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PDF Content Summary: WEB-300E, WEB-600E/U, CP-300E, Series Controllers CP-600E/U APPLICATION The Honeywell WEB-300E, CP-300E, WEB-600E/U, WEB-600E-O/U, and CP-600E/U controllers are compact, embedded controller/server platforms that allow integrated control and management of external devices over the Internet. The 300E uses a PowerPC 405 400Mhz processor; the 600E uses a PowerPC 440 524Mhz processor. Each controller supports two optional communications cards as well as optional I/O expansion modules. Onboard static RAM (SRAM) provides WEBs-AX station backup capability without any battery installed. An optional backup battery is also available. IMPORTANT This document covers the mounting and wiring of the Honeywell WEB-300E, WEB-300E-O, CP-300E, WEB-600E/U, CP-600E/U, and WEB-600E-O/U controllers. It assumes that you are an engineer, technician, or service person who is performing control system installation. Instructions in this document apply to the products listed in Table 1. Not covered in this document is the WEBs-AX software installation and configuration required for a fully functioning unit. In addition, the mounting and wiring of JACE expansion options are covered in separate documents. See “Related Documentation” on this page, and “Expansion Options” on page 5. Related Documentation For more information on configuring and using the WEB- 300E or WEB-600E/U controller, refer to the following documents: • JACE WEBs-AX Install and Startup Guide • JACE Data Recovery Service (SRAM Support) - Engineering Notes • IO-16-H Input/Output Module Installation Instructions (95-7756) • IO-34-H Input/Output Module Installation Instructions (95-7753) Various optional card installation documents, such as: • NPB-LON Installation Instructions (62-0263) • NPB-2X-RS485 Option Card Installation Instructions (95-7778) • NPB-RS232 Option Installation Instructions (95-7779) • WEBs-AX NPB-GPRS Modem Installation Instructions (62-0301) • NPB-ZWAVE Option Card Installation Instructions (62-0349) • WEBs-AX Ndio Guide • WEBs-AX User Guide INSTALLATION INSTRUCTIONS 31-00010-01 WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS Table 1. Model Description WEB-300E WEB-300E, includes two Ethernet ports, one RS-232 port, and one RS-485 port. Web User Interface and Niagara Connectivity included. oBIX Client/Server driver included. WEB-300E-O WEB-300E with Open License, includes two Ethernet ports, one RS-232 port, and one RS-485 port. Web User Interface and Niagara Connectivity included. oBIX Client/Server driver included. CP-300E Comfort Point 300E, includes two Ethernet ports, one RS-232 port, and one RS-485 port. Web User Interface and Niagara Connectivity included. oBIX Client/Server driver included. WEB-600E/U The WEB-600E/U is designed for Battery less operation and DIN rail mounting. Standard features include WEBs-AX station and Web User Interface. Standard drivers include oBIX Client / Server and Niagara Network (Fox) Client / Server. WEB-600E-O/U The WEB-600E-O/U with Open License is designed for Battery less operation and DIN rail mounting. Standard features include WEBs-AX station and Web User Interface. Standard drivers include oBIX Client / Server and Niagara Network (Fox) Client / Server. WEB-600E-US/U The WEB-600E-US/U is designed for Battery less operation and DIN rail mounting. Standard features include WEBs-AX station and Web User Interface. Standard drivers include oBIX Client / Server and Niagara Network (Fox) Client / Server. Made in USA controller. WEB-600E-US-O/U The WEB-600E-US-O/U with Open License is designed for Battery less operation and DIN rail mounting. Standard features include WEBs-AX station and Web User Interface. Standard drivers include oBIX Client / Server and Niagara Network (Fox) Client / Server. Made in USA controller. CP-600E/U The CP-600E/U is designed for Battery less operation and DIN rail mounting. Standard features include CP-AX station and Web User Interface. Standard drivers include oBIX Client / Server and Niagara Network (Fox) Client / Server. WEB-300E-AX-DEMO Base Unit including two Ethernet ports, one RS-232 port, and one RS-485 port. Web User Interface and Niagara Connectivity included. oBIX Client/Server driver included. Includes NPB- WPM-US/U, NPB-LON/U, NPB-2X-RS485/U, IO-16-REM-H/U, NPB-BATTERY/U, NPB-RS232/U. Requires AX release 3.7.106 or higher. CP-300E-DEMO Base Unit including two Ethernet ports, one RS-232 port, and one RS-485 port. Web User Interface and Niagara Connectivity included. oBIX Client/Server driver included. Includes NPB- WPM-US/U, NPB-LON/U, NPB-2X-RS485/U, IO-16-REM-H/U, NPB-BATTERY/U, NPB-RS232/U. Requires AX release 3.7.106 or higher. W-600E-AX-DEMO/U Office Demo WEB 600E Controller CP-600E-AX-DEMO/U Comfort Point 600E Demo Controller NPB-PWR-H/U 24Vac/dc input/15Vdc output power supply module, DIN mountable. NPB-PWR-UN-H/U 120–240Vac universal input/15Vdc output power supply module, DIN mountable. NPB-WPM-US/U Wall Adaptor (US) PREPARATION Unpack the controller and inspect the package contents for damaged or missing components. If damaged, notify the appropriate carrier at once and return any damaged components for immediate repair or replacement. See “Returning a Defective Unit” on page 17. Included in this Package Included in this package you should find the following items: • A WEB-300E, WEB-300E-O, CP-300E, WEB-600E/U, WEB-600E-O/U, or a CP-600E/U controller. • WEB-300E, WEB-600E/U, CP-300E, CP-600E/U Series Controllers Installation Instructions (31-00010). • a hardware bag containing the following items: — One (1) grounding wire, with quick-disconnect 0.187" female connector. Material and Tools Required The following supplies and tools are typically required for installation: • A suitable power module, as one of the following types: — NPB-PWR-H/U: 24Vac or 24Vdc, in-line, DIN mount capable, with grounding wire. — NPB-PWR-UN-H/U: 120–240Vac, in-line, DIN mount capable, with grounding wire. — NPB-WPM-US/U: External wall-mount power adapter. 31-00010—01 2 NOTE: Using an NPB-PWR-H/U power module pro- vides the widest operating temperature range. See “Environmental Requirements” on page 3. • If using a NPB-PWR-H/U (24V) power module, either one of the following: — UL listed, Class 2, 24Vac transformer, rated at min- imum of 7.5VA to 20VA (approximate range of con- troller alone, to fully-expanded unit with four additional IO-16-H/U modules and other option boards). Note that a dedicated transformer is required (cannot also power additional equipment). — 24Vdc power supply, capable of supplying at least 1A (24W). • DIN rail, type NS35/7.5 (35mm x 7.5mm) and DIN rail end-clips (stop clips), recommended for any installation that includes NPB-PWR-H/U or NPB-PWR-UN-H/U power module and/or optional I/O modules. • Suitable tools and fasteners for mounting unit and accessories. • #2 phillips screwdriver: used to install and remove any option card. • Small flat-blade screwdriver: used for making wiring connections to removable screw terminal plugs, also for mounting and removing modules from DIN rail. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS PRECAUTIONS This document uses the following warning and caution CAUTION Work in a static-free area. conventions: Discharge any static electricity you may have accumulated. Discharge static electricity by CAUTION Cautions remind the reader to be careful. They alert readers to situations where there is a chance that the reader might perform an action that cannot be undone, might receive touching a known, securely grounded object. Do not handle printed circuit boards (PCBs) without proper protection against static discharge. Use a wrist strap when handling PCBs. The wrist strap clamp must be secured to earth ground. unexpected results, or might lose data. Cautions contain an explanation of why the Battery Precautions action is potentially problematic. CAUTION WARNING The optional NiMH battery used in this device may present a risk of fire or chemical burn if Warnings alert the reader to proceed with mistreated. Do not disassemble, heat above extreme care in situations where there is a 122oF (50oC), or incinerate. Replace battery chance that the reader might do something pack with type NPB-BATTERY/U only. Use of that can result in personal injury or equipment another battery may present a risk of fire or damage. Warnings contain an explanation of explosion. why the action is potentially dangerous. • Dispose of used battery promptly. Keep away from children. Do not disassemble and do not Safety Precautions The following are warnings relating to the installation and dispose of in fire. • Replace external backup battery with Listed Power Source Battery Only. start-up of the controller. Be sure to heed these warnings to prevent personal injury or equipment damage. MOUNTING WARNING Depending on power module used, the circuit powering the controller is 120–240Vac at 50/60 Hz (if a NPB-PWR-UN-H/U), 24Vac at 50/60 Hz Before mounting the controller, install any option card(s). See “About Option Cards” on page 5. Also see “RS-485 Biasing” on page 11. Then mount the controller in a location that allows clearance for wiring, servicing, and module removal. or 24Vdc (if a NPB-PWR-H/U), or from 100– 240Vac at 50/60 Hz (if a NPB-WPM-US/U). Disconnect power before installation or NOTE: This product is for indoor use only, altitude to 2,000m (6,562 ft.) maximum. servicing to prevent electrical shock or equipment damage. • Make all connections in accordance with national and local electrical codes. Use copper Depending on installed options, the allow- able temperature range varies. See “Environ- mental Requirements” below. conductors only. • To reduce the risk of fire or electrical shock, install in a controlled environment relatively free of contaminants. • This device is only intended for use as a Avoid mounting the controller in a manner that would make it difficult to operate the dis- connect device. See “Physical Mounting” for more details. monitoring and control device. To prevent data loss or equipment damage, do not use it for Environmental Requirements any other purpose. • Do not expose the unit to ambient operating temperatures outside the range: Static Discharge Precautions Static charges produce voltages high enough to damage electronic components. The controller’s microprocessors and associated circuitry are sensitive to static discharge. Follow these precautions when installing, servicing, or operating the system: 0°C (32°F) to 60°C (140°F), providing the unit: — Is UN-H/U not powered moduleby a, and the AC line input NPB-PWR- — The optional NiMH battery pack is not installed. Otherwise, 0°C (32°F) to 50 (122°F) is the ambient operating temperature range. • Relative humidity range is 5% to 95% non-condensing. • Pollution Degree III. • Supply (mains) voltage requirements are as follows: — Allowable voltage fluctuation to -15%, +10%, Temporary overvoltages +/- 15%. — Transient overvoltages: Overvoltage Category II. a Powering the controller with the wall mount adapter (NPB-WPM-US/U) at 60°C (140°F) is supported, how- ever, at 60°C its output is derated 50%, i.e. 15V at 0.5A (7.5W). No IO modules are supported. 3 31-00010—01 WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS • If mounting inside an enclosure, that enclosure should be designed to keep the unit within its required Physical Mounting operating range considering a 20-watt dissipation by The following information applies about physically the controller, plus dissipation from any other devices mounting the unit. installed in the same enclosure. This is especially important if the controller is mounted inside an enclosure with other heat producing equipment. • Do not mount the unit: — in an area with excessive moisture, corrosive fumes, or explosive vapors. — where vibration or shock is likely to occur. — in a location subject to electrical noise. This includes the proximity of large electrical con- tactors, electrical machinery, welding equip- ment, spark igniters, and variable frequency drives. 31-00010—01 4 • You can mount the controller in any orientation. It is not necessary to remove the cover before mounting. • Mounting on a 35mm wide DIN rail is recommended. The controller’s unit base has a molded DIN rail slot and locking clip, as do the power supply modules and both types of I/O expansion modules. Mounting on a DIN rail ensures accurate alignment of connectors between all modules. • If DIN rail mounting is impractical, you can use screws in mounting tabs on the controller, as well as any end- connected accessory (NPB-PWR-H/U, etc.). Tab mounting dimensions are on the last page of this document. MOUNTING ON DIN RAIL REMOVING FROM DIN RAIL DIN RAIL END CLIP Fig. 1. WEB and CP 300E or 600E Series controller and accessory mounting details. To mount on DIN rail 1. Securely install the DIN rail with at least two screws, near the two rail ends. 2. Position the controller on the rail, tilting to hook DIN rail tabs over one edge of the DIN rail (Fig. 1). 3. Use a screwdriver to pry down the plastic locking clip, and push down and in on the unit, forcing the locking clip to snap over the other DIN rail edge. 4. Mount any accessory module (I/O module, NPB- PWR-H/U) onto the DIN rail in the same manner. 5. Slide the accessory module along the DIN rail to connect its 20-position plug into the controller. 6. Repeat this for all accessories, until all are mounted on the DIN rail and firmly connected to each other. NPB-PWR-H/U OR NPB-PWR-UN-H/U INSTALL DIN RAIL END CLIP CONTROLLER (STOP CLIP) AT BOTH ENDS OF FINAL ASSEMBLY. DIN RAIL END CLIP CONTROLLER IO-16-H/U UP TO FOUR (4) IO-16-H/U MODULES 7-1/8 (181) ARE SUPPORTED 6-3/8 (162) IO-16-H/U NPB-PWR-H/U OR 2-3/64 (52) NPB-PWR-UN-H/U 4-7/64 CONTROLLER (104) 10-23/64 (263) 13-37/64 (345) 16-13/16 (427) 20-3/64 (509) 23-17/64 (591) NOTE: IF INSTALLING IO MODULES AND USING THE NPB-PWR-H/U OR NPB-PWR-UN-H/U POWER SUPPLY MODULE, THE POWER SUPPLY MODULE INSTALLS AT THE END OF THE CHAIN. M34983 7. To keep the final assembly together, secure at both ends with DIN rail end-clips provided by the DIN rail vendor. This also prevents the assembly from slid- ing on the DIN rail. See Fig. 1. Removing and Replacing the Cover You must remove the controller’s cover to install any option cards, or to install (or replace) the optional NiMH backup battery. The cover snaps onto the base with four plastic end tabs—two on each end. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS COVER COVER TABS COVER (2 EACH END) LIFTED AWAY PRESS IN TABS PRESS IN TABS M34985 Fig. 2. Press in four tabs on ends of cover to remove. NOTE: If accessory modules are plugged into the controller, you may need to slide them away Board Layout from the unit to get to the end cover tabs. Fig. 3 shows the location of LEDs, option slots, and other features of the 300E or 600E controller with cover • To remove the cover, press in the tabs on both ends of removed. For a side view of communications ports and the unit, and carefully lift it off. other features, see Fig. 6 on page 10. • To replace the cover, orient it so the cutout area for comm ports is correct, then push inwards to snap in place. SERIAL PORT LEDS ON BOTTOM STATUS LEDS (VISIBLE WITH COVER ON): BOARD, REMOVE COVER TO SEE: OPTION SLOT 2 COM 1 COM 2 LAN2 LAN1 BEAT STATUS (SEC) (PRI) MODE JUMPER (FOR SERIAL SHELL ACCESS) BRACKET FOR OPTIONAL NORMAL NIMH SERIAL SHELL BACKUP BATTERY 20-PIN CONNECTOR (I/O AND POWER MODULES) OPTION SLOT NPM3E OR NPM6E CONNECTORS PROCESSOR MODULE WITH INTEGRAL SRAM EARTH GROUND OPTION SLOT 1 SECONDARY ETHERNET (RJ-45) PRIMARY RS-485 (3-POS.) BARREL POWER LAN2 (TOP BOARD) COM RS-232 (DB-9) COM1 (BOTTOM (BOTTOM BOARD) BOARD) Fig. 3. WEB and CP 300E or 600E Series controller main board layout details. The controller ships with onboard static RAM (SRAM) that can provide station backup during power loss, and also has two (2) open option card slots for a variety of available option cards. For details, see “About Expansion Options” below, and also “About Backup Configurations” on page 13. EXPANSION OPTIONS The controller provides for field-installable expansion using these types of options: 5 31-00010—01 SPADE LUG ETHERNET CONNECTOR FOR (RJ-45) LAN1 (TOP BOARD) WALL MOUNTED POWER MODULE (WPM-XXX) M34990 • Option cards — Install on connectors on the controller’s base board. See “About Option Cards” on page 5. • Accessory modules — To “chain” on the controller’s 20-pin connector. See “About Accessory Modules” on page 6. About Option Cards The controller has two (2) available option slots for option cards designed for use with controllers. Each slot has a 30-pin connector. Installing an option card is recommended before mounting the unit. See “Installing an Option Card” on page 6. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS WARNING Option Power to the controller must be OFF when 31-00010—01 6 cards typically provide additional communications features, with the following available models (with others still in development) listed in Table 2. installing or removing option cards, or damage will occur! Also, you must be very careful to plug an option card into its connector properly (pins aligned). Table 2. Option Description Notes Dual, optically-isolated, RS-485 adapter with two 3- If installed in Option slot 1, ports operate as COM3 and NPB-2X-RS485/U position removable screw-terminal connector plugs. COM4. Option slot If two 1, 485 and option COM5, cards, COM6 ports for Option are COM3, slot 2. COM4 for NPB-LON/U FTT-10A removable LON screw-terminal (LonWorks) connector adapter with plug. a 2-position Port option, operates or LON2 as in LON1 slot 2 if if only two one LON LON cards. NPB-RS232/U Single Supports port baud RS-232 rates adapter, up to 115200. with a DB-9M connector. If If installed two 232 option in option cards, slot ports 1, port are operates COM3 as for COM3. Option slot 1 and COM4 for Option slot 2. GSM cellular modem card using GPRS (General NPB-GPRS-W-H/U Packet Radio Service), with onboard socket for SIM card, and a Wyless SIM. Installing an Option Card For option-specific details, see the Installation Instructions document that accompanies the particular option card. The following procedure provides a basic set of steps. Mounting an option card in a WEB/CP 300E or 600E controller. 1. If a station is running, stop it using the platform Application Director view. 2. Remove power from the controller—see the previ- ous Warning. 3. Remove the cover. See “Removing and Replacing the Cover” on page 4. 4. If the optional NiMH battery/bracket assembly is installed, remove it by taking out the four screws holding it in place, setting them aside for later. Two of these screws will also secure the option card, once installed. a. Unplug the battery from the connector on the controller’s base board. b. Remove the blanking plate from the option slot to be used. 5. If no optional NiMH battery/bracket assembly is installed, remove the blanking plate for the option slot to be used, retaining the two screws. NOTE: If you are also installing the optional NiMH battery/bracket assembly now, remove and retain the other two screws, that is for the other option slot. 6. Carefully insert the pins of the option card into the socket headers of the option card slot. The mount- ing holes on the option board should line up with the standoffs on the base board. If they do not, the con- nector is not properly aligned. Press until the option card is completely seated. 7. Place the custom end plate for the option card over the connector(s) of the option card. With some option cards, the card’s end plate is pre-fastened. 8. If installing (or replacing) the optional NiMH battery/ bracket assembly: Includes SMA coax tilt-and-swivel antenna. The NPB-GPRS-W-H/U model is bundled with a Wyless-provisioned SIM card. Z-Wave wireless serial gateway between the JACE’s US model is 908.42 MHz for U.S. usage. NPB-ZWAVE/U WEBs-AX Includes RP-SMA station and coax an tilt-and-swivel RF wireless Z-Wave antenna. domain. If installed in option slot 1, card operates as COM3. a. Plug the battery connector plug into the battery connector on the controller’s base board. b. Set the battery and bracket assembly over the option card slots, with the mounting holes aligned with the standoffs. c. Place the four screws through the bracket, end plates, and into the standoffs on the controller base board. With a screwdriver, hand tighten the screws. For more details, see “NiMH Battery Installation and Maintenance” on page 14. Otherwise, place the two screws through the option card end plate and into the standoffs on the base board. With a screwdriver, hand tighten the screws. 9. Replace the cover on the controller. 10. Restore power to the controller and verify normal operation. About Accessory Modules The controller has a 20-pin, right-angle, Euro-DIN connector that accepts custom-built accessory modules. The connector provides power and signal lines to any connected modules. WARNING Power to the controller must be OFF when inserting or unplugging accessory modules. Wait for all LED activity to stop (all LEDs off). Also, do not connect live voltages to the inputs or outputs of an I/O module while it is in an “un- powered state” before plugging the module into the controller. Otherwise, damage to the I/O module and/or controller may result! Each accessory module has a DIN-mount base, and typically provides two (2) 20-pin connectors that allow you to “chain” multiple accessories. Table 3 lists the currently available modules. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS Table 3. Accessory modulesa compatible with the WEB/CP 300E and WEB/CP 600E/U Series controller Option Description Notes NPB-PWR-H/U a A wall mount AC adapter (NPB-WPM-US/U) is also available; however, it is not an accessory module that mounts on the 20-pin connector of the controller. WIRING See Fig. 3 on page 5 to locate connectors and components on the controller. Make connections to the controller in the following order. 1. Install any option card (LON, RS-485, RS-232, etc.) in the available option slots. See “Installing an Option Card” on page 6 for a pro- cedure. For complete details, refer to the document that shipped with the option card. If installing the optional NiMH battery, do that after inserting option card(s). See “NiMH Battery Installa- tion and Maintenance” on page 14. 2. Connect supplied grounding wire from the earth ground lug on the controller, as well ground wire for each accessory module, to a nearby earth ground- ing point. See “Grounding” on page 7. 3. Prepare power wiring (leave unit powered off). See “Power Wiring” on page 7. 4. Connect communications cables. See “Communi- cations Wiring” on page 9 for ports on the controller. For ports on any installed option card (485-PWR, LON, RS-485, modem) see the option’s specific mounting and wiring guide for details. 5. If I/O accessory modules are installed, connect I/O wiring. Refer to the appropriate mounting and wiring guide for details. 6. Apply power to the unit. See “Initial power up and checkout.” on page 12. Grounding An earth ground spade lug (0.187") is provided on the controller base for connection to earth ground. For maximum protection from electrostatic discharge or other forms of EMI, connect the supplied earth grounding wire to this lug and a nearby earth ground. Keep this wire as short as possible, see Fig. 4 on page 8. Wire the earth ground spade lug of accessory modules in the same manner. 7 31-00010—01 DIN-mountable, 24V isolated power module, used to power the controller from a dedicated, external, Class-2, 24Vac transformer or a 24Vdc power supply. Only one NPB-PWR-H/U per controller. • Do not install if using NPB-WPM-US/U or NPB-PWR-UN-H/U. • For wiring, see “NPB-PWR-H/U” on page 8. NPB-PWR-UN-H/U DIN-mountable, Universal 120–240Vac input, 15Vdc output, 30W power supply to power the controller. Only one NPB-PWR-UN-H/U per controller. • Do not install if using NPB-WPM-US/U or NPB-PWR-H/U. • For wiring, see “NPB-PWR-UN-H/U” on page 8. IO-16-H/U DIN-mountable, 16 points I/O module, used to provide I/O points as noted. Up to four (maximum) IO-16-H/U modules are supported. Each provides these I/O points: • 8 - Universal Inputs (UIs). • 4 - Digital Outputs (DOs), SPST-relay type. • 4 - Analog Outputs (AOs), 0–10Vdc type. Wiring is covered in the IO-16-H/U Installation Instructions. IO-34-H/U DIN-mountable, combined 34 points I/O with 24V isolated power module, used to provide I/O points as well as power the controller from a dedicated, external, Class-2, 24Vac transformer or a 24Vdc power supply. Only one IO-34-H/U module per controller. This module provides these I/O points: • 16 - Universal Inputs (UIs). • 10 - Digital Outputs (DOs), SPST-relay type. • 8 - Analog Outputs (AOs), 0–10Vdc type. Wiring is covered in the IO-34-H/U Installation Instructions. Power Wiring The controller power source. must This can be powered be eitherby a DIN-mountable an approved 15 module: Vdc the NPB-PWR-H/U, a 24Vac/dc-powered module, or the NPB-PWR-UN-H/U, a line-powered 120–240Vac module. Or, an external Class 2 wall mount AC adapter (NPB- WPM-US/U) can be used for controller power. NOTE: See “Environmental Requirements” on page 3 for mains supply requirements. The controller does not include an on/off switch. To apply power, you either: • if NPB-PWR-H/U, plug in its 2-position power connector. • if NPB-PWR-UN-H/U, energize the AC circuit (120– 240 Vac) wired to that module. • if NPB-WPM-US/U, plug in the power connector to the controller. CAUTION Do not connect both the NPB-WPM-US/U and NPB-PWR-H/U / NPB-PWR-UN-H/U supplies at the same time, or equipment damage may result. Power consumption depends mainly on installed I/O modules, and may vary from: • Controller alone (with or without installed option cards): approximately 7.5 VA (AC) or 7.5 W (DC). • Controller (with or without installed option cards), plus four (4) IO-16-H/U modules: up to 20 VA (AC) or 20 W (DC). a A fourth power option is available: a IO-34-H/U acces- sory module, which is a combination of the NPB-PWR- H/U module and two IO-16-H/U modules (plus two extra relays). Refer to its mounting and wiring document for more details. For a listing of modules, see “About Acces- sory Modules” on page 6. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS If desired, you can use the wall mount NPB-WPM-US/U in your office (to initially commission the controller), and then NPB-PWR-H/U install the controller at the job using either a NPB-PWR-H/ U or NPB-PWR-UN-H/U module. The following sections provide more details: • “NPB-PWR-H/U” on page 8 (24 Vac/dc-powered in-line 31-00010—01 8 Use the NPB-PWR-H/U module to power the controller (and if installed, IO-16-H/U modules) from a dedicated Class 2, 24Vac transformer, or from a 24Vdc power supply. module) • “NPB-PWR-UN-H/U” on page 8 (Universal 120V– 240Vac-powered in-line module) • “NPB-WPM-US/U (Wall Mount AC Adapter)” on page 9 NOTE: If there is no optional NiMH backup battery, using the NPB-PWR-H/U allows a higher operating temperature. See “Environmental Requirements” on page 3. NOTE: If powering from a 24V transformer, do not power any other equipment with it. Other- wise, conducted noise problems may result. Also, do not ground either side of the trans- former’s 24V secondary. NPB-PWR-H/U (COVER REMOVED) SUPPLIED EARTH GROUNDING WIRE CONTROLLER EARTH GROUNDDEDICATED 24VAC TRANSFORMER NEITHER SIDE OF SECONDARY TIED TO EARTH GROUND Fig. 4. NPB-PWR-H/U module wiring connections. Located at the bottom of the NPB-PWR-H/U module is a 2-position power connector, and an earth ground spade lug, as shown in Fig. 4. Connect the supplied earth ground wire to a nearby earth ground point. Unplug the power connector plug from the module and make connections to it as shown. CAUTION Do not plug 24V power into the NPB-PWR-H/U (reinsert connector plug) until all other mounting and wiring is completed. See “Initial power up and checkout.” on page 12. NPB-PWR-UN-H/U The NPB-PWR-UN-H/U module lets you power the controller (and if installed, connected I/O modules) from AC line power, with a universal input range from 120– 24VDC POWER SUPPLY (POLARITY NOT CRITICAL) NEITHER SIDE TIED TO EARTH 24VAC OR 24VDC +– M34991 240Vac. If installing IO-16-H/U modules, the NPB-PWR- UN-H/U module mounts as the last (end) module in the chain. (See Fig. 1 on page 4). WARNING • A 120Vac or 240Vac circuit powers the NPB- PWR-UN-H/U. Disconnect power to this circuit before installation to prevent electrical shock or equipment damage. • Make all connections in accordance with national and local electrical codes. Use copper conductors only. • Do not exceed the 30W capacity of NPB- PWR-UN-H/U by the powered devices. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS REMOVE COVER 6-PIN CONNECTOR NOT USED L N 120 OR 240VAC 50–60 HZ SINGLE PHASE LINE SUPPLIED EARTH EARTH GROUNDING WIRE GROUND NEUTRAL NOTE: THE 6-PIN CONNECTOR ON THE NPB-PWR-UN-H/U IS NOT USED WITH A WEB-300E OR WEB-600E/U SERIES CONTROLLER. THE 6-PIN CONNECTOR IS DESIGNED FOR USE WITH OTHER CONTROLLERS OR MODULES, AND MUST BE LEFT UNUSED. M34992 Fig. 5. NPB-PWR-UN-H/U module wiring connections. Wiring NPB-PWR-UN-H/U input power and earth ground. 1. Remove power from the AC circuit being wired to the NPB-PWR-UN-H/U. See the previous Warning. 2. Remove the NPB-PWR-UN-H/U cover. To do this, press in the four tabs on both ends of the unit, and lift the cover off. If the controller or a IO-16-H/U accessory module is plugged into the unit, you may need to slide it away to get to the cover tabs. 3. Connect the supplied earth grounding wire to a nearby grounding point. See Fig. 5. 4. Make AC circuit connections line (mains) and neu- tral to the terminals labeled “INPUT PWR.” 5. Replace the cover on the NPB-PWR-UN-H/U mod- ule. Make sure all modules in the mounted assem- bly are firmly connected together and secured. CAUTION Do not energize the AC circuit wired to the NPB-PWR-UN-H/U until all other controller mounting and wiring is completed. See “Power Up and Initial Checkout” on page 12. NPB-WPM-US/U (Wall Mount AC Adapter) The NPB-WPM-US/U is a self-contained, isolated, Class 2, switching power supply designed to plug into a standard building power receptacle of appropriate voltage. 9 31-00010—01 To supply power to the controller, you simply plug the barrel connector plug from the NPB-WPM-US/U into the barrel power connector on the controller’s base board (see Fig. 3 on page 5). NOTE: The adapter’s 15W output rating is derated 50% at the 60°C (140°F) maximum ambient temperature (for a controller without a NiMH battery), such that no I/O modules are sup- ported at 60°C. See “Environmental Require- ments” on page 3. CAUTION Do not plug the barrel connect plug from the NPB-WPM-US/U into the controller until all other mounting and wiring is completed. See “Initial power up and checkout.” on page 12. Communications Wiring Communications ports are on the controller’s bottom side, which include: • Ethernet • Serial NOTE: Prior to connecting cables, provide strain relief for them to prevent damage to the controller. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS SECONDARY ETHERNET (RJ-45) PRIMARY ETHERNET (RJ-45) OPTIONAL NIMH BATTERY LAN 2 LAN 1 AND BRACKET ASSEMBLY, IF INSTALLED, MOUNTS ON TOP OF THE OPTION SLOT AREA. OPTION 20-PIN SLOT AREA (SLOT #1 THIS SIDE) RS-485 (3-POS.) COM2 31-00010—01 10 CONNECTOR (I/O AND POWER MODULES) EARTH GROUND SPADE LUG RS-232 BARREL POWER (DB-9) CONNECTOR FOR COM1 WPM-XXX (WALL MOUNT AC ADAPTER) M34993 Fig. 6. WEB/CP 300E or WEB/CP 600E/U controller bottom side (cover removed). Ethernet Two, female 10/100-Mbit Ethernet connections are provided on the controller. These RJ-45 connectors are labeled LAN1 (PRI) and LAN2 (SEC). Use a standard Ethernet patch cable for connecting to a hub or Ethernet switch. The factory-default IP address for LAN1 is 192.168.1.12n, where the last numeral n in the address matches the last digit in the controller’s serial number, and the subnet mask is 255.255.255.0. By default, LAN2 is disabled. NOTE: Typically, you only use LAN1 (primary port), unless you have a specific application for the other LAN2 port. For example, isolating a driver’s network traffic, using LAN2. Do not use LAN2 as the primary port. If enabling LAN2, note that LAN1 and LAN2 must be connected to different subnets. Further, a controller does not provide IP routing or bridg- ing operation between the two LAN ports. Refer to the JACE WEBs-AX Install and Startup Guide for details on changing IP address using the platform Commissioning Wizard (TCP/IP configuration step). Serial There are two “RS” serial ports on the controller’s base board. Each has a UART capable of operation up to 115,200 baud. At the bottom of the board (see Fig. 6) is Base RS-232 DB-9 Port (COM1) RS-485 Port (COM2) Pinout Reference Signal DB-9 Pinouts DB-9 Plug (male) DCD Data carrier detect 1 3-Position connector (male) S + – an RS-232 port using an DB-9 plug (male) connector. To the right of this is a two-wire plus shield RS-485 port, using a 3-position screw-terminal connector plug. NOTE: A green “receive” LED and yellow “transmit” LED are provided for both serial ports. These LEDs are on the controller’s bottom board, on the side opposite to the serial connectors (see Fig. 3 on page 5). These LEDs are labeled on the board (COM1, COM2) and are not visible with the cover on. RS-232 An RS-232 serial port using a male DB-9 connector always operates as COM1. You can use standard DB-9 serial cables with this port. The controller is a serial DTE device, such that another DTE device (PC, for example) requires a “null modem” cable. If connecting to a DCE device such as a modem, use a straight-through cable. Table 4 provides standard serial DB-9 pinouts. NOTE: If rebooted with the mode jumper in the “Serial Shell” position (see Fig. 3 on page 5), the RS-232 port provides “system shell” access. See the JACE WEBs-AX Install and Startup Guide for related details. Table 4. Base serial port (RS-232 and RS-485) pinouts. RXD Receive data 2 TXD Transmit data 3 DTR Data terminal ready 4 GND Ground 5 DSR Data set ready 6 RTS Request to send 7 CTS Clear to send 8 not used on the controller 9 RS-485 An RS-485 port uses a 3-position, screw terminal connector, and always operates as COM2. As shown in the Table 4 pinouts, from left-to-right the screw terminals are shield (S), plus (+), and minus (–). Wire in a continuous multidrop fashion to other RS-485 devices, meaning “minus to minus”, “plus to plus,” and “shield to shield.” Connect the shield to earth ground at one end only, such as at the controller. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS RS-485 Biasing — RS-485 bias resistors are different than “ter- mination resistors”, externally installed at the The RS-485 port on the controller’s base board has a pair two physical ends of a daisy-chained RS-485 of two-pin jumpers that can be shorted with jumper blocks trunk, across the “+” and “–” terminals. Termi- to provide “biasing”. As shipped from the factory, these nation resistors are typically 100 or 120 ohm pins are not shorted, thus the RS-485 port is unbiased. value resistors. NOTE: See “Need for RS-485 Bias” before following the “Adding RS-485 Bias” procedure. In — Whenever termination resistors are used, RS-485 biasing is typically required. many cases, the default unbiased RS-485 port is preferred. Adding RS-485 Bias To add biasing, you must power off the controller and Need for RS-485 Bias remove a few assemblies (such as metal shield and NPM3E or NPM6E processor module) to access the base board NOTE: A full discussion of communication line ter- mination is beyond the scope of this docu- ment. jumper pins, located behind the RS-485 port. Then you must reposition the two shorting blocks on these jumper pins. Then you reassemble the unit by remounting the processor module, hex standoffs, metal shield, and shield screws. Biasing sometimes improves RS-485 communications by eliminating “indeterminate” idle states. When you install two, 2-pin shorting blocks on the controller’s RS-485 bias jumper pins, this adds two onboard 3.3K ohm resistors into the controller’s RS-485 circuit, as follows: • from RS-485 “+” to 5V. • from RS-485 “-” to Ground. WARNING Remove all power from the controller before working on the unit. Observe static discharge precautions. See the “Static Discharge Precautions” section. NOTES:— In general, only one device on an RS-485 trunk should be biased. Otherwise, undue loading of the circuit may result, with fewer If the controller is already installed or mounted, it is recommended that you remove it first. Then work on a flat, stable, well-lit work surface. devices supported. Fig. 7. Basic stages of controller disassembly. Disassembling the controller. 1. Remove all power from the controller. (See previous Warning). 2. Remove the plastic cover. See “Removing and Replacing the Cover” on page 4. 11 31-00010—01 1 COVER REMOVED, PHILLIPS HEAD REVEALS METAL SHIELD SCREWS 2 METAL SHIELD LIFTED AWAY NPM3E OR NPM6E METAL PROCESSOR STANDOFFS MODULE BOARD 3 PROCESSOR MODULE LIFTED AWAY JUMPER BLOCK FOR RS-485 BIASING M34995 3. Remove the four Phillips head screws that secure the metal shield, and set them aside. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS
4. Remove the metal shield and set it aside. To do this, carefully pry up from the top (hole vented side) first, then push out the other side to slip the port holes past the port edges. Then lift the shield up and away. NOTE: Be mindful of the “side clips” on the control- ler’s two Ethernet ports. 31-00010—01 12 5. Use a 1/4 in. (7 mm) nutdriver to unscrew the four metal standoffs, and set them aside. 6. Carefully pry up the NPM3E or NPM6E processor module board, noting that the two-row, 50-pin con- nector is on the option card side. Keep the board level as you work it loose from this connector. 7. Set the processor module board aside. Note the jumper block on the base board behind the RS-485 port (see bottom of Fig. 7). SHORTING BLOCKS POSITION OF PRE-INSTALLED LIFTED AWAY SHORTING BLOCKS (NO BIASING) M34996 SHORTING BLOCKS INSTALLED ACROSS JUMPER PINS (BIASING ADDED)
Fig. 8. Install shorting blocks across both sides of jumper block to add RS-485 bias.
Installing shorting blocks to add RS-485 biasing. 1. Locate the four jumper pins behind the RS-485 port, with 2-pin shorting blocks installed on one pin each. See Fig. 8. 2. To add biasing, remove and replace both shorting blocks back onto the jumper pins, as shown in Fig. 8. Reassembling the controller. 1. Carefully replace the processor module board onto the 50-pin connector, with its corner mounting holes aligned on the four lower standoffs. Press down on the connector to fully seat the board. See Fig. 7 on page 11. 2. Refasten the four metal hex standoffs, hand tighten- ing with a 1/4 in. (7 mm) nutdriver. 3. Replace the shield back onto the unit. To do this, carefully ease it over the port side first, then spring it down over the other side. Make sure that its corner holes align with the metal standoffs below. 4. Refasten the four Phillips head screws that secure the shield to the standoffs. 5. Replace the plastic cover onto the unit. POWER UP AND INITIAL CHECKOUT Ensure power wiring to the controller is ready—see “Power Wiring” on page 7. See Fig. 3 page 4 for the location of status LEDs and connectors. See Fig. 4 on page page 8 for the location of the NPB-PWR-H/U module’s power connector. After completing all mounting and wiring, do the following: Initial power up and checkout. 1. Apply Power. 2. Check the Status LED. Also see the section “About Backup Configurations” on page 13. Apply Power To apply power, insert the power plug into either the NPB- PWR-H/U module, or if using a NPB-WPM-US/U wall adapter, the controller. If using the line-voltage input NPB- PWR-UN-H/U power supply module, energize the 120– 240Vac circuit wired to the module. CAUTION Do not connect both the NPB-WPM-US/U and NPB-PWR-H/U / NPB-PWR-UN-H/U supplies at the same time, or equipment damage may result. Check the Status LED When power is applied, the green LED labeled “STATUS” will light. This indicates that the system is OK, with power applied. When the controller finishes booting, the yellow “BEAT” LED should be blinking steady at a 50% duty cycle, typically at a 1Hz rate. In most cases, this blink pattern starts about 30 seconds after power is applied. If after applying power, the STATUS LED goes out, or if the BEAT LED comes on (steady) and stays lit over 2 minutes, seek technical assistance. See the section “LED Status Indicators” on page 13, especially “Heartbeat”.
WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS ABOUT BACKUP NiMH battery pack CONFIGURATIONS A custom 10-cell NiMH (nickel metal hydride) battery assembly is available as a separately orderable option for A 300E or 600E series controller allows two separate and configurable methods to preserve unsaved station data when "power quality events" occur, including loss of primary power or low-voltage dips (brownout): a 300E or 600E series controller. This battery assembly incudes a metal bracket with the tie-wrapped NiMH battery pack. It is the same battery assembly installed in the previous 201 and 600 series controllers. • Using the integral static RAM (SRAM) on the controller’s NPM3E or NPM6E processor module. This default method can allow the unit to operate “battery- less”, that is, without installing the optional NiMH battery pack. Note in this configuration a controller reboot is likely to occur whenever a power outage or voltage dip is sustained for more than one AC line cycle (1/50th or 1/60th of a second) or a number of line This battery allows the controller to continue station operation through short power bumps, ranging from a few seconds to a minute or more in duration (up to 10 minutes, if also using SRAM). If a longer outage, the NiMH battery provides enough run time for the unit to backup data and then shutdown. Shutdown occurs automatically, after data is backed up to on-board flash memory. cycles, depending on the load and power supply. Critical station data will already be saved prior to any power quality event, but the NiMH battery option is available to prevent nuisance controller reboots/station restarts during extended or frequent power outages. • An optional on-board NiMH battery pack. Installing this battery allows the controller to continue operation (without rebooting) over short power outages or brownouts lasting several seconds (or if also using SRAM, up to 10 minutes). For longer duration outages, The controller charges the battery during normal operation, until fully charged. Typically, the charge operation completes within 18 hours. Following a power outage, the battery is charged again, as necessary. The power and battery circuitry is monitored by a station running on the JACE (via its PowerMonitorService). Station alarms are generated whenever primary power is lost, or if the battery is uncharged or unable to hold a sufficient charge. the battery allows the controller to perform a NOTE: A NiMH battery characteristic is to lose “controlled shutdown”, safely backing up the station charge if not left in charge mode (trickle before shutting down. charge). Leaving the battery unconnected, or in the unit powered off will cause the battery Starting in the WEBs-AX 3.6.47 maintenance build, the to fully discharge in a matter of weeks. Note controller can use both the NiMH backup battery and that a new NiMH battery may be partially dis- available SRAM for backup protection (prior to this, SRAM charged. Therefore, allow at least 18 hours support required removing backup batteries). Configuring for a new battery to charge if it has not been for both backup battery and SRAM support provides the in a powered unit. most comprehensive backup protection. This allows the controller to “ride out” brief power outages, while also The NiMH battery assembly should be replaced protecting against a scenario of a battery too weak (or approximately every three years, or more often if the unit aged) to perform a controlled shutdown. is in a high temperature environment. For more details, see “NiMH Battery Installation and Maintenance” on SRAM page 14. The controller’s NPM3E or NPM6E processor module includes on-board SRAM and associated circuitry, LED STATUS INDICATORS allowing “battery-less” operation. This is the same circuitry as provided by the “SRAM option card” for earlier The controller includes several LEDs that can help QNX-based controller models, available since the initial determine the status of the unit. They are located in two release of WEBs-AX 3.6.47. Therefore, an SRAM option places: the top of the controller, visible through the cover, card is not needed (or supported) in a 300E or 600E and for serial ports, on the bottom board (only with cover series controller. removed). The default configuration is to use SRAM for station From left-to-right these LEDs include: backup, via the platform “DataRecoveryService” that is automatically created in the controller’s running station. However, in some cases, a station may be a poor candidate for SRAM support, requiring too many resources by this associated platform service. An Visible on cover: • Ethernet Ports • Heartbeat • Status example is a station with many rapidly changing values all captured as histories, on COV. In this case, you may wish to disable SRAM support, and install and use only the Bottom board only: • Serial Ports optional NiMH battery pack. For an overview, see “About Backup Configurations” on page 13. Complete WEBs-AX details on the operation of SERIAL PORT LEDS ON BOTTOM BOARD, REMOVE COVER TO SEE: COM 1 COM 2 STATUS LEDS (VISIBLE WITH COVER ON): LAN2 LAN1 (SEC) (PRI) BEAT STATUS the controller’s integral SRAM are in the JACE Data Recovery Service (SRAM support) - Engineering Notes document. M34997 LED Status Indicators. 13 31-00010—01
WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS
Ethernet Ports Each Ethernet port has a green LED, labeled on the top cover “LAN2” (or “SEC”), and “LAN1” (or “PRI”). The LED indicates activity on that LAN2 (secondary) port or LAN1 (primary) port as follows: • Off — No Ethernet link is made. • On — Ethernet link is present, but no activity on the LAN. • Blinking — Ethernet link is present with data activity on the LAN. Heartbeat A yellow heartbeat “BEAT” LED is next to the Ethernet LEDs, also visible on the cover. In normal operation, this LED blinks at 1 Hz, at 50%/50% on/off duty cycle. During controller bootup, this LED blinks at 1 Hz with a 90%/10% on/off duty cycle on any controller running WEBs-AX-3.7 update 1 (build 3.7.106) or later. When bootup completes, the platform daemon is started, and the normal (50%/50%) duty cycle heartbeat flash pattern returns.CAUTION This same 90%/10% on/off “BEAT” flash occurs during critical operations, such as any firmware upgrade (in progress) to the controller and/or any attached I/O modules. To be safe, do not remove power from the controller while its “BEAT” LED flashes with a 90%/10% on/off duty cycle. Wait for the normal (50%/50%) flash to return before removing power. If the “BEAT” LED stays on constantly, does not light, or blinks very fast—more than 1Hz (once per second), seek technical support. Status The green “STATUS” LED is next to the heartbeat LED, and is visible on the cover. This LED provide a CPU machine status check, and should remain lit whenever the controller is powered. If the status LED does not light while power is applied, seek technical support. Serial Ports LEDs for the two serial ports are located on the controller’s bottom board, on the opposite side of the RS- 232 and RS-485 ports. Labels “COM1” and “COM2” 31-00010—01 14 correspond to the software configuration of the COM ports. LEDs show the transmit and receive activity for the serial ports and optional modem. NOTE: You must remove the cover to see these LEDs. See “Removing and Replacing the Cover” on page 4. • The yellow transmit LED indicates that the controller is sending data out the serial port over a communications line to a connected device. • The green receive LED indicates that the controller is receiving data from a connected device. Serial port LEDs provide a fixed on-time when data is detected on the port. If the receive LED is on constantly, this indicates a problem with the communications channel, such as a shorted wire or reversed wiring. MAINTAINING THE CONTROLLER This section provides information on the following topics: • Cleaning • NiMH Battery Installation and Maintenance (optional) • Replacement Parts • Replacing the Controller Base Assembly • Returning a Defective Unit Cleaning If dust or metal filings are present inside the unit, clean with vacuum or compressed air. Otherwise, no cleaning inside the unit is required. Optionally, if the cover becomes dirty, you can wipe it with a damp cloth and mild detergent. NiMH Battery Installation and Maintenance • Installing or replacing the optional NiMH battery • Battery maintenance • Battery disposal INSTALLING OR REPLACING THE OPTIONAL NIMH BATTERY The optional NiMH battery pack is sold as an assembly, that is a custom battery pack with an attached cable and connector plug, mounted on a bracket. To install (or replace) the battery, you must remove power to the controller and remove its cover. Then you mount the battery assembly on top of the option card area (Fig. 9). INSTALLED NiMH BATTERY ASSEMBLY NiMH BATTERY PLUGGED INTO CONNECTOR ON CONTROLLER MOUNTING SCREWS (4) OPTIONAL NiMH BATTERY ASSEMBLY (NPB-BATTERY/U) BRACKET PART OF ASSEMBLY CONTROLLER WITH COVER REMOVED NiMH BATTERY CONNECTOR ON CONTROLLER BOARD M34988
Fig. 9. Optional NiMH battery pack in WEB/CP-300E or WEB/CP-600E/U controller.
CAUTION Use only NiMH battery packs approved for use with the controller. Installing/replacing WEB/CP-300E or WEB/CP-600E/U series controller NiMH battery assembly. 1. If replacing an existing battery in a controller not currently configured for SRAM usage, backup the controller’s configuration to your PC using the appropriate WEBs-AX software tool (for example, Workbench). 2. If a station is running, stop it using the platform Application Director view. 3. Remove all power from the controller. Wait for all LED activity to stop (if a battery is already installed, this may take a minute or two). 4. Remove the cover. See “Removing and Replacing the Cover” on page 4. Note the Option Slot area where the NiMH battery assembly mounts. 5. If a battery assembly is already mounted, unplug the battery from the connector on the controller board (see Fig. 9). 6. Remove the four screws that secure both option slot end plates (and if installed, the existing battery assembly bracket). Set the screws aside. Remove any existing battery assembly (if applica- ble). 7. Plug the battery connector plug of the new battery assembly into the battery connector on the control- ler (see Fig. 9). 8. Set the new NiMH battery assembly on top of the option card slots, over the option card end plates. Ensure the bracket mounting holes are aligned with the standoffs. 9. Place the four screws through the battery bracket, option card end plates, and into the standoffs on the controller’s base board. Using a screwdriver, hand tighten these screws. 10. Replace the cover. 11. Restore power to the controller and verify normal operation. Battery maintenance Battery life expectancy is a function of its discharge cycles (the number of discharges and their depth) and the ambient temperature of the battery during normal operation. In most applications, the NiMH battery should see relatively few discharges. Therefore, ambient temperature has more to do with the life expectancy of the battery than does any other factor. If the controller is installed in a conditioned space, this battery should provide dependable service for approximately three years (average). In an environment where the operating temperature reaches the highest range (50 oC or 122 oF), you should only expect the battery to last around one year. A new NiMH battery is typically only partially charged when shipped. Additionally, NiMH batteries lose charge over time if not kept trickle-charged (for more details, see “NiMH battery pack” on page 13). Therefore, even a new or replacement battery will require up to 18 hours of powered operation before it can provide reliable backup power (is at full charge). The controller monitors the NiMH battery and periodically loads the battery to test its ability to maintain battery- backed functions. Investigate any battery trouble message, and check the battery connections to the unit. Replace the battery as required. To order a new battery, see “Standard Replacement Parts” on page 16. Battery disposal Please dispose of the used NiMH battery in accordance with local, state, and federal regulations.
WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS 15 31-00010—01 WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS WARNING Non-replaceable Do not incinerate or mutilate the battery, as this may cause it to burst or release toxic materials. 31-00010—01 16 Parts Other than the parts listed in the replacement parts sections, there are no serviceable components on the base assembly. MEMORY If regulations specify returning the old battery to a recycling center, but no acceptable recycling center can be found, please return the old NiMH battery pack to Any addition, modification, or replacement of memory components requires software configuration and is not a field upgrade. Tridium for proper disposal. FUSE The controller contains a non-user replaceable fuse, REPLACEMENT PARTS soldered on the circuit board. This fuse provides protection from internal shorts or connection to incorrect power supplies. If the fuse circuitry is suspect, seek Servicing the controller may call for replacement parts. technical support. See “Returning a Defective Unit” on There are three categories of parts: page 17. • Non-replaceable Parts • Standard Replacement Parts Standard Replacement Parts • New Replacement Unit Standard replacement parts are listed in Table 5, and can be ordered from stock without restriction. Standard replacement parts cannot be returned for credit and should be disposed of in an appropriate manner. Table 5. Standard replacement parts for a WEB/CP 300E or WEB/CP 600E controller. Part Number Description NPB-BATTERY/U Optional NiMH Battery Pack—see “NiMH Battery Installation and Maintenance” on page 14 H10027/U RS-485 connector plug, 3-position. New Replacement Unit To replace an entire unit, order and install a new WEB/ CP-300E or WEB/CP-600E/U controller. If the faulty controller is still in warranty, you can receive credit by returning it. Be sure to contact the vendor for a return authorization (RA) number before shipping an item for return credit. See “Returning a Defective Unit” on page 17, for more details. NOTE: Before ordering a new controller, it is strongly recommended that you contact your normal technical support resource to elimi- nate the possibility of a software issue or mis-configuration problem. Replacing the Controller Base Assembly NOTE: Before handling circuit boards, discharge any accumulated static by touching a nearby earth ground. For details, see the “Static Dis- charge Precautions” section on page 6. To replace a controller with a new replacement unit, proceed as follows: REPLACING A WEB/CP-300E OR WEB/CP-600E/U CONTROLLER. 1. If possible, use the appropriate WEBs-AX software tool to back up the controller’s configuration to your PC. 2. Remove power to the controller. The unit should power down automatically. Wait for all LEDs to remain off. NOTE: If IO accessory modules are installed, and any I/O points have voltage, turn the devices off or disconnect power to them. 3. Note positions of all communications and other wir- ing cables going to the controller, as well as installed accessory modules (if they must be removed). If necessary, label connectors and accessory modules to avoid mis-connection later, after the controller is replaced. 4. Unplug all Ethernet, serial, LON, modem, and I/O connectors from the controller. 5. If IO accessory modules are installed: a. If DIN rail mounting with DIN end-clips was used, you may be able to remove the DIN rail end clip that secures the 600E controller end of the assembly, and then slide the controller away from the rest of the assembly. Then you can remove the controller from the DIN rail (see Fig. 1 on page 4), leaving the mounting and wiring of IO modules untouched. In this case, after removing the controller from the DIN rail, go to Step 6. b. If tab (screw) mounting was used instead of DIN rail mounting, or if a combination of DIN mount- ing and tab screws was used (into the control- ler’s “accessory side” tab holes, see last page), you will need to remove accessory modules first, before removing the controller. In this case: (1) Making a careful note of all wiring termina- tions, unplug the I/O connector plugs and earth ground wires from the installed IO modules. (2) Remove the installed accessory modules, starting with the end module. (3) Remove any screws fastening the controller, and remove it (see Fig. 1). 6. Remove the cover of the old unit. See See “Remov- ing and Replacing the Cover” on page 4. Note the position of installed option cards, if any. You must transfer them to the replacement controller. 7. Remove any option cards from the old controller and install them into the replacement controller, if applicable. See See “Installing an Option Card” on page 6. for more details. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS 8. Check the RS-485 biasing jumpers on the existing Prior to returning the unit, contact your vendor to obtain a unit, and duplicate on the replacement unit (See return materials authorization (RMA) number and other “Disassembling the controller.” on page 11.) instructions. 9. Mount the replacement controller as it was previ- ously, using the same DIN rail location and/or Please provide: screws. • Product model 10. Reconnect/remount any removed accessory mod- • Serial number ules, being careful to replace in the same order, • Nature of the defect using the same DIN rail location and/or screws. • PO number to secure the RMA Secure all modules as done previously. 11. Reconnect the earth ground wire to the controller’s grounding lug and any installed accessory modules. CERTIFICATIONS 12. Reconnect any Ethernet, serial, modem, and I/O connectors. 13. If using IO modules, and any of your I/O points have voltage, turn the devices back on, or reconnect power to them. 17 31-00010—01 The WEB/CP-300E and WEB/CP-600E/U controller each has the following agency listings, compliances, and certifications: 14. Replace the cover. See “Removing and Replacing • UL 916 - Underwriters Laboratories, Energy the Cover” on page 4. Management Device, CAN/CSA C22.2 Canadian 15. Restore power to the unit. It should boot up as a Safety Standards new unit (See “Check the Status LED” on page 12.). • FCC Part 15, Class B - Federal Communications 16. Using the WEBs-AX platform tools, re-commission Commission the controller, and install the saved station data- • ICES-003, Class B - Industry Canada Interference- base. For more details, see the JACE WEBs-AX Causing Equipment Standard Install and Startup Guide. • EU 202/95/EC RoHS (Restriction of Hazardous Substances) Returning a Defective Unit • CE Declaration of Conformity (Council Directive 004- 108-EC) For proper credit on an in-warranty unit, ship the defective For complete details on listings and compliances for these unit per the vendor’s return material procedures. controllers, refer to the document Agency Listings and Approvals for Tridium Hardware Products. NOTE: If the defective unit is under warranty, please follow return instructions provided in this section. If the unit is out of warranty, please discard TAB MOUNTING DIMENSIONS any replaced part. Do not return an out-of- warranty controller. Measurements are in inches and (mm). Note that DIN mounting is recommended over tab mounting. See Fig. 1 on page 4. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS 6-23/32 (171) 11/64 DIA. (4) WEB-300E OR WEB-600E/U 3-3/4 (95) 2-1/2 (64) NOTE: ELECTRONIC AND PRINTED VERSIONS OF THIS DOCUMENT MAY NOT SHOW DIMENSIONS TO SCALE. VERIFY ALL MEASUREMENTS BEFORE DRILLING. DIN MOUNTING IS RECOMMENDED OVER TAB MOUNTING. SEE FIGURE 1. NPB-PWR-H/U NPB-PWR-UN-H/U, OR IO-16-H/U DISTANCE BETWEEN CENTER OF TABS FROM ONE UNIT TO 2-1/2 ANOTHER UNIT. (64) NOTE: IF MOUNTING ACCESSORY MODULES, FUTURE REMOVAL/REPLACEMENT OF THE CONTROLLER IS SIMPLIFIED IF YOU DO NOT INSTALL SCREWS IN THE “ACCESSORY MODULE SIDE” TABS OF THE CONTROLLER (SEE ABOVE). 31-00010—01 18 4 (102) WEB-600E/U IO-16-H/U OR IO-16-H/U NPB-PWR-H/U ACCESSORY MODULE SIDE TABS 6-23/32 (171) 3-1/4 3-1/4 (83) (83) 3-31/64 (89) M35000 Fig. 10. Tab mounting. WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS 19 31-00010—01 WEB-300E, WEB-600E/U, CP-300E, CP-600E/U SERIES CONTROLLERS
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