 5-5
CPU C1 RX (Comm 1) Red ON = RX activity (top left; see Figure 5-6)
CPU C1 TX (Comm 1) Red ON = TX activity (top right; see Figure 5-6)
CPU C2 RX (Comm 2) Red ON = RX activity (middle left; see Figure 5-6)
CPU C2 TX (Comm 2) Red ON = TX activity (middle right; see Figure 5-6)
CPU C3 RX (Comm 3) Red ON = RX activity (bottom left; see Figure 5-6)
CPU C3 TX (Comm 3) Red ON = TX activity (bottom right; see Figure 5-6)
CPU ENET Port 1 Green ON = RX activity (top; see Figure 5-6)
CPU ENET Port 1 Yellow ON = TX activity (bottom; see Figure 5-6)
ECOM1 EC 4/8 RX (Comm 4) Red ON = RX activity (top left; see Figure 5-7)
ECOM1 EC 4/8 TX (Comm 4) Red ON = TX activity (top right; see Figure 5-7)
ECOM1 EC 5/9 RX (Comm 5) Red ON = RX activity (2nd from top left; see Figure
5-7)
ECOM1 EC 5/9 TX (Comm 5) Red ON = RX activity (2nd from top right; see Figure
5-7
ECOM1 Radio RX (Comm6)1 Red ON = RX activity (3rd from top left; see Figure
5-7) (Note: Radio no longer offered- ignore -
always ON)
ECOM1 Radio TX (Comm6)1 Red ON = TX activity (3rd from top right; see Figure
5-7) Note: Radio no longer offered (always
OFF)
ECOM1 Modem RX (Comm7)1 Red ON = RX activity (bottom left;; see Figure 5-7)
1
ECOM1 Modem TX (Comm7) Red ON = TX activity (bottom right; see Figure 5-7)
1
ECOM2 EC4/8 RX (Comm 4/8) Red ON = RX activity (top left; see Figure 5-8)
1
ECOM2 EC4/8 TX (Comm 4/8) Red ON = TX activity (top right; see Figure 5-8)
1
ECOM2 EC5/9 RX (Comm 5/9) Red ON = RX activity (2nd from top left; see Figure
5-8)
ECOM2 EC5/9 TX (Comm 5/9) 1 Red ON = TX activity (2nd from top right; see Figure
5-8
ECOM2 EC6/10 RX (Comm 6/10) 1 Red ON = RX activity (3rd from top left; see Figure
5-8)
ECOM2 EC6/10 TX (Comm 6/10) 1 Red ON = TX activity (3rd from top right; see Figure
5-8)
ECOM2 EC7/11 RX (Comm 7/11) 1 Red ON = RX activity (bottom left;; see Figure 5-8)
1
ECOM2 EC7/11 TX (Comm 7/11) Red ON = TX activity (bottom right; see Figure 5-8)
DI/OM INPUT (12 LEDs,1 per point) Red LED ON = Input is present
LED OFF = Input not present (see Figure 5-9)
DI/OM OUTPUT (4 LEDs,1 per point) Red LED ON = Output is ON (see Figure 5-9)
HSCM INPUT (4 LEDs, 1 per point) Red LED ON = Input activity on input is present
LED OFF = No activity on input (see Figure 5-
9)
1
Radio or modem with Type 1 comm board only

Revised Dec-2013 Service & Troubleshooting 5-13

ControlWave EFM Instruction Manual

SCM System As the EFM runs its application, status codes post to the six LEDs on
Status LED the SCM. Table 5-2 provides activity descriptions of the LEDs; Figure
Codes 5-5 shows what the LEDs look like for each hex code.

Table 5-2. System Status LED Codes on SCM

Status in
Hex LED 6 ED 5 LED 4 LED 3 LED 2 LED 1 Activity Indicator
00 0 0 0 0 0 0 Application Running
01 0 0 0 0 0 1 Unit in Diagnostic Mode
03 0 0 0 0 1 1 Unit Running Diagnostics
04 0 0 0 1 0 0 Flash XSUM Error
05 0 0 0 1 0 1 Error Initializing Application Device
07 0 0 0 1 1 1 Flash Programming Error
08 0 0 1 0 0 0 Using Factory Defaults (flashed at start)
09 0 0 1 0 0 1 Battery Failure Detected (flashed at
startup)
0A 0 0 1 0 1 0 Currently Loading the Boot Project
0B 0 0 1 0 1 1 System Initialization in Progress
10 0 1 0 0 0 0 Waiting in Recovery Mode
11 0 1 0 0 0 1 Error Testing SDRAM
12 0 1 0 0 1 0 Error Testing SRAM
20 1 0 0 0 0 0 Application Loaded
28 1 0 1 0 0 0 Stopped at Break Point
30 1 1 0 0 0 0 No Application Loaded
38 1 1 1 0 0 0 Running with Break Points
3B 1 1 1 0 1 1 Waiting for a Power-down (after NMI)
3E 1 1 1 1 1 0 Waiting for Updump to be Performed
3F 1 1 1 1 1 1 Unit Crashed (Watchdog Disabled)

5-14 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 5-5. SCM Status LED Hexadecimal Codes

CPU Module The CPU module has six comm port activity LEDs on the CPU board.
LEDs Units equipped with an Ethernet port have two additional LEDs
located on the Ethernet RJ-45 connector. Table 5-3 details assignments
for the LEDs on the CPU module.
An ON LED indicates an associated transmit (TX) or receive (RX)
activity.
Table 5-3. CPU Module LEDs

LED Ref LED Function

C1 Transmit (TX) COM1
C1 Receive (RX) COM2
C2 Transmit (TX) COM2
C2 Receive (RX) COM2
C3 Transmit (TX) COM3
C3 Receive (RX) COM3
E1 – Bottom Ethernet Link Transmit (TX)
E1 – Top Ethernet Link Receive (RX)

Revised Dec-2013 Service & Troubleshooting 5-15

ControlWave EFM Instruction Manual

Figure 5-6. CPU Module Comm Connectors and LEDs

5-16 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

SLOT # 3 SLOT # 4
Receive LEDs Transmit LEDs
Comm. Port 4 Status LEDs Comm. Port 8 Status LEDs
Comm. Port 5 Status LEDs Comm. Port 9 Status LEDs
Comm. Port 6 Status LEDs Comm. Port 10 Status LEDs
Comm. Port 7 Status LEDs Comm. Port 11 Status LEDs

Comm. Port 4 Comm. Port 8

RS-232 RS-232

Comm. Port 5 Comm. Port 9

RS-485 RS-485

Comm. Port 6 Comm. Port 10

Radio Radio

(Radio no longer offered) (Radio no longer offered)

Comm. Port 7 Comm. Port 11
Modem Modem

Figure 5-7. Type 1 Expansion Comm Module Comm Connectors and LEDs

SLOT# 3 SLOT# 4
Comm. Port 4 Comm. Port 8
Receive LED Receive LED
Transmit LED Transmit LED

Comm. Port 4 Comm. Port 8

RS-232 RS-232

Comm. Port 5 Comm. Port 9

Receive LED Receive LED
Transmit LED Transmit LED

Comm. Port 5 Comm. Port 9

RS-232 RS-232

Comm. Port 6 Comm. Port 10

Receive LED Receive LED
Transmit LED Transmit LED

Comm. Port 6 Comm. Port 10

RS-485 RS-485

Comm. Port 7 Comm. Port 11

Receive LED Receive LED
Transmit LED Transmit LED

Comm. Port 7 Comm. Port 11

RS-485 RS-485

Figure 5-8. Type 2 Expansion Comm Module Comm Connectors and LEDs

Revised Dec-2013 Service & Troubleshooting 5-17

ControlWave EFM Instruction Manual

Figure 5-9. I/O Module LEDs

5.3.2 Checking Wiring/Signals

Check I/O field wiring at the terminal blocks and at the field device.
Inspect the wiring for continuity, shorts, and opens. Check I/O signals at
their respective terminal blocks (see Figure 3-2 for wiring diagrams).

5.3.3 Calibration Checks

To calibrate the MVT and the RTD, use TechView software. See the
TechView User’s Guide (D5131) for more information.

5.3.4 Common Communication Configuration Problems

If serial communications do not function, it is often due to one of the
following issues:
 Baud rate mismatch – the baud rate at both ends of the
communication line must match. If communications fail during a
download of a new flash configuration profile (FCP) file, you may
have changed the baud rate of the active communication line, since
baud rate changes occur immediately on FCP download. You can
always re-establish factory default baud rates for communication
ports by powering down the unit, and then setting CPU switch SW2-
3 to OFF and restoring power.
 Incorrect BSAP local address – this address must be an integer from
1 to 127 and must be unique on this particular BSAP communication
line. You set the BSAP local address using the flash configuration
utility. If this ControlWave EFM is a BSAP slave node, and the
range of addresses defined for the BSAP master port end of the
communication line does not encompass the local BSAP address
defined for this ControlWave EFM, BSAP communications will not
function.

5-18 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

 Incorrect EBSAP Group number – if you use expanded BSAP the

EBSAP group number must be correct; if you are not using EBSAP,
the group number must be 0.
If IP communications do not function, it is often due to incorrect IP
addresses or masks. Check to see that the IP address you defined for the
ControlWave EFM is compatible with the range of IP addresses defined
for the communication line on which the unit resides. Also check that
the IP address of the default gateway is correct.

5.4 WINDIAG Diagnostic Utility

WINDIAG is a software-based diagnostic tool you use to test the
performance of I/O modules, CPU memory, communication ports, and
other system components. .
WINDIAG is a PC-based program, so the EFM must be attached to and
communicating with a PC running WINDIAG. Set configuration switch
SW2-8 OFF (closed) on the CPU module to enable the diagnostic
routines.
Establish communication between the EFM (with/without an
application loaded) and the PC with a local or network port under the
following conditions:
 Turn CPU module switch SW2-8 OFF to run the WINDIAG
program. Setting this switch off prevents the boot project from
running and places the EFM in diagnostic mode.
 Use a null modem cable to connect RS-232 ports between the EFM
and the PC; use an RS-485 cable (see Section 2.4.4) to connect the
RS-485 ports of the EFM and the PC.
 Reserve the port running a diagnostic test for exclusive use; you
cannot use that port for any other purpose during testing.
 Connect any EFM communication port to the PC provided their port
speeds match. Most PCs have a COM1 port (typically RS-232 and
defaulted to 9600 bps operation).
 Configure the EFM communication port to be tested using
WINDIAG for 9600 baud, 8-bits, no parity, 1 stop bit, and
BSAP/ControlWave Designer protocol operation. Communication
port COM1 is only forced to 9600 bps operation when you have set
switch SW2-3 on the CPU module to OFF.
Table 5-4. COM Port Defaults for Diagnostics

Port Module Default Configuation

COM1 CPU RS-232: 115.2 kbd using IP PPP protocol
To run diagnostics, set RS-232 to 9600 baud by setting CPU
switches SW2-3 and SW2-8 OFF.
COM2 CPU RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.

Revised Dec-2013 Service & Troubleshooting 5-19

ControlWave EFM Instruction Manual

Port Module Default Configuation

COM3 CPU RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM4 ECOM Types 1 or RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
2 ControlWave Designer protocol.
COM5 ECOM Type 1 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 2 RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM6 ECOM Type 1 Not applicable
ECOM Type 2 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM7 ECOM Type 1 Not applicable
ECOM Type 2 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM8 ECOM Types 1 or RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
2 ControlWave Designer protocol.
COM9 ECOM Type 1 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 2 RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM10 ECOM Type 1 Radio port
ECOM Type 2 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM11 ECOM Type 1 Modem port
ECOM Type 2 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
You can connect an optional Ethernet port (situated on the CPU
module) directly or via a network to a PC equipped with an Ethernet
port (see Section 2.9.5).
Before starting the WINDIAG program, place any critical processes the
EFM is handling under manual control. You cannot run WINDIAG
while the EFM is running applications. Set the CPU modules switches
SW2-3 and SW2-8 to OFF, and perform the following steps:
1. Start the NetView program in OpenBSI with your current
network NETDEF file. A menu displays (similar to the one in
Figure 5-10):

5-20 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 5-10. NetView

2. Select Start >Programs > OpenBSI Tools >Common Tools >

Diagnostics. The Main Diagnostics menu (Figure 5-11)
displays.

Figure 5-11. WINDIAG Main Diagnostics Menu

3. Select the module to be tested. Enter any prompted parameters

(slot #, etc.). WINDIAG performs the diagnostics and displays
pass/fail results.
4. After performing all diagnostic testing, exit WINDIAG and then
exit the NetView if you don’t have any other EFM units to test.
When you close NetView, the system asks whether you want to
close OpenBSI. Select Yes.

Revised Dec-2013 Service & Troubleshooting 5-21

ControlWave EFM Instruction Manual

5. Set switch SW2-8 on the CPU module to ON (open). The EFM

should resume normal operation.

5.4.1 Available Diagnostics

Using WINDIAG, you can test all EFM modules with the exception of
the SCM. WINDIAG’s Main Diagnostics Menu (see Figure 5-11)
provides the following diagnostic selections:
Option Tests
CPU & Peripherals Checks the CPU module (except for RAM &
PROM).
Analog Output Checks AOs on AI/O, AO, or Mixed I/O modules.
High Speed Counter Checks HSCs on HSC or Mixed I/O modules.
Prom/Ram Checks the CPU’s RAM and PROM hardware.
Analog Input Checks AIs on AI/O, AI, or Mixed I/O modules.
Communications Checks Communication ports 1 through 9 (but
not COM6 or COM7). The External loop-back
tests require the use of a loop-back plug.
Discrete I/O Checks DIs on DI, DI/O, or Mixed I/O modules
and/or checks DOs on DO, DI/O, or Mixed I/O
modules.
Ethernet Checks Ethernet Port 1. The Loop-back Out
Twisted Pair tests require the use of a loop-back
plug.

Port Loop-back WINDIAG allows you to select the communication port (1 through 4)
Test to test. Depending on the type of network (RS-232 or RS-485) and the
port in question, a special loop-back plug is required:
 RS-232 ports use a 9-pin female D-type loop-back plug (shown in
Figure 5-12).

Figure 5-12. RS-232 Loop-back Plug

 RS-485 ports use a 9-pin female D-type loop-back plug (shown in

Figure 5-13).

5-22 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 5-13. RS-485 Loop-back Plug

These tests verify the correct operation of the serial ports.

Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure Use this procedure to test the comm ports.
1. Connect an external loop-back plug to the port on the CPU,
ECOM1, or ECOM2 module to be tested. Valid ports are:
 J3 of CPU module for COM1
 J4 of CPU module for COM2
 J5 of CPU module for COM3
 J4 of ECOM1 module for COM4/8
 J5 of ECOM1 module for COM5/9
 J4 of ECOM2 module for COM4/8
 J5 of ECOM2 module for COM5/9
 J6 of ECOM2 module for COM6/10
 J7 of ECOM2 module for COM7/11

2. Select Communications on the WINDIAG Main Diagnostics

Menu. The Communications Diagnostic screen opens:

Revised Dec-2013 Service & Troubleshooting 5-23

ControlWave EFM Instruction Manual

Figure 5-14. Communications Diagnostic Menu

3. Enter 5 in the Number of Passes field.

4. Select a port to test (click  to display all available ports).

Note: The port you select must correlate to the port on which you
placed the loop-back plug in step 1.
5. Select 115200 or ALL ASYNC as the baud rate (click  to
display all available rates).
6. Click RUN to start the test. At the completion of the test (which
generally takes about 5 seconds), any failed results appear in the
Status field to the right of the RUN button:
 TXD RXD Failure
 CTS RTS Failure
7. Click Return to Menu to display the WINDIAG Main Menu.
Ethernet Port The Ethernet option on the WINDIAG Main Menu allows you to
Loop-back Test select the Ethernet communication port (1) to test.
This test configures the Ethernet port’s ability to transmit and receive
via the twisted pair. The text transmits frames and compares them
against received frames. You need a special loop-back plug (shown in
Figure 5-15) to perform the Ethernet loop-back test:

5-24 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

Figure 5-15. RJ-45 Ethernet Loop-back Plug

Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure Use this procedure to test the Ethernet port.
1. Connect an external Ethernet loop-back plug (see Figure 5-15)
to the Ethernet port on the CPU module to be tested.
2. Select Ethernet on the WINDIAG Main Diagnostics Menu.
The Ethernet Diagnostic screen opens:

Figure 5-16. Ethernet Diagnostic Menu

3. Enter 1 in the Number of Passes field.

Revised Dec-2013 Service & Troubleshooting 5-25

ControlWave EFM Instruction Manual

4. Enter 1 in the Ethernet Port to Test field.

5. Click RUN next to the Loop-back out twisted pair field to start
the test. At the completion of the test, any failed results appear in
the Status field next to the Loop-back out twisted pair label:
 No Hardware Present
 Loop-back Send Failed
 Loop-back Receive Failed
 Loop-back Compare Failed
 Error Information Returned
6. Disconnect the loop-back plug and reconnect the Ethernet cable
to the EFM and the Ethernet hub.
7. Click Return to Menu to display the WINDIAG Main Menu.

5.5 Core Updump

In some cases—such as when a EFM fails for no apparent reason—you
can upload a copy of the contents of SRAM and SDRAM to a PC for
support personnel and service engineers to evaluate. This upload is
called a “core updump.”
A core updump may be required if the EFM spontaneously enters a
watchdog state that affects all system operation. This occurs when the
system crashes as a result of a CPU timeout (resulting from improper
software operation, a firmware glitch, and so on). In some cases, the
watchdog state can recur but you cannot logically reproduce the
conditions.
The CPU module’s RAM contains “crash blocks,” a firmware function
provided specifically for watchdog troubleshooting. You can view and
save the crash blocks by viewing the Crash Block Statistic Web Page
(see the Web_BSI Manual, D5087). On request, you can forward crash
block files to our technical support personnel. If they need additional
information to evaluate the condition, the technical support group may
request a core updump. Once the core updump process generates a file,
you can forward that file to the support personnel for evaluation and
resolution.
Use the following steps to preserve the “failed state” condition at a
system crash and perform a core updump:
1. Set switch SW2-1 on the CPU module to OFF (Disable
Watchdog Timer). If switch SW2-4 is ON, set it to OFF (Enable
Core Updump).
Note: The factory default setting for switch SW2-4 is OFF.

2. Wait for the error condition (typically 3F on the SCM’s status

LEDs).

5-26 Service & Troubleshooting Revised Dec-2013

 ControlWave EFM Instruction Manual

3. Connect the ControlWave EFM’s Comm Port 1 to a PC using a

null modem cable.
4. If the SCM’s mode switch has a Run/Remote/Local switch, set it
as follows. Set both SW1-1 and SW1-2 to the right (open)
operation or both to the left (closed).
5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and
generate a receive using the 1KX-Modem protocol. Save the
resulting core updump in a file so you can forward it later to the
technical support group.
By setting the CPU module switches SW2-1 and SW2-4 both off before
the EFM fails, you prevent the EFM from automatically recovering
from the failure and enable it to wait for you to take a core updump.
Once you complete the core updump, set the CPU module’s switch
SW2-1 to ON (Watchdog Enabled) and SW2-4 to OFF (Core Updump
Disabled).
Additionally, for the SCM mode switch, set switch SW1-1 to open
(right) and SW1-2 to closed (left).
With these switches set, power up the EFM and recommence standard
operations.

Revised Dec-2013 Service & Troubleshooting 5-27

This page is intentionally left blank
 ControlWave EFM Instruction Manual

Appendix A – ControlWave EFM Electronic Flow Meter –

Special Instructions for Class I, Division 2
Hazardous Locations
1. The ControlWave Electronic Flow Meter (EFM) is listed by
Underwriters Laboratories (UL) as nonincendive and is suitable for
use in Class I, Division 2, Groups C and D hazardous locations or
non-hazardous locations only. Read this appendix carefully before
installing a nonincendive ControlWave Electronic Flow Meter
(EFM). In the event of a conflict between the ControlWave EFM
Instruction Manual (CI-ControlWave EFM) and this appendix,
always follow the instructions in this appendix
2. The ControlWave Electronic Flow Meter (EFM) includes both
nonincendive and unrated field circuits. Unless a circuit is
specifically identified in this appendix as nonincendive, the circuit is
unrated. Unrated circuits must be wired using Div. 2 wiring methods
as specified in article 501-4(b) of the National Electrical Code
(NEC), NFPA 70 for installations in the United States, or as
specified in Section 18-152 of the Canadian Electrical Code for
installation in Canada.
3. The local communications port terminates in a D-Type connector on
the bottom of the ControlWave Electronic Flow Meter (EFM)
enclosure. The wiring on this connector is unrated. No connections
may be made to this port unless the user ensures that the area is
known to be nonhazardous. Connections to this port are temporary,
and must be short in duration to ensure that flammable
concentrations do not accumulate while it is in use.
4. The optional power system (solar panel and battery) approved for
use with the nonincendive ControlWave Electronic Flow Meter
(EFM) are described in the model specification. The connection to
the solar panel is approved as a nonincendive circuit so that Division
2 wiring methods are not required. The nominal panel voltage must
match the nominal battery voltage (12V).
5. An RTD is normally supplied with the ControlWave EFM.
Connection to the RTD is approved as a nonincendive circuit, so
that Division 2 wiring methods are not required.
6. Signal connectors available for customer wiring are listed in Table
A1. I/O connections are unrated and must be wired using Div. 2
wiring methods.

Revised Dec-2013 Appendix A A-1

ControlWave EFM Instruction Manual

7. The UL listed nonincendive ControlWave EFM may include

radio/modem communications (listed on the model spec.) that is
used in conjunction with a 30W Solar Panel and 12V, 33AH Lead
Acid Battery System. Connection to the radio or modem is approved
as a nonincendive circuit, so that Division 2 wiring methods are not
required.
8. The UL listed nonincendive ControlWave EFM may include a
Digital to Relay I/O Board (option). No field wiring
connections/removals should be made at the Digital to Relay I/O
Board unless the area is known to be nonhazardous. Digital to Relay
I/O Board I/O circuitry is unrated an must be wired using Div. 2
wiring methods.
9. The UL listed nonincendive ControlWave EFM may include a 21V
Power Supply Board (option). No field wiring connections/removals
should be made at the 21V Power Supply Board unless the area is
known to be nonhazardous. 21V Power Supply Board Transmitter
Interface circuitry is unrated and must be wired using Div. 2 wiring
methods.

WARNING #1 EXPLOSION HAZARD

Do NOT disconnect Solar Power from the Battery or any other power
connections within the ControlWave EFM enclosure (including
connectors TB1 through TB6 on the Power Distribution Board,
connector TB1 on the System Controller Module, any power
connections to optional items such as radio, modem, Digital to Relay
I/O Board, 21V Power Supply Board, or cabling to the Display/Keypad)
unless the area is known to be nonhazardous.

WARNING #2 EXPLOSION HAZARD

Substitution of components may impair suitability for use in Class I,
Division 2 environments.

WARNING #3 EXPLOSION HAZARD

The area must be known to be nonhazardous before
servicing/replacing the unit and before installing or removing I/O
wiring.

WARNING #4 EXPLOSION HAZARD

Do NOT disconnect equipment unless power has been disconnected
and the area is known to be non-hazardous.

A-2 Appendix A Revised Dec-2013

 ControlWave EFM Instruction Manual

Table A-1. Module/Board Customer Wiring Connectors

Module/Item Connector Wiring Notes
CPU Module J3 – COM1, 9-pin Male D- Factory connected to local comm. port.
sub Refer to item 3 of this appendix.
CPU Module J4 – COM2, 9-pin Male D- Remote comm. port: For radio or external
sub RS-232 network comm. Refer to model spec. and
J5 – COM3, 9-pin Male D- item 6 of this appendix. When used for
sub RS-485 network comm., use Div 2 wiring
methods. If COM2 is used in conjunction
with a radio/modem refer to item 7 of this
appendix.
SCM Module J2 – Display interface RJ- Factory Wired.*
45 female
SCM Module P2 – MVT interface Factory Wired.*
SCM Module TB1 – Input power Typically factory wired *
SCM Module TB2 – RTD Interface Field wired – refer to Item 5 of this
appendix.
Exp. Comm. Module 1 J4 – COM4, 9-pin Male D- Remote Comm. Port: For radio or
sub RS-232 external Network Comm. Refer to model
J5 – COM5, 9-pin Male D- spec. and item 6 of this appendix. When
sub RS-485 used for Network Comm., use Div. 2
wiring methods. If COM4 is used in
conjunction with a radio/modem refer to
item 7 of this appendix.
Exp. Comm. Module 1 J8 – COM7, RJ11 female Modular connection to phone company
equipment.
Exp. Comm. Module 2 J4 – COM8, 9-pin Male D- Remote Comm. Port: For radio or
sub RS-232 external Network Comm. Refer to model
J5 – COM9, 9-pin Male D- spec. and item 6 of this appendix. When
sub RS-485 used for Network Comm., use Div. 2
wiring methods. If COM8 is used in
conjunction with a radio/modem refer to
item 7 of this appendix.
Exp. Comm. Module 2 J8 – COM11, RJ11 female Modular connection to phone company
equipment. Refer to the warning #2, #3,
#4, and item 7 of this appendix.
Analog I/O Module TB1/TB2 – 10-pin terminal Field I/O wiring connectors are unrated;
blocks use Div. 2 wiring methods.*
Digital I/O Module TB1/TB2 – 10-pin terminal Field I/O wiring connectors are unrated;
blocks use Div. 2 wiring methods.*
HSC Input Module TB1/TB2 – 10-pin terminal Field I/O wiring connectors are unrated;
blocks use Div. 2 wiring methods.*
Mixed I/O Module TB1/TB2 – 10-pin terminal Field I/O wiring connectors are unrated;
blocks use Div. 2 wiring methods.*
Digital to Relay I/O Board J1 10-pin in-line connector Field I/O wiring connector is unrated; use
Div. 2 wiring methods. Refer to item 8 of
this appendix.*
Power Distribution Board (See TB1 – 3-pin terminal block Primary Power Input – User wired *
warning #1 of this appendix) TB2 – 2-pin terminal block Main Power Out 1 – Factory wired *
TB3 – 2-pin terminal block Main Power Out 2 – Factory wired *
TB4 – 2-pin terminal block Fused Power Out 1 – Factory wired *

Revised Dec-2013 Appendix A A-3

ControlWave EFM Instruction Manual

Module/Item Connector Wiring Notes

TB5 – 2-pin terminal block Fused Power Out 2 – Factory wired *
TB6 – 2pin terminal block Fused Power Out 3 – Factory wired *
21V Power Supply Board (See TB1 – 3-pin terminal block 12V power input – Factory wired *
warning #1 and item 9 of this TB2 – 4-pin terminal block 21V Transmitter Power – Field wired
appendix) TB2 is unrated, use Div. 2 wiring
methods.
Enclosure bottom Local Port circular Local comm. port – Factory wired. Refer
connector to item 3 of this appendix. *

Note: * These wires should only be installed/removed when the item

(PCB) in question is installed / removed or when checking
wiring continuity. The area must be known to be nonhazardous
before servicing / replacing the unit and before installing or
removing PCBs, connectors, or individual I/O or power wires.
Refer to warnings #2, #3, #4 of this appendix. All input power
and I/O wiring must be performed in accordance with Class I,
Division 2 wiring methods as defined in Article 501-4(b) of the
National Electrical Code, NFPA 70, for installations within the
United States, or as specified in Section 18-152 of the Canadian
Electrical Code for installation in Canada.

A-4 Appendix A Revised Dec-2013

 ControlWave EFM Instruction Manual

Appendix D – Modem Installation

D2.1 Modem Installation & Configuration

D2.1.1 Installing an Internal MultiTech Modem (MT9234SMI)

To install a Model MT9234SMI Modem onto an ECOM Module,
perform the following steps:
Remove the ECOM Module from the controller (see Figure D1).

Figure D1. Expansion Comm. Module Component Identification Diagram

1. Unplug the antenna cable from the RF Connector on any installed

radio module. Grasp the ECOM Module with one hand. Squeeze
both sides of the cover panel (just below the unit’s top) and pull up
and away to release the cover panel and EMI Gasket from the PCB
(see Figure D2).

Revised Dec-2013 Modem Installation D-1

ControlWave EFM Instruction Manual

Figure D2. MultiTech Modem Installation Diagram

Note: If necessary, you can use a small screwdriver to pry the cover
panel from the PCB.
2. Install the nylon support post included in the kit onto the ECOM
Module.

D-2 Modem Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

3. Mount the MultiTech Modem to the ECOM Module making sure

that the interface connectors (J6, J7, J9 & J10 on the ECOM
Module) align.
4. Plug the antenna cable(s) (if present - removed in Step 2) into the
appropriate RF connector of an installed radio module(s).
5. Snap the cover panel onto the ECOM Module PCB and insert the
ECOM Module into the appropriate backplane slot, i.e., Slot 3 or 4.
6. Apply power and test the unit.

D2.1.2 Configuring the MultiTech Modem (MT9234SMI)

To configure a model MT9234SMI Modem (installed on an ECOM
Module), perform the following steps:
1. If required, remove the ECOM Module from the controller (see
Figure D1).
2. Place the modem into configuration mode by setting ECOM
Module jumper JP2 onto pins 2 and 3. This enables
configuration of the modem through Comm. Port 4 for modem
on ECOM1 or through COMM. Port 8 for modem on ECOM2.
3. Connect a full duplex ControlWave null modem cable (see
Figure D3) between a PC and Comm. Port 4 (ECOM1) to
configure modem on ECOM1 or Comm. Port 8 (ECOM2) to
configure modem on ECOM2.
PC CW u/CW EFM
9-Pin Female 9-Pin Female
“D” Connector “D” Connector
P1 P2

5 = GND (Looking into 1 = DCD

To P2 Pin-5 6 = DSR
Wire Terminal Side
4 = DTR of 2 = RXD
To P2 Pin-6
7 = RTS
8 = CTS Cable Connectors)
3 = TXD 3 = TXD
7 = RTS
To P2 Pin-2 or
To P2 Pin-1 8 = CTS
2 = RXD vice 4 = DTR
To P2 Pin-3 versa
6 = DSR
To P2 Pin-4
1 = DCD 5 = GND
To P2 Pin-7

Figure D2. Internal Modem Configuration P/N 392843-01-3 Full-duplex Null Modem
Cable Diagram

4. Open HyperTerminal on the PC and set the PC communication

port settings as follows:

Revised Dec-2013 Modem Installation D-3

ControlWave EFM Instruction Manual

 Bits per second: 9600

 Data bits: 8
 Parity: None
 Stop bit: 1
 Flow Control: None
 Send Factory Default AT&F0.
 Disable Flow Control AT&K0.
 Set baud rate using AT Command for example:
AT$SB9600,
(Modify for whatever baud rate you require.)
 Write to memory AT&W.
5. Set ECOM Module configuration jumper JP2 into a storage
position.

D-4 Modem Installation Revised Dec-2013

 ControlWave EFM Instruction Manual

Appendix Z – Sources for Obtaining Material Safety Data

Sheets
This device includes certain components or materials which may be
hazardous if misused. For details on these hazards, please contact the
manufacturer for the most recent material safety data sheet.
Manufacturer General Emerson Part
Description Number & Media
Notes
DURACELL (DL 2032) LITHIUM W15020X0012
MANGANESE
http://www.duracell.com DIOXIDE COIN
CELL BATTERY
PANASONIC (CR 2032)

http://www.panasonic.com

ENERGIZER (CR 2032)

http://www.energizer.com

SANYO (CR 2032)

VARTA (CR 2032)

http://www.varta-
microbattery.com

B.B. Battery Co., Ltd. 12V – 33AH/20 HR 395407-03-6

SEALED LEAD
(BP33-12) ACID BATTERY
http://www.bb-battery.com/

Revised Dec-2013 Appendix Z Z-1

This page is intentionally left blank
 ControlWave EFM Instruction Manual

Index

A D
ACCOL3 Firmware Library ................................. 1-9 Defaults
Analog averaging .............................................. 1-12 Comm Ports .................................................... 4-2
Diagnostic software........................................... 5-19
B Digital to relay I/O board
removing and replacing ................................ 5-10
Backplanes ......................................................... 1-3
Disconnecting RAM Battery ..................... 5-11, 5-12
Backups .............................................................. 4-5
Display/Keypad ................................................. 2-50
Battery
Downloading
Disconnecting ...................................... 5-11, 5-12
the ControlWave project ................................. 4-4
Lithium backup ............................................. 5-10
removing and replacing the lead-acid battery 5-8
E
replacing ....................................................... 5-10
Bezel ECOM
Removing ....................................................... 5-6 Installation .................................................... 2-44
Replacing........................................................ 5-6 ECOM Modules
Boot FLASH memory removing ......................................................... 5-8
amount............................................................ 1-5 replacing ......................................................... 5-8
Energy calculation............................................. 1-13
C Energy integration ............................................. 1-13
Environmental specifications .............................. 2-2
Cables
Ethernet Loop-back Test ......................... 5-24, 5-25
RS-232 ......................................................... 2-35
Ethernet Ports ................................................... 2-42
RS-485 ......................................................... 2-40
Extension calculation ........................................ 1-12
Chassis ............................................................... 2-6
Checking
F
LEDs ............................................................. 5-12
Wiring ........................................................... 5-18 Features .............................................................. 1-1
Class I, Division 2 ........................................ 2-2, A-1 Field repair .......................................................... 5-6
Communication problems Figures
common reasons for ..................................... 5-18 1-1. ControlWave EFM Enclosure .................. 1-2
Communication Ports 1-2. CPU Module ............................................ 1-5
defaults ........................................................... 4-2 1-3. Expansion Communications (ECOM)
Ethernet ........................................................ 2-42 Module .......................................................... 1-7
Modem.......................................................... 2-46 1-4. Two ControlWave EFM I/O Modules with
RS-232 ......................................................... 2-34 bezel ............................................................. 1-8
RS-485 ......................................................... 2-41 1-5. ControlWave Programming Environment 1-9
Communications 2-1. 4 Slot ControlWave EFM Component ID
Ethernet Loop-back Test ..................... 5-24, 5-25 Diagram ........................................................ 2-3
Loop-back Test .................................... 5-22, 5-23 2-2. 8 Slot ControlWave EFM Component ID
protocols supported ...................................... 1-10 Diagram ........................................................ 2-4
ControlWave project 2-3. 8 or 4 Slot ControlWave EFM Housing ... 2-7
downloading ................................................... 4-4 2-4. ControlWave EFM Bottom View.............. 2-8
Core Updump ................................................... 5-26 2-5. Side View of ControlWave EFM ............. 2-9
CPU Module 2-6. 4-Slot ControlWave EFM ...................... 2-10
description ...................................................... 1-4 2-7. 8-Slot ControlWave EFM – Base Chassis
Installation .................................................... 2-29 Assembly Dimensions ................................ 2-11
jumpers ......................................................... 2-30 2-8. ControlWave EFM NEMA 3X Enclosure
Lithium battery backup ................................. 5-10 Dimensions ................................................. 2-12
removing ......................................................... 5-6 2-9. Process Flange and Optional Manifold
replacing ......................................................... 5-6 Block Connectors ....................................... 2-14
switches ........................................................ 2-31 2-10. ControlWave EFM Direct Mount
Installation with Cathodic Protection .......... 2-15

Revised Dec-2013 Index IND-1

ControlWave EFM Instruction Manual

2-11. ControlWave EFM Remote Installation with 5-13. RS-485 Loop-back Plug ...................... 5-23
Cathodic Protection .................................... 2-16 5-14 Communications Diagnostic menu....... 5-24
2-12. System Controller Module Component ID 5-15 RJ-45 Ethernet Loop-back Plug ........... 5-25
Diagram ...................................................... 2-18 5-16. Ethernet Diagnostic Menu ................... 5-25
2-13. SCM TB1 Wiring ................................. 2-22 Firmware upgrade ............................................... 5-2
2-14. 30 or 40 Watt Solar Panel Mounting HyperTerminal ................................................ 5-3
Diagram ...................................................... 2-23 LocalView ....................................................... 5-3
2-15. Enclosure with Sealed Lead-acid Battery System Firmware Downloader ....................... 5-2
Installed ...................................................... 2-25 FLASH memory
2-16. Power Distribution Board .................... 2-26 amount............................................................ 1-5
2-17. Power Distribution Board and Other Flow calculations
Options – Snap Track Mounting ................ 2-27 supported...................................................... 1-11
2-18. 21V Power Supply Board .................... 2-28 Flow rate calculations
2-19. CPU Module with Three Serial Ports .. 2-29 AGA3 ............................................................ 1-12
2-20. CPU Module with Three Serial Ports and AGA7 ............................................................ 1-12
One Ethernet Port ...................................... 2-30 Flow time calculations
2-21. Male DB9 9-Pin Connector ................. 2-35 AGA3 ............................................................ 1-12
2-22. Full-duplex and Half-duplex Cable ...... 2-36 AGA7 ............................................................ 1-12
2-23. Full-duplex and Half-duplex Cable ...... 2-36 Fuse
2-24. Communication Interface Cable for SCM .............................................................. 2-18
Connection to Case-Mounted (External) Radio
or Modem ................................................... 2-37 G
2-25. Full-duplex and Half-duplex Cable ...... 2-37
2-26. PC Connected to ControlWave EFM via D- Grounding ......................................................... 2-13
Type Local Port .......................................... 2-37
2-27. PC Connected to ControlWave EFM via H
Circular Local Port...................................... 2-38 Hazardous locations
2-28. RJ-45 Ethernet Connector .................. 2-42 special instructions for .................................... A-1
2-29. Standard 10/100Base-T Ethernet Cable Historical data storage ...................................... 1-13
(CPU Module to Hub) ................................. 2-42 Housings ...................................................... 1-3, 2-6
2-30. Point-to-Point 10/100Base T Ethernet Humidity
Cable .......................................................... 2-43 specifications .................................................. 2-2
2-31. ECOM1 with Two Serial Ports, and a HyperTerminal .................................................... 5-3
Modem ....................................................... 2-44
2-32. ECOM2 with Two RS-232 and Two RS- I
485 Ports .................................................... 2-45
2-33. Full-duplex and Half-duplex Cable ...... 2-46 I/O Configurator .................................................. 1-9
2-34. ECOM Modem Installation .................. 2-46 I/O Modules
2-35. PTSN Field Connections for ControlWave general............................................................ 1-8
Micros (and EFMs) ..................................... 2-48 removing ......................................................... 5-7
2-36. Phone Cord Wiring .............................. 2-48 replacing ......................................................... 5-7
2-37 Bezel Assembly.................................... 2-50 Installation
2-38. Optional 2-Button & 25-Button Keypads ..2- Class 1, Div 2 ................................................. 2-2
51 CPU .............................................................. 2-29
4-1. Mode Switch............................................ 4-2 ECOM ........................................................... 2-44
4-2. Saving a Backup of Your Project ............ 4-6 Overview......................................................... 2-5
5-1. HyperTerminal Mode Menu .................... 5-4 SCM .............................................................. 2-19
5-2. HyperTerminal (Ready to Download)...... 5-4
5-3. Send File dialog box................................ 5-5 J
5-4. HyperTerminal (Download in progress) .. 5-5 Jumpers
5-5. SCM Status LED Hexadecimal Codes.. 5-15 CPU .............................................................. 2-30
5-6. CPU Module Comm Connectors & LEDs ..5- SCM .............................................................. 2-19
16
5-7. Type 1 ECOM Comm Connectors and LEDs5-17 K
5-8. Type 2 ECOM Comm Connectors and LEDs5-17
5-9. I/O Module LEDs ................................... 5-18 Keypad/Display ................................................. 2-50
5-10 NetView ................................................ 5-21
5-11. WINDIAG Main Diagnostics Menu ...... 5-21
5-12. RS-232 Loop-back Plug ...................... 5-22
IND-2 Index Revised Dec-2013
 ControlWave EFM Instruction Manual

L Repair in field ...................................................... 5-6

RS-232 Ports .................................................... 2-34
Lead acid battery
Cables........................................................... 2-35
removing and replacing .................................. 5-8
RS-485 Ports .................................................... 2-41
LEDs
Cables........................................................... 2-40
Checking....................................................... 5-12
configuration switch ...................................... 2-33
CPU module ................................................. 5-15
Run switching.................................................... 1-15
LocalView............................................................ 5-3
Running diagnostic software ............................. 5-19
Loop-back Test ........................................ 5-22, 5-23
S
M
Sampler ............................................................. 1-16
Material Safety Data Sheets (MSDS)
SCM ............. See System Controller Module (SCM)
how to obtain .................................................. Z-1
SDRAM memory
Memory
amount ............................................................ 1-6
Boot FLASH.................................................... 1-5
Service Tools ...................................................... 5-1
FLASH amount ............................................... 1-5
Site Considerations ............................................. 2-1
SDRAM amount.............................................. 1-6
Soft Switches
SRAM amount ................................................ 1-6
lock/unlock switch ......................................... 2-32
Mode switch ........................................................ 4-1
use/ignore switch .......................................... 2-32
Modem ................................................................ D-1
Software Tools .................................................... 1-8
Communication Ports ................................... 2-46
Specifications
Modem (case mounted)
for temperature, humidity, vibration ................ 2-2
removing and replacing ................................ 5-10
SRAM memory
Modules
amount ............................................................ 1-6
CPU ....................................................... 1-4, 2-29
control switch ................................................ 2-32
I/O ................................................................... 1-8
Switches
SCM ....................................................... 1-6, 2-17
CPU .............................................................. 2-31
Mounting the housing ......................................... 2-7
Mode ............................................................... 4-1
System Controller Module (SCM) ..................... 2-17
N Installation .................................................... 2-19
Nominations ...................................................... 1-16 Jumpers ........................................................ 2-19
LEDs ............................................................. 5-14
O Mode Switch ................................................... 4-1
removing ......................................................... 5-7
Odorizer ............................................................ 1-16 replacing ......................................................... 5-7
Operator’s keypad/display ................................ 2-50 TB1 Connectors............................................ 2-22
System Firmware Downloader ............................ 5-2
P
Packaging T
modules .......................................................... 2-6 Tables
Power 1-1. CPU Module Configurations 1-4
connecting or disconnecting ........................... 4-1
Power distribution board 2-1. SCM Switch SW1 .................................. 2-20
removing and replacing .................................. 5-9 2-2. Bulk Power Requirements ..................... 2-21
Power supply board (21V) 2-3. Solar Panel Tilt Angle ............................ 2-24
removing and replacing .................................. 5-9 2-4. 21V Power Supply Board Terminal
Pressure tap ..................................................... 1-13 Designations ............................................... 2-28
Protocols 2-5. CPU Module Switch SW1 ..................... 2-31
supported in ControlWave ............................ 1-10 2-6. CPU Module Switch SW2 ..................... 2-32
PSTN ................................................................ 2-47 2-7. RS-485 Configuration Switch ................ 2-33
PSTN Modem ................................................... 2-46 2-8. RS-232 Connectors on CPU ................. 2-34
2-9. RS-232 Connectors on ECOM .............. 2-34
R 2-10. RS-232 Port Connector Pin Assignment . 2-
35
Radio (case mounted) 2-11. RS-232 Port Connector Pin Assignment . 2-
removing and replacing ................................ 5-10 38
RAM Battery 2-12. RS-485 Connectors on CPU ............... 2-40
Disconnecting ...................................... 5-11, 5-12 2-13. RS-485 Connectors on Type 1 ECOM 2-40

Revised Dec-2013 Index IND-3

ControlWave EFM Instruction Manual

2-14. RS-485 Connectors on Type 2 ECOM 2-40 U

2-15. RS-485 Port Connector Pin Assignment .2-
Unpacking components ...................................... 2-6
40
Updump ............................................................ 5-26
2-16. RS-485 Network Connections............. 2-41
switch ............................................................ 2-32
2-17. Ethernet 10/100Base-T CPU Module Pin
Upgrading firmware ............................................ 5-2
Assignments ............................................... 2-43
4-1. Default Comm Port Settings (by PCB) .... 4-2
5-1. LED Assignments on Modules .............. 5-12 V
5-2. System Status LED Codes on SCM ..... 5-14 Vibration
5-3. CPU Module LEDs ................................ 5-15 specifications .................................................. 2-2
5-4. COM Port Defaults for Diagnostics ....... 5-19 Volume calculations
A-1. Module/Board Customer Wiring Connectors supported...................................................... 1-11
......................................................................... 3 Volume integration ............................................ 1-13
TB1 Connector
SCM.............................................................. 2-22 W
Temperature
specifications .................................................. 2-2 Watchdog
Troubleshooting .................................................. 5-1 enable switch ................................................ 2-32
common communication configuration problems WINDIAG .......................................................... 5-19
................................................................... 5-18 Wiring
general.......................................................... 5-12 Checking....................................................... 5-18

IND-4 Index Revised Dec-2013

This page is intentionally left blank
ControlWave EFM Instruction Manual
CI-ControlWave EFM December 2013

Headquarters:
Emerson Process Management
Remote Automation Solutions
6005 Rogerdale Road
Houston, TX 77072 U.S.A.
T +1 281 879 2699 | F +1 281 988 4445
www.EmersonProcess.com/Remote
Europe:
Emerson Process Management
Remote Automation Solutions
Unit 8, Waterfront Business Park
© 2013 Remote Automation Solutions, a business unit of Emerson Process Management. All
Dudley Road, Brierly Hill
rights reserved.
Dudley UK DY5 1LX
T +44 1384 487200 | F +44 1384 487258 Remote Automation Solutions, a business unit of Emerson Process Management, shall not be
www.EmersonProcess.com/Remote liable for technical or editorial errors in this manual or omissions from this manual. REMOTE
North American/Latin America: AUTOMATION SOLUTIONS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
Emerson Process Management THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
Remote Automation Solutions WITH RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL REMOTE AUTOMATION
6005 Rogerdale Road SOLUTIONS BE LIABLE FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL
Houston TX USA 77072 DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS
T +1 281 879 2699 | F +1 281 988 4445 OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL,
www.EmersonProcess.com/Remote FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.
Middle East/Africa: Bristol, Inc., Bristol Canada, BBI SA de CV and Emerson Process Management Ltd, Remote
Emerson Process Management Automation Solutions (UK), are wholly owned subsidiaries of Emerson Electric Co. doing
Remote Automation Solutions business as Remote Automation Solutions, a business unit of Emerson Process Management.
Emerson FZE FloBoss, ROCLINK, Bristol, Bristol Babcock, ControlWave, TeleFlow, Helicoid and
P.O. Box 17033 OpenEnterprise are trademarks of Remote Automation Solutions. AMS, PlantWeb and the
Jebel Ali Free Zone — South 2 PlantWeb logo are marks of Emerson Electric Co. The Emerson logo is a trademark and service
Dubai U.A.E. mark of the Emerson Electric Co. All other marks are property of their respective owners.
T +971 4 8118100 | F +971 4 8865465
The contents of this publication are presented for informational purposes only. While every
www.EmersonProcess.com/Remote
effort has been made to ensure informational accuracy, they are not to be construed as
Asia-Pacific: warranties or guarantees, express or implied, regarding the products or services described
Emerson Process Management herein or their use or applicability. Remote Automation Solutions reserves the right to modify
Remote Automation Solutions or improve the designs or specifications of such products at any time without notice. All sales
1 Pandan Crescent are governed by Remote Automation Solutions’ terms and conditions which are available
Singapore 128461 upon request. Remote Automation Solutions does not assume responsibility for the selection,
T +65 6777 8211| F +65 6777 0947 use or maintenance of any product. Responsibility for proper selection, use and maintenance
www.EmersonProcess.com/Remote of any Remote Automation Solutions product remains solely with the purchaser and end-user.

Remote Automation Solutions