WEB-603 and CP-603 Network Controllers
Contents
1. SEC LAN2 g LAN1 PRI SEC 0 BEAT j STATUS O LAN1 PRI Ethernet Each 10 100Mb Ethernet port LAN2 Secondary and LAN1 Primary has one green LED on the NPM6E module LED activity for an Ethernet port is as follows e Off No Ethernet link is made e On Ethernet link is present but no activity on the LAN e Blinking Ethernet link is present with data activity on the LAN NOTE The LAN2 Secondary Ethernet port in not supported in WEB R2 BEAT Heartbeat In normal operation the yellow BEAT LED should blink about once per second If the heartbeat LED stays on constantly does not light or blinks very fast more than once per second contact System Engineering for technical support CAUTION During the boot up of a WEB 603 AX immediately following a core software upgrade its heartbeat LED may blink in a 90 on 10 off pattern Do not remove power during this period or data loss may result 1 O firmware upgrade may be in progress STATUS The STATUS LED provides 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 contact System Engineering for technical support 62 0431 01 LEDs on main circuit board The WEB 603 AX s main circuit board has LEDs for LON and Serial ports and Relay Output Status LEDs LON Two LEDs are located near the LON port and show tra2. 603 AX s cover door is removable A knurled edge slotted head screw secures the door closed NOTE For a more secure installation use a padlock in the security tab that protrudes through the door Remove or replace the enclosure door Removing the enclosure door allows more light inside the unit and makes mounting and wiring easier 1 Loosen the cover screw and open the enclosure door about half way 2 Ifthe grounding wire near the bottom is fastened to the screw post on the inside of the door use a 1 4 6mm nut driver to unfasten it from the door 1 Screw post on inside of enclosure door 2 Green grounding wire with eyelet 3 1 4 Keps nut to secure grounding wire to post NOTE Set the nut aside to reuse later 3 Slide the door towards the top of the unit until the hinge tabs on the door clear the hinge slots on the enclosure 4 Lift the door away from the unit When installation is finished replace the door and grounding wire in the reverse fashion Enclosure knockouts and mounting Mounting the controller notes 1 With the controller s enclosure door opened or removed position the controller on the wall in the location where The WEB 603 AX s enclosure has seven 1 2 13mm you are installing it knockouts one on top for AC line power two on the left side 2 Make sure that the location provides the necessary typically used for comm cabling and four on the bottom minimum clearances around
3. battery backed functions You should investigate any battery trouble message Check the voltage level and its connections to the unit Replace the battery as required To order a new battery see the Standard Replacement Parts section on page 18 Replacing the 12V battery The battery is secured in the enclosure by a metal bracket and a nut Fig 11 Fig 11 12V sealed lead acid battery in WEB 603 AX enclosure 62 0431 01 16 Table 6 WEB 603 AND CP 603 NETWORK CONTROLLERS Item Description 6 position power connector unplug when replacing battery Enclosure mounting stud and Keps nut securing battery strap Metal battery bracket bottom hooks into slot in enclosure bottom Quick connect Faston battery terminals ol AJ O N terminals 12V 1 2Ah sealed lead acid battery with 0 187 Faston quick connect A WARNING When replacing the battery or harness maintain proper polarity as marked on the label inside the unit Although the controller is fully protected against shorted battery terminals the battery itself is not internally protected Use extreme care to not short circuit the battery A shorted battery may overheat rapidly and damage the power wiring harness or cause other physical harm to the hardware To replace the battery follow the steps in Replacing the 12V sealed
4. lead acid backup battery Replacing the 12V sealed lead acid backup battery 1 If applicable backup the controller s configuration to your PC using platform tools in WEBs AX Workbench 2 Stop any running station using the Application Director platform view 3 Unplug the 6 position power connector Do not remove the male connector plug from the wiring harness 4 Use a 1 4 6mm socket unscrew the lock nut from the battery bracket 5 Hold the battery in place while you remove the battery bracket 6 Disconnect the two quick connect terminals on the battery 7 8 The controller will lose its time and date settings if it is disconnected from both battery and AC power for more than one hour 9 10 Remove the old battery and recycle as defined by your regional codes For recycling within the US see the labeling on the battery 11 Connect the quick connect terminals to the new battery ensuring that the 12 RED wire is connected to the positive battery terminal 13 BLACK wire is connected to the negative battery terminal 14 Secure the new battery to the bottom of the unit with the bracket and tighten the lock nut 15 Plug in the power connector in and verify normal operation Battery less option A unit running WEBs AX not WEB R2 can be software configured to operate battery less using only the onboard SRAM of the NPM6E processor module to maintain data in a power loss or brownout event
5. object Input accuracy is in the range of 1 of span Fig 3 shows the wiring diagram Fig 3 Thermistor wiring UM G Ul2 UB G Ul4 10K Thermistor Shielded Twisted Cable 61m 200 ft maximum J O Stud in enclosure Shiel NOTE Ulinputs are optimized to provide the best resolution around the 10K ohm range For a sensor with a range far from 10K ohms such as a 100 ohm or 1000 ohm type resolution will be poor To use such a sensor it is recommended you install a transmitter that produces a Vdc or mA signal and then wire the transmitter to the UI according to the 0 10 Vdc or 4 20 mA instructions Resistive Inputs support resistance inputs with a range of 0 100K ohms Input accuracy is within 1 of input span range Fig 4 shows the wiring diagram Fig 4 Resistive wiring UM G Ul2 UB G Ul4 DODODO Resistance Range 0 100K ohms Shielded Twisted Cable 61m 200 ft maximum Stud in enclosure 62 0431 01 10 0 10 Vdc WEB 603 AND CP 603 NETWORK CONTROLLERS Inputs support self powered 0 10 Vdc sensors Input impedance must be greater than 5K ohms 0 10 volt accuracy is 2 of span without user calibration Fig 5 shows the wiring diagram Fig 5 0 10 Vdc wiring Un G Ul2 Ul3 G Ul4 DODODO 0 10Vdc Sensor self powered sensor 0 10 Vdc Shielded Twisted Cable T 61m 200 ft maximum Shield Range 0 10 Vdc Input Imped
6. the controllers TCP IP configuration 62 0431 01 Serial There are two serial ports on the WEB 603 AX controller see Fig 2 on page 6 The top serial port is an RS 232 port using an RJ 45 connector Below this is a two wire with shield non isolated RS 485 port RS 485 The controller s RS 485 port uses a 3 position connector with screw terminals from top to bottom shield plus and minus Use shielded twisted pair cabling wired 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 Follow the field device manufacturers recommendations regarding cable type gauge maximum number of devices and maximum cable lengths RS 232 One RS 232 serial port uses a female socket RJ 45 connector Wire using an 8 conductor flat silver satin stranded cable with standard male plug RJ 45 connectors Connect the flat satin cable maximum distance 50 feet through the enclosure knockout nearest the port This straight through cable is then connected to a socket to socket type RJ 45 to DB 9 adapter The controller is a serial DTE device such that another DTE device for example PC requires a null modem adapter part number 10148 optional item If connecting the controller to a DCE device for example modem use a straight through adapter Table 4
7. 6 for the locations of the power connector and status LEDs on the controller Checking the Heartbeat LED Verify the STATUS LED on the NPM6E processor module is lit green This indicates that the system is OK and that power is applied Once the controller boots the adjacent yellow BEAT heartbeat LED begins blinking with a typical rate of about 1 Hz Blinking should begin within 30 seconds after power is applied AN CAUTION During the boot up of a WEB 603 AX immediately following a core software upgrade its heartbeat LED may blink in a 90 on 10 off pattern Do not remove power during this period or data loss may result I O firmware upgrade may be in progress If after applying power the STATUS LED goes out or if the BEAT LED comes on steady and stays lit longer than 2 minutes contact Systems Engineering for technical assistance Also see BEAT page 14 About the Battery The WEB 603 AX controller is provided with a sealed lead acid 12V battery If battery trouble messages are generated upon power up contact Systems Engineering for technical support NOTE As shipped the backup battery in a new WEB 603 AX controller not fully charged Allow 24 hours of powered operation before relying on the battery to preserve station data on loss of power For more information on the use and replacement of the battery refer to the Required Battery Maintenance section on page 16 Commissioning Notes To commi
8. 603 AX controller either model WEB 603 AX U S or WEB 603I AX International e a hardware bag containing the following items 499 ohm resistors quantity 6 6 position I O screw terminal connector plugs quantity 4 3 position RS 485 screw terminal connector plug quantity 1 2 position LON screw terminal connector plug quantity 1 if a WEB 603 AX wire nuts quantity 2 This NETWORK CONTROLLER 603 Mounting and Wiring Guide document e Optional items if ordered RJ 45 to DB 9 adapter for the RS 232 port Silver satin patch cable used between the adapter and serial port Material and Tools Required The following supplies and tools are used for installation 1 4 6mm nut driver used to remove the transformer shield and also the enclosure door grounding wire If installing an option card WEB AX units only a 2 Phillips screwdriver e Small flat blade screwdriver used for I O LON and RS 485 connectors Also for power terminals if a WEB 6031 AX International model e Suitable tools fasteners and supplies for mounting the controllers metal enclosure and also for fastening electrical conduit NOTE If removing or installing the circuit board from the enclosure a 1 4 inch thin walled socket is recommended do not use a nut driver See Replacing the WEB 603 AX circuit board page 18 62 0431 01 PRECAUTIONS This document uses the following warning and caution conven
9. 78 Kbps Refer to the LonWorks FTT 10A Free Topology Transceiver User s Guide 078 0156 01F for technical guidelines associated with free topology restrictions and the Junction Box and Wiring Guidelines for Twisted Pair LonWorks Networks 005 0023 01 for more detailed information on wiring specifications These documents are available on Echelon s web site www echelon com I O WIRING The WEB 603 AX provides six 6 universal Inputs supporting analog inputs temperature resistance voltage and current and digital inputs contact closure pulse count as well as four 4 form C SPDT relay Outputs See Fig 2 on page 6 for the location of these inputs and outputs NOTE For proper operation each input or output used requires a special WEBs Direct Input Output Ndio object to be properly configured in the station database These objects act as the station interface to the physical I O points For details please refer to the appropriate WEBs software configuration document IfWEB AX the WEB AX NDIO Guide IfWEB R2 x the WEBs Standard Programming Reference 9 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS Inputs Each of the 6 universal inputs can support any one of the following e Thermistor Type 3 10K Resistive 0 10 Vdc 4 20 mA Binary Input Thermistor The inputs support Type 3 10K Thermistor temperature sensors with a sensor range of 10 to 135 F 23 3 to 57 2 C using the appropriate WEBs
10. Electrical and Electronic Equipment on page 3 19 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS 250 mm Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 customer honeywell com 9 84 or 97 0 218 1 5 54 mm 0 438 11 1 mm 0 406 10 3 mm 5 94 or 5 151 mm Honeywell U S Registered Trademark 2012 Honeywell International Inc 62 0431 01 M S 11 12 Printed in United States
11. Honeywell WEB 603 and CP 603 Network Controllers INSTALLATION INSTRUCTIONS ABOUT THIS GUIDE This document covers the installation instructions of the Honeywell WEB 603 AX and CP 603 controllers It assumes that you are an engineer technician or service person who has performed control system installations Instructions in this document apply to the following products Table 1 Model Description 1 0 Ports Notes WEB 603 AX JACE controller with onboard I O points mounted in metal 6 Universal Inputs Uls for 10K ohm WEB 603I AX enclosure Has pre wired power transformer and rechargeable Type Ill thermistor sensors 4 20mA or 0 CP 603 AX 12V backup battery WEB 603 AX and CP 603 AX are for U S 10Vdc sensors or dry contact closure CP 6031 AX installations WEB 603I AX and CP 6031 AX are for International 4 Form C SPDT Relay Outputs Controller uses an NPM6E processor module with a PowerPC for 24Vac dc up to 2A resistive loads 440EP CPU 256MB DDR RAM 128MB Serial Flash 512KB Boot 2 Ethernet 10 100 Mbit s ports RJ 485 Flash 512KB Static RAM SRAM and runs the QNX Real time 1 LonWorks FTT 10A port 2 position Operating System and the Oracle Hotspot Java Virtual Machine 1 RS 485 port 3 position Can host either a WEB R2 station WEBs 2 301 535 or later or a 1 RS 232 RJ 45 connector WEB AX station WEB AX 3 6 49 or later for WEB products and All I O connections and LON RS 485 CP AX Station C
12. I E w Card Installation Se ds Ol e j ton El B EE Ta ids E WEBs AX units il o J E beoosoosoosooes only on page al a ammm TIT 15 T 5 ay NPMGE processor ASK od module N O LEDs o LAN2 SEC 0 LAN1 PRI Secondary Ethernet E Sono BEAT LAN 2 port RJ 45 A 0 5 E s v STATUS 0 5 89 See LEDs on 0 E vew NPMGE processor Eve module on page 14 O j foo aw Joe Primary Ethernet _ ZA Serial Shell jumper LAN1 port RJ 45 eas See Ethernet on page 8 WwW Normal ga Serial Shell See Serial Shell mode on page 14 x 5 com 1 SI _ Power RS 232 LEDs 288 8 Connector Sa SR RS 232 port RJ 45 es ODE 000000 56 1 b COM 1 obblslela BaBa mA eo mj a De ole 1 co _ ia g See RS a 0 0500 El mm Gabo F Pb ye AA BO Bmg lo00000 ma PE a i 3 oboe z a a Y RS 485 LEDs aA EG z g Goce E 88 EE cmo B 3 RS 485 port aee aerea aa a8 a Y le d
13. ING Mount the controller in a location that allows clearance for wiring servicing and module removal For mounting details refer to Fig 1 on page 4 a drill template is provided on the last page of this document Pay attention to the following recommendations and precautions when mounting and installing the unit e This product is intended for indoor use only The unit should not be exposed to ambient conditions outside of the range of 0 C 32 F to 50 C 122 F and relative humidity outside the range 5 to 95 non condensing pollution degree 1 e If the controller is mounted inside an enclosure that enclosure should be designed to keep the unit within its required operating range considering a 20 watt dissipation by the controller This is especially important if the controller is mounted inside an enclosure with other heat producing equipment e Minimum clearance from the wall on which the unit is mounted is 0 2 inches provided by the dimpled mounting feet Ensure that this space is not compromised and that airflow is not blocked behind the unit Do not mount the unit in an area where excessive moisture corrosive fumes or explosive vapors are present where vibration or shock is likely to occur ina location subject to electrical noise This includes the proximity of large electrical contractors electrical machinery welding equipment and spark igniters e The unit is designed to be wall mounted with the batt
14. NG All communications wiring is made through knockouts adjacent to the communication ports Prior to connecting cables ensure that the grommet bushing has been installed for each knockout Employ strain relief on the communication wiring to prevent damage to the controller Ethernet Two female 10 100 Mbit Ethernet connections are provided on the controllers NPM6E processor module These RJ 45 connectors are labeled LAN1 PRI for primary and LAN2 SEC as secondary Use a standard Ethernet patch cable for connecting to an Ethernet switch or hub The factory default IP address for LAN1 is 192 168 1 12n where the last numeral n matches the ast digit in the controller s serial number and the subnet mask is 255 255 255 0 By default LAN2 is disabled NOTE Only LAN1 is supported if configuring the controller for WEBs R2 LAN2 is not supported NOTE If configuring for WEB AX LAN2 can be used in addition to LAN 1 Typically you only use LAN 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 NOTE If enabling LAN2 note LAN1 and LAN2 must be connected to different subnets Further a WEB controller does not provide IP routing or bridging operation between the two LAN ports Refer to the Install and Startup documents in the Related Documentation on page 1 for further details on changing
15. Or the unit can be configured to use both its sealed lead acid backup battery and SRAM backup NOTE Although a WEB 603 AX running WEBs AX can be configured to run without its provided backup battery in most cases it is expected for the battery to be used This provides immunity to power quality events including momentary power outages or brownouts which otherwise can result in a controller reboot even if for only one or two AC cycles 1 60th or 1 30th of a second NOTE For a number of reasons other models of SRAM equipped controllers running WEBs AX may be better candidates for a battery less installation Typically such controllers use a smaller more difficult to replace NiMH nickel metal hydride battery pack and are often mounted in areas harder to access than a WEB 603 AX controller Refer to the documents listed in the Related Documentation on page 1 for configuration details on SRAM support Replacement Parts Servicing the WEB 603 AX controller may call for replacement parts There are three categories of parts e Non replaceable Parts e Standard Replacement Parts e Field Replacement Units Non replaceable Parts Other than the parts listed in the replacement parts sections there are no serviceable components on the base assembly MEMORY Any addition modification or replacement of memory components requires software configuration and is not a field upgrade For additional information
16. P AX 3 6 49 or later for CP products depending ports use pluggable screw terminal on license connectors Regardless of release WEBs host platform configuration requires WEBs AX Workbench 3 6 49 or later If hosting an R2 station the existing R2 WEBs Java Desktop Environment JDE build 2 301 535 or later is used to access the controller s running station For complete specifications please refer to the product data sheet for the WEB 603 AX controller NOTE Not covered in this document is the WEB R2 or WEB AX software installation and configuration required for a fully functioning unit See the Related Documentation section below The content of this documentation equally applies to CP 645 AX product Related Documentation For software details on configuring and using the WEB 603 AX controller consult the following documents e Retrofit Board WEB R2 Install amp Startup Guide if WEB R2 e JACE WEB AX Install and Startup Guide if WEB AX e JACE Data Recovery Service SRAM Support Engineering Notes if WEB AX 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS PREPARATION Unpack the controller and inspect the package contents for damaged or missing items If damaged notify the appropriate carrier and return for immediate repair or replacement e Included in this Package e Material and Tools Required Included in this Package Included in this package you should find the following items e aWEB
17. ance gt 5K ohms O Stud in enclosure 4 20 mA Inputs support self powered or controller powered 4 20 mA sensors For controller powered sensors the controller s two V terminals supply 20 Vdc at up to 80 mA combined Input accuracy is 2 of span without user calibration The input requires an external 499 ohm resistor for current input six are supplied with the unit Fig 6 on page 11 shows wiring used for a self powered sensor top and a 2 wire controller powered sensor bottom Fig 6 4 to 20 mA wiring Self UM G Ul2 UI3 G U4 Powered 20000 499 Ohm resistor supplied with unit Shielded Twisted Cable Stud in 61m 200 ft maximum enclosure Shield Controller UN G Ul2 UI6 V G V Powered 19 2 900 499 Ohm resistor supplied with unit Shield Stud in enclosure Shielded Twisted Cable 61m 200 ft maximum 4 20 mA Sensor self powered sensor Range 0 20 mA t 4 20 mA Sensor controller powered sensor Range 0 20 mA 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS Binary Input The inputs support both pulse contacts and normal dry equipment status contacts e Pulse contacts may have a change of state COS frequency of up to 20 Hz with a 50 duty cycle Note Minimum dwell time must be gt 25ms Standard dry contacts must have a 1 Hz or less COS frequency with minimum dwell time gt 500ms Both types of d
18. ble of 120Vac or if an International model 240Vac plus sufficient capacity for test equipment e About the transformer Making the power connection to the transformer WEB 603 AND CP 603 NETWORK CONTROLLERS About the transformer The WEB 603 AX for U S installations ships with a 120Vac 50 60 Hz transformer The WEB 603I AX for International ships with a 240Vac 50 60 Hz transformer The transformer provides power to the controller in a 14 CT 14 configuration 28Vac center tapped The power connector has been disconnected for shipping The following things should be noted about the controller s transformer A WARNING Wiring hazard Wiring is to be made to the supplied transformer All connections should be made in accordance with national and local electrical codes Use copper conductors only Do not power other devices from the transformer of the controller The transformer should be dedicated to running the controller Do not attempt to use any other power source or otherwise defeat the isolation provided by the integral transformer A two wire power source including a 24V transformer can cause permanent damage or greatly shorten the life of the unit Verify that neither side of the transformer s secondary winding is connected to earth ground or building neutral Making the power connection to the transformer With the 6 position power connector disconnected from the controller s circuit board unscrew th
19. consult your regional Tridium office FUSES The controller contains a non user replaceable fuse soldered on the circuit board and is not user serviceable If this circuitry is suspect contact your regional Tridium office for technical support See the Returning a Defective Unit section on page 19 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS Standard Replacement Parts Standard replacement parts are listed in Table 7 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 7 Standard replacement parts Part Number Description 50000276 014 Battery 12 Vdc 1 2 AH see Replacing the 12V battery page 16 H10026 LON LonWorks Trunk Connector Plug 2 position H10140 RS 485 connector plug 3 position H10139 1 0 connector plug 6 position 10149 Resistor 499 ohm 1 0 6w 10138 Battery ground harness also includes 6 position power connector H10148 Adapter RJ 45 to DB 9 null modem for serial port to connect to DTE device H10180 Silver satin patch cable 4 feet used between adapter and serial port H10181 Silver satin patch cable 10 feet used between adapter and serial port H10182 Silver satin patch cable 25 feet used between adapter and serial port Field Replacement Units NOTE Before ordering an FRU it is strongly recommended that you contact your norma
20. e nut and locking washer and remove the metal divider shield over the transformer NOTE As typically required by code high voltage Class 1 wiring must be confined behind the transformer s enclosure divider Be sure to replace this barrier after completing the wiring Do not pinch wires underneath the barrier when re installing the barrier WEB 603 AX Using the provided wire nuts connect 120Vac 60 Hz power to the transformer and power connector using the information in Table 2 Table 2 US models building power termination Building Power Source US Type of Wire Ungrounded Hot Black Typical Color of Wire Termination point Either wire of the 120V transformer Grounded Neutral White Other wire of the 120V transformer Grounding Ground Earth Green or bare copper Grounding stud WEB 6031 AX Connect 240Vac 60 Hz power to the power terminal block using the information in Table 3 Table 3 International models building power termination Building Power Source International Type of Wire Ungrounded Hot Brown Typical Color of Wire Termination point Either empty terminus of the terminal block Grounded Neutral Blue Other empty terminus of the terminal block Grounding Protective Earth Ground Green yellow or bare copper Grounding stud 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS COMMUNICATIONS WIRI
21. ery situated towards the bottom of the unit For proper airflow at temperature extremes do not mount the unit oriented in any other way 3 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS Fig 1 WEB 603 AX mounting details 0 16 4 mm Mounting Surface 1 88 48 mm 2 50 T Heynd2 11 1 mm Detail H Conduit Knockout typ of 7 1 2 13mm ii 11 8 300 mm Minimum 1 00 1 00 25 mm E 25 mm Min Min j 9 75 248 mm 2 00 51 mm i 5 94 ai 1 52 Min 151 mm 39 mm 0 72 l FAA ON NE aes coe 1 18 mm l o i i ROC er BE 2 25 i 57 mm o o i i 2 25 57 mm O ll i i o l TOE NE I o Sat 9 84 Mount This i 250 mm 1 15 6 o End Up o T 396 mm 11 6 ts Min 295 mm i ae pet A l i Hee al i i 1 i o o i i o i i i 0 221 5 6 mm 1 Y Dia il l eene es 1 i b Se ej XA pr 2 00 t 2 0 m 2 0 ely 2 0 sa 3 0 l 51 mm 51 mm 51 mm 51 mm 76 mm i Minimum Clearance Area 218 5 5 mm Mounting is summarized in the following sections e Removing and replacing 62 0431 01 the enclosure door Enclosure knockouts and mounting notes WEB 603 AND CP 603 NETWORK CONTROLLERS Removing and replacing the enclosure door The WEB
22. esent inside the unit clean with Cleaning vacuum or compressed air Otherwise no cleaning inside the e Required Battery Maintenance unit is required Optionally if the outside of the metal e Replacement Parts ns enclosure becomes dirty you can wipe it with a damp cloth e Replacing the WEB 603 AX circuit board and mild detergent Returning a Defective Unit Required Battery Maintenance Typically regular maintenance includes eventual replacement of the 12V sealed lead acid backup battery unless a WEB AX unit installed without the battery see Battery less option on page 17 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 battery should see relatively few discharges Therefore ambient temperature has more to do with determining the life expectancy of the battery than does any other factor If the controller is installed in a conditioned space the battery should provide dependable service for approximately three years average In an environment where the operating temperature is higher that is 50 C or 122 F you should only expect the battery to last approximately one year The battery is automatically float charged during normal operation while power is applied to the unit The controller monitors the battery and periodically loads the battery to test its ability to maintain
23. g studs 10 Replace the FRU circuit board on the mounting studs and spacers carefully securing with the seven 1 4 nuts Again be mindful of small surface mount components located near board mounting points 11 Reconnect any Ethernet serial LON and modem connectors 12 Reconnect all I O connectors 13 Turn on building power to the unit 14 Plug the 6 position power connector in and verify normal operation 15 If any of your I O points have voltage turn the devices back on or reconnect power to them 16 Using WEBs AX Workbench to make a platform connection re commission the WEB 603 AX including the following a Install the correct WEBs release and set the date and time b Install the new license file c Restore the station database and start the station RETURNING A DEFECTIVE UNIT For proper credit on an in warranty unit ship the replaced circuit board per the vendor s return material procedures Prior to returning the unit contact your vendor to obtain a return materials authorization RMA number and other instructions Please provide e Product model e Nature of the defect e Serial number PO number to secure the RMA CERTIFICATIONS Federal Communications Commission FCC This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause interference with radio communications It has been tested and found to comply with the limi
24. l technical support resource to eliminate the possibility of a software issue or mis configuration problem To replace a faulty unit order from the field replacement units FRUs listed in Fig 12 An FRU consists of only the WEB 603 AX circuit board without connector plugs FRU parts can be ordered from stock but the replaced circuit NOTE board removed from the WEB 603 AX must be returned to your vendor for credit Be sure to contact the vendor for a return authorization RA number see Returning a Defective Unit page 19 before shipping an item for return credit or repair To allow proper licensing of the replacement unit please have information ready about the existing unit including its serial number model number and license information when placing the order Fig 12 Field replacement units for WEB 603 AX Part Number Description WEB RB 603 AX Circuit board WEB 603 AX or WEB 603I AX WEBs AX configurable also for WEB R2 Replacing the WEB 603 AX circuit board CAUTION Be aware of small surface mounted components on the circuit board near each mounting point Use a 1 4 6mm thin walled socket not a nut driver to carefully loosen or tighten the nuts that secure the WEB 603 AX circuit board to the 7 mounting studs A nut driver can cause board damage to adjacent components while a socket if used carefully typically does not Retain and reuse metal spacers on all mounting stud
25. nsmit and receive activity e Works device is transmitting a message Serial Two LEDs for each RS 232 and RS 485 serial port are located near the ports on the main circuit board They show transmit and receive activity for these serial ports e The yellow transmit LED indicates that the controller is sending data out the serial port over a communications line to a connected device e The green receive LED indicates that the controller is receiving data from a device These LEDs are driven by pulse detectors that 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 Relay Output Status Four 4 relay output status LEDs are located below the associated form C relay just above the screw terminals for each output s wiring Under normal operation these yellow LEDs indicate activity as follows e Off Relay coil is not energized e On Relay coil is energized Therefore for a circuit with a normally open contact an On status indicates that the contact is closed For a circuit with a normally closed contact an On status indicates that the contact is open CONTROLLER JUMPERS The controller has jumper blocks to allow for Serial Shell mode operation and for RS 485 port biasing as described below Serial Shell mode The controllers NPM6E processor module has a four pin jumper heade
26. o damage electronic components The Controller printed circuit board contains components that are sensitive to static discharge Follow these precautions when installing or servicing the system WEB 603 AND CP 603 NETWORK CONTROLLERS N CAUTION Static charge hazard e Work in a static free area e Discharge any static electricity you may have accumulated Discharge static electricity by 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 WEEE Waste of Electrical and Electronic Equipment X Recycling of Electronic Products International Installations In 2006 the European Union adopted regulations WEEE for the collection and recycling of all waste electrical and electronic equipment It is no longer allowable to simply throw away such equipment Instead these products must enter the recycling process To properly dispose of this product please take it to a local recycling center If a local recycling center cannot be found please return it to one of these offices Tridium Europe Ltd Tridium Asia Pacific Pte Ltd Tridium Inc 1 The Grainstore 17 Changi Business Park Central 1 2256 Dabney Road Suite C Brooks Green Road Honeywell Building Richmond VA 23230 Coolham West Sussex Singapore 486073 RH13 8GR United Kingdom MOUNT
27. provides pinouts for both adapter types WEB 603 AND CP 603 NETWORK CONTROLLERS Table 4 RJ 45 to DB 9 adapter pinouts RJ 45 and DB 9 Pinout RJ 45 DB 9 Socket References Type of Adapter Socket Pin Signal Pin Null Modem 5 DCD Data carrier detect 1 RJ 45 Socket Shomer OF Cees E PER anemi dela E female Part number 10148 6 RXD Receive data 3 8 DSR Data set ready 4 4 GND Ground 5 1 DTR Data terminal ready 6 7 CTS Clear to send 7 2 RTS Request to send 8 8 1 not used on the JACE 4 9 Straight through 5 DCD Data carrier detect 1 DB 9 Socket female PA to a DCE 6 RXD Receive data 2 3 TXD Transmit data 3 5 1 1 DTR Data terminal ready 4 4 GND Ground 5 00000 8 DSR Data set ready 6 000 O 2 RTS Request to send 7 9 6 7 CTS Clear to send 8 not used on the JACE 4 9 NOTE Silver satin cable is not standard Ethernet UTP cable in which the pairs are twisted around each other The twisting of the pairs may cause undesirable effects on the serial communication therefore we recommend the use of flat silver satin cable instead e Flat silver satin cable is unshielded If installing this cable in a noisy electrical environment run the cable through conduit LonWorks LON A single two pin LonWorks FTT 10A Weidmuller connector is provided on the controller This connection supports twisted pair unshielded polarity insensitive peer to peer communications at
28. r and a 2 pin jumper block that you can reposition as needed to enable or disable Serial Shell mode operation In this mode the RS 232 COM1 port on the controller allows system shell menu access using serial parameters 115200 8 N 1 NOTE You must reboot the coniroller after repositioning this jumper before any serial shell mode change becomes effective When done using serial shell don t forget to return to the jumper block to its normal position and reboot again The default jumper setting is Normal no serial shell see WEB 603 AX board layout details on page 6 RS 485 port biasing The controller has one RS 485 port COM2 on the left side of the circuit board near the bottom Fig 10 RS 485 bias jumpers on WEB RB 603 and WEB RB 645 E Unbiased Biased This RS 485 port has an adjacent four pin jumper header on which you can install two 2 pin jumper blocks to enable RS 485 biasing if needed See Fig 10 above As shipped from the factory these pins are not shorted thus the RS 485 port is unbiased See Need for RS 485 bias for related background details Need for RS 485 bias NOTE A full discussion of communications line termination is beyond the scope of this document Biasing sometimes improves RS 485 communications by eliminating indeterminate idle states When you install two 2 pin shorting blocks on an RS 485 port s bias jumper pin
29. ry contacts support 3 3 Vdc open circuits or 330 pA short circuit current Fig 7 on page 12 shows the wiring diagram Fig 7 Binary input wiring UM G Ul2 UB G Ul4 Pulse 220222 Range 20 Hz 50 Duty Cycle Minimum dwell time gt 25ms Shielded Twisted Cable 61m 200 ft maximum Stud in enclosure UM G Ul2 UI3 G Ul4 oaao Dry Contacts Shielded Twisted Cable 61m 200 ft maximum Stud in enclosure Outputs Four 4 form C relay outputs provide isolated dry contact control of 24 VAC DC loads at up to 2A resistive An LED indicator for each relay is located between the relay and the wiring connection point see the Relay Output Status section on page 14 Fig 8 shows example wiring diagrams Fig 8 Example DO relay output wiring Normally Open N O NC1 C1 NO1 NC2 C2 NO2 Normally Closed N C NC1 C1 NO1 NC2 C2 NO2 loads de energized if loads energized if controller loses power controller loses power Loads 24Vac at 2A resistive max AC Mains Line AC Mains Line 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS POWER UP AND INITIAL CHECKOUT Ensure power wiring to the transformer has been completed before proceeding see the Power Wiring section on page 7 The WEB 603 AX controller does not include an on off switch To apply power insert the 6 position power plug into the circuit board Refer to Fig 2 on page
30. s this adds two onboard 3 3K ohm resistors into the controller s RS 485 circuit as follows e from RS 485 to 5V e from RS 485 to Ground WEB 603 AND CP 603 NETWORK CONTROLLERS NOTE In general only one device on an RS 485 trunk should be biased Otherwise undue circuit loading may result with fewer devices supported e RS 485 bias resistors are different than termination resistors externally installed at the two physical ends of a daisy chained RS 485 trunk across the and terminals Termination resistors are typically 100 or 120 ohm value resistors e Whenever termination resistors are used RS 485 biasing is typically required OPTION CARD INSTALLATION WEBS AX UNITS ONLY The WEB 603 AX circuit board provides one 30 pin option card slot compatible with WEB 200 600 style option cards Option card usage is supported only if the unit is configured with WEBs AX and not WEB R2 A WARNING Power to the controller must be OFF when installing or removing an option card or damage will occur A WARNING Also you must be very careful to plug an option card into the connector properly pins aligned Refer to the installation document that accompanies a specific option card for complete details Table 5 lists the different option card types with notes specific to the WEB 603 AX controller provides a basic set of installation steps Table 5 Option card types and WEB AX no
31. s between the board s back and enclosure Before handling circuit boards discharge any accumulated static by touching the metal surface of the controller For details see Static Discharge Precautions page 2 To replace the WEB 603 AX circuit board with an FRU circuit board in the field follow Replacing an FRU circuit board Using the appropriate WEBs software tool back up the station database to your PC Open the cover of the unit If any of your I O points have voltage turn the devices off or disconnect power to them Turn off building power to the unit The unit should power down automatically Unplug the 6 position power connector from the board Note positions of all communications and I O connectors going to the circuit board If necessary label connectors to avoid mis connection later after circuit board is replaced ROP ONS 62 0431 01 18 WEB 603 AND CP 603 NETWORK CONTROLLERS NOTE The software that runs on the controller expects the terminal positions to be the same to collect data from or to control the attached devices 7 Unplug all Ethernet serial LON modem and I O connectors from the circuit board 8 Using a 1 4 socket see previous carefully remove and retain the seven 1 4 nuts securing the circuit board Be mindful of small surface mount components located near board mounting points 9 Remove the circuit board Make sure that metal spacers behind the board remain on the seven mountin
32. ssion the controller open a Workbench AX 3 6 49 or later platform connection to the controller You can do this using an Ethernet patch cable between your Workbench PC and the LAN1 primary port on the NPM6E processor module where the factory default IP address for the LAN1 port is 192 168 1 12n where nis the last numeral of the controllers serial number and the default subnet mask is 255 255 255 0 Then in the commissioning process you reassign IP parameters as needed Or first you can move a jumper on the NPM6E module to put the controller in serial shell mode Then after rebooting it you can communicate using an RS 232 connection between your PC and the RS 232 COM1 port on the controller s base board This lets you use system shell to reassign its IP parameters before starting the commissioning process from Workbench See Serial Shell mode on page 14 See Related Documentation page 1 for documents that cover JACE WEBs installation and startup 13 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS CONTROLLER LEDS The WEB 603 AX controller provides a number of LEDs including the following e LEDs on NPM6E processor module Ethernet Heartbeat Status e LEDs on main circuit board LON Serial and Relay Output Status LEDs on NPM6E processor module Fig 9 shows the LEDs on the NPM6E processor module with descriptions below Fig 9 LEDs on NPM6E processor module O f LAN2
33. tes Option card model type NPB RS232 Single RS 232 port Uses COM3 WEB 603 AX Notes NPB 2X 485 Dual RS 485 ports Uses COM3 and COM4 NPB LON LonWorks FTT 10 Operates as LON2 NPB ZWAVE Wireless Z Wave serial gateway Uses COM3 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS Installing an option card WEBs AX units only 1 If applicable backup the controller s configuration to your PC using platform tools in WEBs AX Workbench 2 Stop any running station using the Application Director platform view 3 Unplug the 6 position power connector from the circuit board 4 Using a 2 Phillips head screwdriver remove the two screws from the option card mounting posts and set them aside 5 Carefully insert the pins of the option card into the option card socket The mounting holes on the option card should line up with the standoffs on the base board If they do not the connector is not properly aligned Press until the option card is completely seated 6 Place the custom end plate that came with the option card over the connector s of the option card 7 Replace the two screws through the end plate and into the standoffs on the controllers base board Using a screwdriver hand tighten these screws 8 Plug in the power connector in and verify operation Maintaining the WEB 603 AX Cleaning This section provides information on the following topics If dust or metal filings are pr
34. the controllers enclosure typically used for I O cabling As needed locate and remove left and right sides top and bottom See Fig 1 on the necessary knockouts and install the necessary conduit or page 4 cable clamps in the knockout holes This may easiest to do 3 Carefully mark the mounting hole locations and remove before mounting the controller to the wall the controller 4 Drill the needed pilot holes in the wall For example if using wall anchors you might drill 5 16 holes 5 Mount the controller to the wall using the appropriate fasteners 6 As needed install wiring conduit to the controllers enclosure See Board Layout page 6 and Wiring Summary page 7 for further details 5 62 0431 01 WEB 603 AND CP 603 NETWORK CONTROLLERS BOARD LAYOUT Refer to Fig 2 for location of I O terminals communication ports LEDs and other features of the WEB 603 AX controller Fig 2 WEB 603 AX board layout details LON port j i See LonWorks H A a pa 1 0 O Option ean LON 9 E o 60 Un i connector area i E as SE ES Slgaovolla ota 8 e See Option LON LEDs AA m p A
35. tions 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 unexpected results or might lose data Cautions contain an explanation of why the action is potentially problematic Ah WARNING Warnings alert the reader to proceed with extreme care in situations where there is a chance that the reader might do something that can result in personal injury or equipment damage Warnings contain an explanation of why the action is potentially dangerous Safety Precautions The following items are warnings of a general nature relating to the installation and start up of the controller Be sure to heed these warnings to prevent personal injury or equipment damage AA WARNING Electrical shock hazard e A 120Vac circuit powers the transformer in the unit Disconnect power before installation or servicing to prevent electrical shock or equipment damage Make all connections in accordance with national and local electrical codes Use copper conductors only e To reduce the risk of fire or electrical shock install in a controlled environment relatively free of contaminants e This device is only intended for use as a monitoring and control device To prevent data loss or equipment damage do not use it for any other purpose Static Discharge Precautions Static charges produce voltages high enough t
36. ts for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area may cause interference in which case users at their own expense will be required to take whatever measures may be required to correct the interference Any unauthorized modification of this equipment may result in the revocation of the owner s authority to continue its operation Canadian Department of Communications DOC This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Cet appareil numerique de la classe A respecte toutes les exigencies du Reglement sur le material broilleur du Canada Declaration of ROHS Compliance amp This product meets all requirements of RoHS Directive EU 202 95 EC All components used in this product are ROHS compliant and there have been no leaded solders used in manufacture Related to the RoHS Restriction of Hazardous Substances Directive is another European Directive 2002 96 EC on Waste Electrical and Electronic Equipment WEEE The WEEE Directive aims to reduce the waste arising from electrical and electronic equipment and improve the environmental performance of everything involved in the life cycle of electrical and electronic equipment For related details see the precaution WEEE Waste of
37. u au la aj 0 lO O 0 Ol Oo COM2 OT peo Df pb p See RS 485 on der pe Ge Ge BE BE Relay Output page 8 eT Chey E aE 2 AR L J Status LEDs COM2 O oO la a G a a 10 a 0 al do ooo 20 8 a a a a 0 0 o a oo Seb og boo Gd OA dod Oo RS 485 Bias _ OYHEEeateEEBEBEREBEE SEG Eb cos Seas ee we mogoocoocoooeo oS be tr z jumpers 1 o 2 0700 coco OOC See RS 485 port biasing on page 15 L__ Universal Inputs 1 6 gt Lo Relay Outputs 1 4 gt See Inputs page 10 See Outputs page 12 62 0431 01 6 WIRING SUMMARY See Fig 2 on page 6 to locate connectors and other components on the controller Make connections to the Controller in the following order 1 With the 6 position power connector disconnected from the board wire the power to the transformer US models or the power terminal block International models See Power Wiring page 7 2 Connect communications cables See Communications Wiring page 8 3 Connect the I O wiring See I O Wiring page 9 4 Apply power to the unit See Power Up and Initial Checkout page 13 POWER WIRING Building power is wired directly to the transformer supplied with the controller There is no disconnect switch in the unit therefore you should wire the controller to an external switch or breaker Some local codes require the switch to be in sight of the unit The switch must be capa
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