Emerson Process Management Bristol ControlWave ExpressPAC User manual
Emerson Process Management Bristol ControlWave ExpressPAC provides a complete automation solution designed to address a wide range of process control applications. Due to its open architecture and scalability, the device is suitable for both small and large systems, from a single RTU to a powerful plant-wide control system. Some of the key features include advanced networking capabilities for easy integration into existing networks, a modular design for easy expansion, and an extensive library of basic IEC 61131-3 functions and function blocks for efficient programming.
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Product Data Document
420DS-1k
July 16, 2007 - Page 1
Bristol ® ControlWave ® PAC
Process Automation Controller
Bristol® ControlWave® PAC, from Emerson Process Management, is a highly adaptable, high performance Process Automation Controller with exceptional networking capability to provide a complete Process Automation Management Solution. Designed with a great emphasis on scalability and modularity, ControlWave can be configured to maximize the performance of a wide range of control systems, from small or mid-size applications to large ones. Additionally, due to its small form factor and rugged industrial design, ControlWave offers an outstanding ability to match the requirements of the most demanding process plant and SCADA system environments. Above all, Emerson has developed this innovative controller to provide cost-effective solutions by minimizing the time required for installation and configuration.
Through this new open architecture, ControlWave provides an ideal hybrid union of PLC, RTU and
DCS without compromising the unique features and capabilities of each product. Consequently, the
ControlWave Process Automation Controller not only introduces the great possibilities of an open architecture for emerging communication standards, but it also provides a simple solution for existing networks. From its conception, ControlWave was intended as a very flexible system capable of satisfying the requirements of local, expanded, remote and distributed I/O combinations. It is widely accepted as a scalable platform because it can be used for small applications using a single rack, but it can also be expanded to large applications spanning an entire plant.
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Hardware Features
586 based processor provides unparalleled performance
Up to three 100/10 MB Ethernet ports
Ethernet remote I/O
Up to four serial communication ports
2, 4, and 8 I/O slot panel mount chassis, panel or 19” rack mount on 8 slot chassis
Single and double density I/O modules
Hot Swap I/O replacement
Security key-lock to prevent unauthorized access
Internal loop power for I/O simplifies installation
AOs maintain last/preset value on CPU
Watchdog
DOs maintain last or zero value on CPU
Watchdog
Wide temperature range (-40 to +70ºC)
Class I, Div. 2 hazardous location and CE approval
Open, industry standards for programming, configuration and communication
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Product Data Document
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July 16, 2007 - Page 2
Scalability
ControlWave PAC meets the needs of a wide range of applications, from a unit controller RTU to a powerful plant process control system through its modular architecture, large I/O capacity and Ethernet networking capability.
For smaller I/O configurations, the low power
ControlWave Micro and Express are ideal RTU packages with all of the same software capabilities of their ControlWave PAC big brother.
ControlWave Micro is a compact modular RTU/PLC hybrid, providing up to eleven serial communication ports and optional built-in 100/10 Base-T Ethernet ports. Built-in spread spectrum radio and dial-line modem options reduce integration cost, enhance communication flexibility and provide communication back-up.
The base unit is used to house the power system,
CPU and 2 or 6 I/O modules. The base is expandable up to fourteen I/O slots through 2,4 or 8 slot plug-on I/O expansion bases.
ControlWave Express is a very compact, low profile
SCADA RTU with a fixed I/O point count. Extremely low power consumption makes ControlWave Express highly suitable for many remote sites common in water, wastewater, and natural gas applications
Open Standards for Programming, Network Configuration and Communication
Only ControlWave brings the perfect combination of industry standards to minimize learning, engineering and implementation costs.
By adhering to such industry standards as Ethernet,
TCP/IP, Microsoft Windows , COM/DCOM, FTP, OLE and ActiveX, ControlWave is able to achieve the highest degree of openness in control system architecture and bring the optimal process efficiency and productivity needed to ensure a successful system implementation.
Bristol ® ControlWave ® PAC
ControlWave Designer with ACCOL III
To minimize your engineering and development time, we have adopted the international standard for PLC programming, IEC 61131-3. ControlWave
Designer is a fully IEC 61131-3 compliant programming environment for the ControlWave family of products. ControlWave Designer includes all five
IEC 61131-3 process languages for batch, continuous and discrete control: Function Block Diagram,
Structured Text, Sequential Function Chart, Ladder
Logic Diagram and Instruction List.
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ControlWave Designer includes an extensive library of more than 200 basic IEC 61131-3 functions and function blocks common to many IEC 61131-3 based products. These include:
Flip-flops, Counters & Timers
Ladder diagram functions - coils and contacts, etc.
Numerical, Arithmetic & Boolean functions
- Sine, Cosine, Add, Sub, Square Root, And, Or, etc.
Selection & Comparison - Min, Max, Greater than, Equal, Less than, etc.
Type conversions - Integer to Real, Boolean to
Word, etc.
ACCOL III
In addition to the basic functions and function blocks, ControlWave Designer brings the benefit of over twenty years of SCADA and plant control experience in Emerson’s Bristol ACCOL III function block library. ACCOL III includes over sixty function blocks valuable for use in oil & gas, water and wastewater and process measurement & control applications. Further, ACCOL III is designed to take full advantage of the significant features offered by
ControlWave.
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Briefly, this library includes function blocks for:
Average, Compare, Totalize
Scheduling & Sequencing
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Product Data Document
420DS-1k
July 16, 2007 - Page 3
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• PID & Lead/Lag
AGA gas flow and liquids calculations
File handling
In addition, ControlWave ensures data integrity, in the event of a communication interruption, by storing critical time-stamped alarm and historical data in the controller memory. This data is then securely retrieved when communication is restored.
Specifications
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CPU
AMD Elan 520 processor: 586 CPU-100 Mhz
Data Memory: 2 MB SRAM battery backed memory
Historical Archive memory: Stored in either flash or battery backed SRAM
Code/ Instruction Memory: 16 MB on-board
Flash
Synchronous Dynamic memory: 4 MB (66MHz
SDRAM coupled to a 32-bit bus)
PCI bus for communication expansion module
2-digit ‘Port 80’ display for booting and run-time diagnostics
Key-lock security switch
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Communication
Two RS-232 serial communication ports with standard PC/AT 9-pin male D-sub connectors on CPU module, both supporting baud rates up to 115.2 KB
Two expansion RS 232 or RS 485 serial communication ports: up to 115.2 KB
1 standard PC/AT 9-pin D-sub Connector and 1
RJ45 8-pin connector
Isolation: RS 485 serial communication ports isolated to 500 Vdc
Up to three independent 100/10 Base-T
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Ethernet ports with RJ45 connectors
Isolation: Ethernet ports isolated to 500 Vdc
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Power Supply and Chassis
12 or 24 Vdc power
Power-fail detection and recovery sequencer
System LEDs for: Active , Fail, & Power OK
Power supply isolation: 500 Vdc
ISA bus for I/O system (supports Hot Swap I/O) able to drive 8 local chassis I/O modules
2 – I/O slot chassis: Panel Mount 7.97”W x
6.97”H x 4.96”D (202.43W x177.03H x 125.98D)
4 – I/O slot chassis: Panel Mount 11.84”W x 6.97”H x 4.96”D (300.73W x 177.03H x
125.98D)
8 – I/O slot chassis: Panel Mount or 19” Rack
Mount 18.96”W x 6.97”H x 4.96”D (481.58W x
177.03H x 125.98D)
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Environmental Specifications
Industrial operational temperature limits
(-40 to + 70 o C)
Humidity: 0-95% (non-condensing)
Vibration limits: 1.0 g acceleration over 10-150
Hz; 0.5 g acceleration over 150-2000 Hz
ControlWave Local I/O
ControlWave ‘Process Friendly’ local I/O modules are designed to maximize usability while minimizing installation, maintenance, and system downtime costs. A pull-down door provides front panel wiring terminal access for technicians. The bezel and even the terminations can be easily removed from the
I/O card to make wiring even easier. In addition, the availability of both local direct and remote DIN rail terminations conveniently accommodates a wide range of applications.
To minimize field wiring and eliminate the need for marshalling strips, the analog input and digital input modules are capable of supplying loop power to two
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Product Data Document
420DS-1k
July 16, 2007 - Page 4 wire transmitters and dry contacts. For maximum channel-to-channel isolation, externally powered analog and digital inputs may be selected.
Status-at-a-glance indicators offer instant visual notification of I/O system problems. Each I/O module has a bi-color Pass/Fail LED to display the on-line diagnostic status. Digital I/O status LED’s are provided for each point. Analog Input modules have a unique feature. Each input point has two
LEDs to indicate input under/over range conditions due to open and shorted field devices. The green
LED, when lit, indicates the input is in a normal range. The Red LED, when lit, indicates the input is under or over range, typically meaning it is open or shorted.
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Features
Convenient ‘Process Friendly’ pluggable local and remote wiring terminations simplify installation
Status-at-a-glance LED indicators
Single and Double density I/O count available for all modules provide application flexibility
Loop powered inputs minimize wiring costs
Easy access pull-down door with terminal wiring labels
Hot Swap I/O replacement
All I/O modules are enclosed in a rugged aluminum shell
Analog outputs configurable for ‘Hold last value,
Bristol ® ControlWave ® PAC
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Fail-Safe state or preset value’
Discrete outputs configurable ‘Hold last value or fail to zero’
Specifications
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All I/O
Surge protection meets C37.90-1978 and
IEC 801-5
Terminations are pluggable and accept a maximum wire size of 14 gauge
‘HOT SWAP’ module replacement is supported.
All I/O is frozen for 300 ms when any module is replaced
Environmental Specifications
Operating Temperature range: -40 to 70 o C
(-40 to 158 o F), storage up to 85 o C
Relative Humidity: 15-95% non-condensing
Vibration: 1.0g for 10-150 Hz, 0.5g for 150Hz to
2000Hz
RFI Susceptibility: 3V/m – 80 MHz to 1000Mhz
(EN50082-2)
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ControlWave Digital Input Module
Number of points: 16 or 32 – non-interrupting inputs
16-bit wide bus access
Input Voltage Range: 24 Vdc nominal
Input current : 5 mA nominal
Optical isolation: 1500 V field input to logic
Surge suppression: 500Vdc MOV to chassis
31 Vdc transorb between signal and isolated ground
Input filtering: 30 ms time constant (contact bounce)
Dry contact or externally powered voltage inputs – 21 Vdc on-board isolated loop power
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Product Data Document
420DS-1k
July 16, 2007 - Page 5
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• supply for contacts
Power Consumption: 100 mA max @5V ( all
LED’s on)
Status indication: LED per point status and module OK/FAIL LED
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ControlWave Digital Output Module
Number of points: 16 or 32
16-bit wide bus access
Output type: solid state open source MOSFET
Operating voltage range: 10 - 31Vdc
Maximum operating frequency: 20 Hz
Current sink load capability: 500 mA at 31V
Electrical isolation: 1500 Vdc
Surge supression: 500 MOV to chassis
31 Vdc transob between signal and isolated ground
Status indicator: LED per point status and module OK/FAIL LED
Configurable Fail State ‘OFF’, or ‘Hold Last
Value’
Power consumption: 143 mA max @ 5 Vdc (all
LEDs ON)
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ControlWave Analog Input Module
Number of Channels: 8 or 16
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A/D Resolution: 14 bit
Input Configuration: Isolated voltage input: 500
V per card to chassis 31 V per channel when externally sourced
Internally or externally sourced current
Input:Single-ended inputs 4-20 mA
Voltage Input: Isolated Differential inputs
1-5 V dc
• Externally sourced current loop with 1–5
V input module and 250 ohm resistor across the input terminals or 4-20 mA input module
Bristol ® ControlWave ® PAC
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Input Impedance: > 1 megOhm for 1-5 Vdc,
250 Ohm for 4-20 mA
Common Mode Rejection: 70 db
Normal Mode Rejection: 26 db
Input Filtering: 300 ms to 99.9% of input signal
Channel Settling Time: 680 microseconds
Conversion Time: 25 microseconds
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0.1% of span 25 o C
0.2% of span -20 o C to 70 o C
0.3% of span -40 o C to 70 o C
Isolated Voltage Common Mode Range: 31 Vdc to isolated common
LED Indicators : Normal, Over-range/Underrange, module FAIL/OK
On board References: 1V, 5V
On-board isolated loop supply for internally powered AI
Surge Supression: 31 Vdc transorb across input signals and (-) input to chassis
500Vdc MOV isolated common to chassis
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Thermocouple Input Module
Number of Channels: 6 AI
Input type: B, R, S, J, E, K, T, C, N, +/- 10 mV
AI Resolution: 16 bit
Input Configuration: Differential thermocouple
Voltage input Impedance: 10 megΩ
Channel data acquisition: 50 microsec
Conversion Time: 66 millisec for all 6 inputs
Input Accuracy: Varies by thermocouple type
0.025% of span at 25°C for 10 mV input
0.95% of span -25°C to 70°C for 10 mV input
Common Mode Rejection: 120 db
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Product Data Document
420DS-1k
July 16, 2007 - Page 6
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• Normal Mode Rejection: 80 db
Electrical Isolation: 500 Vdc channel to channel and channel to bus
Surge Suppression: 180 Vdc transorb between signal and ground meets IEEE 472.1978
Cold Junction Compensation: RTD sensor on terminal block
Local or remote terminations
Power Consumption - 6 inputs:
TC analog input: 0.96 watt
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RTD Input Module
Number of Channels: 4 AI
Input Type; 2, 3, or 4 wire RTD
AI Resolution: 16 bit
Voltage Input Impedance: 9.6 KΩ
Channel Data Acquisition: 50 microsec
Conversion Time: 3 wire - 266 ms, 4 wire - 200 ms, for all 4 inputs
Input Accuracy:
+/- 0.5°C at 25°C
+/- 1.0°C at -40°C to 70°C
Common Mode Rejection: 120 db
Normal Mode Rejection: 80 db
Electrical Isolation: 500 Vdc channel to channel and channel to bus
Surge Suppression: 12 Vdc transorb between signal and ground meets IEEE 472.1978
Local or remote terminations
Power Consumption - 4 inputs:
RTD analog input: 0.6 watt
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ControlWave Analog Output Module
Number of Channels: 4 or 8
Bristol ® ControlWave ® PAC
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Output configurations: 4-20 mA (650 max. drive)
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D/A resolution: 12 bit
• Accuracy:
0.1% of span @ 25 o C for current output
0.2% of span @ -20 to 70 o C for current output
0.3% of span @ -40 to 70 o C for current output
Electrical Isolation from the power system by an opto-coupler and a dc/dc converter.
Settling time: 1 ms
FAIL and OK module status LED
Surge Supression: 31 Vdc transorb across output signals and (-) output to common
Power Consumption: 91 mA max. @5 V (all
LEDs ON)
500Vdc MOV isolated common to chassis
Configurable Output Fail State (hold last value, zero (-5%), to specified value)
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ControlWave Universal Digital Input Module and
Counter (UDI)
Number of points: 6 or 12
Polled DI and High Speed Counter or Low
Speed Counter
Bus Access: 16-bits wide
Frequency Range: 0-10 KHz
Input Voltage Range: 12V, 24V
Debounce circuitry factory set Enabled or
Disabled
Input Current: 5mA +/- 10%
Each counter input can be configured as a polled input, Low Speed Counter, or High Speed
Counter (Roll-over on 65536, not software resettable)
Input Filtering, Software configurable for:
20 micro seconds for high speed counter
1 milliseconds for low speed counter 30 milliseconds for contact closure interruptible DI
Loop power for dry contact inputs
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Product Data Document
420DS-1k
July 16, 2007 - Page 7
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Electrical Isolation: 1500 Vdc to system logic and 500Vdc to chassis
Surge Suppression: 31 Vdc transorb across input and to field common
Terminations: Pluggable, max wire size is
14 gauge. Set, reset, common and Shield terminals per input
Status Indication: Status LED per input, module
PASS/FAIL LED
Remote Termination Modules
The remote termination option for ControlWave Local I/O modules provides a convenient alternative to the standard direct connect termination. Remote terminiations allow a concentration of electrical connections from one or more controllers to be located in one area such as the rear of a 19" cabinet.
All Remote Termination modules are standard DINrail mountable and connect to the I/O module with from one to four pre-wired connector cables. To simplify installation, all I/O modules use the same cable.
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Features
Removes electrical connections from the controller
Passive terminations are DIN-rail mountable
Options for fusing, relays and 120 VAC I/O
A single common connector cable for all I/O
Up to 14 AWG wire with compression screw terminals
Available Modules
AI: 4 points, no fuses
AI: 4 points, with fuses
AO: 2 points, no fuses
AO: 2 points, with fuses
DI: 24 Vdc - 8 points, no fuses
DI: 24 Vdc - 8 points, with fuses
DI: 120 VAC - 8 points
Bristol ® ControlWave
DO: 24 Vdc - 8 points, no fuse
DO: 24 Vdc - 8 points, with fuse
DO: 8 points - 6 Amp relay
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Cable Lengths
18 inch cable
39 inch cable
6-1/2 foot cable
13 foot cable
® PAC
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Product Data Document
420DS-1k
July 16, 2007 - Page 8
ControlWave I/O Expansion Rack
ControlWave I/O Expansion Racks allow for expansion of I/O up to and including total plant wide control consisting of hundreds of I/O points. The process control application program resides in the main ControlWave process controller. It controls both local I/O as well as the I/O in the Expansion
Racks. No control functionality is required in the I/O
Expansion Rack.
The ControlWave I/O Expansion Rack consists of a 2, 4, or 8 slot ControlWave Chassis. The chassis contains an Ethernet communication engine dedicated to communications between the main processor and the expansion I/O. The communication engine also supports timing functionality and battery backed RAM to retain outputs during short power outages. The ControlWave I/O Expansion Rack is connected to the main or host ControlWave controller rack via an Ethernet physical link using TCP/IP.
Ethernet is widely accepted as a networking standard physical data link that allows the ControlWave
I/O Expansion Rack to fit into any local or wide area Ethernet based network, thereby increasing flexibility and providing an economical, reliable, I/O system.
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Hardware Features
10/100 Base T Ethernet Interface
Serial communications ports for Ethernet port setup
2,4, or 8 I/O slot panel mounted stainless steel chassis, panel or 19’ rack mount
Supports all ControlWave I/O modules
Hot swap I/O replacement
Internal loop power for I/O simplifies installation
AO’s maintain last/preset value on CPU watch dog
DO’s maintain last or zero value on CPU watch dog
Wide temperature range (-40 to +70 deg. C)
Class 1, Div. 2 hazardous location and CE approval
Bristol ® ControlWave ® PAC
Scalability
ControlWave I/O Expansion Racks allow for increased system flexibility depending on the process
I/O count. The expansion racks provide a cost effective solution to large I/O count projects, and an economical approach to low or medium I/O count applications. ControlWave meets the needs of a wide range of applications.
Specifications
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Communication Processor
Data Memory: 2 MB SRAM battery backed memory
2-digit “Port 80” display for booting and run-time diagnostics
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Communication
Serial communication port with standard PC/AT
9-pin male D-sub connector, supporting baud rates up to 115.2 KB
Isolation: RS-485 communication port isolated to 500 VDC
One 10/100 Base T Ethernet port with RJ-
45 connector. (This port is used as the main communication link to the Host controller.)
Isolation: Ethernet port isolated to 500 VDC
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Power Supply and Chassis
12 or 24 VDC power.
Power-fail detection and recovery sequencer.
System LED’s for: Active, Fail, and Power OK.
Power supply isolation: 500 VDC.
ISA bus for I/O system (supports Hot Swap I/O) able to drive 8 chassis I/O modules
Chassis dimensions are the same as for the
ControlWave PAC
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Product Data Document
420DS-1k
July 16, 2007 - Page 9
ControlWave Redundancy
Redundant systems are offered for critical processes and harsh applications that require maximum operational readiness and system availability.
ControlWave Redundant Systems are designed to prevent a single point of failure from shutting down the system. ControlWave offers two levels of redundant operation in order to achieve the optimum level of reliability required by the application. Many applications require the level of reliability provided by the cost effective ControlWave Redundant Process
Control and Communication system. Other, even more critical applications may require the higher system availability provided by the ControlWave Redundant I/O system. These designs deliver redundant systems that provide high availability, reliability, and safety.
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ControlWave Redundant System
Dual CPUs, Dual Power Supply Sequencers
Automatic Failure Detection
Automatic Switchover to Hot Standby Controller
Switchover time typically < 500 ms
High Reliability
No Single Point of Failure
Communication Channel Switching
Alarm and Historical Data Backup
No programming required for redundancy data transfer
Upgrade programs on the fly
Convenient Packaging
Refer to product data document 420ds11a.pdf for complete details.
Bristol ® ControlWave ® PAC
OpenBSI
Simply Creative
Emerson’s OpenBSI (Open Bristol System Interface) is a set of network setup, communication diagnostic, and data viewing utilities that provide access to both
Process Control and Communications Redundancy
Local I/O or Expansion I/O Redundancy
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Product Data Document
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ControlWave and Network 3000 controllers and
RTUs. OpenBSI is the only product available in the industry to bring such unique functionality and ease of use to the network level. At the core is the communication interface, written as a Windows communication server API through which other client applications communicate with Emerson networks.
OpenBSI supports both serial BSAP protocol and Ethernet Internet Protocol communication to
ControlWave and Network 3000 RTUs and controllers.
OpenBSI Utilities
Above this communication layer are a group of applications known as OpenBSI Utilities. These client utilities communicate through the server to collect and manage data gathered from the network, gen-
Bristol ® ControlWave ® PAC
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• Allows network configuration through NetView
PC and Network communication diagnostics
OPC Server for interfacing to most HMI software
Harvester collects historical data on request or scheduled basis
NetView is the basic configuration and application interface for all network operations. NetView uses a tree structure for network graphical display in the Windows Explorer style. Network nodes can be added on-line by simply dragging the node icon into the tree. This invokes a configuration Wizard, simplifying network setup. Through the NetView
Wizard, the necessary network parameters are entered for node and IP address, alarm and message routing, and network communication media.
Once configured, selecting any node allows direct access to the common OpenBSI utilities to reprogram, download a new application to the node, review communication statistics, view real-time data through DataViewer, and edit controller/RTU properties.
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• erate files based on collected historical data, collect alarms, and monitor and control OpenBSI communications.
Communication engine for PC applications
Supports ControlWave and Network 3000 serial and IP protocols
RS 232, Dial-line, cellular, radio, CDPD, satellite, and Ethernet connections
Provides on-line download & signal variable changes
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NetView - Network configuration and application LaunchPad
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July 16, 2007 - Page 11
Local Configuration Wizard allows local communication with any attached ControlWave controller or RTU to download system flashware upgrades, configure cold download parameters, and configure
IP and soft-switch parameters.
Bristol ® ControlWave ® PAC
WebBSI - WebBSI is a powerful and flexible software product bringing web technology to all of
Emerson’s Bristol automation and SCADA products.
WebBSI includes a set of ActiveX Controls for reading and writing real-time and historical data, trending, recipe editing and custom display generation.
Through these controls, you can use the standard
Microsoft Internet Explorer web browser to access
Network 3000, TeleFlow and ControlWave products through a set of supplied HTML web pages.
Configuration Wizard simplifies network setup
DataView is an on-line utility used to collect and display several types of process data, including signal values, data array values, signal lists, and audit trail information.
Operators have the ability to alter signal values.
Multiple DataView windows may be open simultaneously.
Custom built web page interface using a standard web browser
Real-time ActiveX Controls
One of the many benefits OpenBSI brings to you is our use of open standards such as ActiveX Controls. ActiveX is another of the Microsoft standards, which allow plug and play with any ActiveX container, using Microsoft ActiveX container technology such as Visual Basic, HTML web pages, and
Microsoft Excel.
The set of available ActiveX Controls provides the basic functions necessary to communicate and collect data from ControlWave.
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ActiveX Controls
Security 0 56-bit encryption - allows the user to sign on to the RTU
Signal Value - displays signal values in various formats
DataView for Real-time data display
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Comm Statistics - works with a standard page that displays the RTU's communication statistics
Configuration Info - works with a standard page that displays and allows the user to change
RTU configuration information
Historical - Collect and view historical archive and audit files
The IP compliant ControlWave opens the door for owner controlled access via web pages. Any generic web page builder can be employed to create user defined pages to access ControlWave. The web pages are populated with these pre-configured
ActiveX controls.
Required Software
Microsoft Internet Explorer
Bristol ActiveX Controls
OpenBSI LocalView or NetView
Historical Data Collection
Historical Data Collection
High Historical Data Integrity
The ControlWave Historical Data Collection system offers exceptional historical data integrity by providing time-stamped historical data storage in
ControlWave flash memory. The historical data is collected, through OpenBSI, on a scheduled or demand basis and converted to .CSV and ODBC compliant file formats for use in spreadsheets and reports. If data is missed due to a communication failure, it is collected when the communications is re-established and the PC historical database is backfilled with the missing data. This distributed historical database architecture provides the greatest data reliability and integrity during communication or PC failuer.
Another important historical feature is the Audit storage and collection system. The Audit Trail is a files stored in ControlWave flash memory containing significant events and time-stamped alarms. The alarms stored in the Audit system provide a histori-
Bristol ® ControlWave ® PAC cal archive in addition to the real-time alarm reporting system.
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This file is also collected through OpenBSI and presented as a text file in the PC. This functionality is extremely useful in providing an event trail during communication or PC downtime or other sytem problem.
Archive collection - collection and storage to disk of the ControlWave archive data
Audit collection - collection and storage to disk of the ControlWave audit data
Exports data files to third party, .CSV & ODBC applications
DDE compliant for use with other popular
Windows applications
OPC Server
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With industry demand for open standards,
ControlWave answers the call by embracing technologies that open the door for maximizing your efficiency and productivity. The OPC standard was developed by the OPC Foundation comprised of hardware and software suppliers from the process control community. OPC allows the engineer to select best in class hardware and software with confidence in their interoperability. Our OpenBSI OPC
Server was among the first to comply with the OPC
Foundation alarm and event server specification.
OPC Data Access 1.0a & 2.0 compatible
Windows, 2000 & XP
Compatible with both ControlWave and Network
3000 systems
32 bit multi-threading, multi-processor design
Automatic database reader
Integrated real-time data monitor
Supports OPC Browser interface
Supports both serial comm and IP Ethernet connections
Supports COM/DCOM & OLE Automation
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Product Data Document
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•
• Primary and Background polling scheme
OPC Alarm & Event Server support
ControlWave Open Network Connectivity
By embracing the open system network technologies available through TCP/IP, Ethernet, OPC, and
Microsoft DNA, as well as pseudo standards such as Modbus and Open Modbus, ControlWave can provide a total Process Automation Management
Solution for in-plant LAN based networks and WIde
Area Network SCADA systems.
With the exceptional connectivity provided by the
ControlWave network, access to real-time data and operating conditions, historical data, maintenance and performance data are all available to the global network. ControlWave provides the needed information to the plant floor technician, operator, engineer, supervisor and corporate management, even external customers.
Communication Protocols
Like all of Emerson’s products, Bristol ControlWave supports BSAP (Bristol Standard Asynchronous
Protocol), Modbus, DFI, CIP, DNP3 and serial ASCII as standard functions. These protocols are implemented in Flashware so no additional hardware is required to use any one or a combination of all protocols.
BSAP Protocol
All Emerson’s Bristol Network 3000 and
ControlWave RTU and controller products support
BSAP protocol. BSAP is widely accepted as providing exceptional data integrity and greatly simplifies communication between controllers. BSAP is provided with interfaces for Master/Slave, vertical networks, and Client/Server, horizontal networks. In either case, variable lists are created in each controller that are easily passed from server to client or slave to master.
BSAP meets the definition of an industry-standard, open architecture protocol because it conforms to
ISO standards 2629, 1745 and 2111, it is not proprietary in that Emerson does not charge a license fee and makes the protocol and documentation avail-
Bristol ® ControlWave ® PAC able to anyone.
•
•
•
•
•
•
•
While BSAP is an open protocol, the added functionality of the messages provide much more capability than is found in other networks.
Global time-synchronization
Time-stamped Alarm reporting
Historical archive data transfer
Audit file transfer
On-line program editing
Diagnostics
Communication statistics
Modbus Protocol
•
•
•
•
•
•
Modbus - Modbus is often considered a de-facto standard protocol because of its broad usage as either the primary or a secondary offering in many measurement and control related products. Even with its common use, Modbus protocol actually has many variations. Consider Modbus RTU and
Modbus ASCII, Master & Slave, Serial and TCP/IP
Open Modbus. In addition, there are considerations regarding supported function codes, floating point values and byte order. ControlWave supports the following:
Modbus serial and TCP/IP Open Modbus
(Ethernet)
Master and slave
Modbus RTU and ASCII
Modes 1 - 7, 8, 15 & 16
IP modes 51, 52, & 53
Integer and IEEE 4 byte floating point
Generic Serial Interface
The Generic Serial Interface is a user programmable Master and Slave protocol used to send and receive messages typically with third party serial
ASCII devices. This protocol can be used to interface with such devices as message boards, card readers and many measurement devices.
Remote Automation Solutions
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Product Data Document
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Key-Lock Security
The front panel keyswitch on ControlWave provides a high level of manual security by allowing three modes of operation to restrict access ot on-line functions.
In Run Mode, ControlWave will reject any attempt to download or modify the running program, either locally or over the network.
In Remote Mode, ControlWave will allow downloading and on-line program modification through the network provided the security access requirements have been met. Local download and on-line modification of the running program is prohibited.
In Local Mode, ControlWave will allow download and on-line modification through either the network connection or through a local serial communication port provided the security access requirements have been met.
Multi-User Security Access
Security is an essential element of any open system, particularly those with Internet access.
ControlWave employs a User Name/Password access system protected by a 56-bit encryption technique through the TCP connection. There can be up to thirty-two users who sign in using their name and password. Both the name and the password can be up to sixteen characters.
The security system provides for up to sixty-four access rights to read and write data values and files via FTP, access and configure historical and audit data information, edit configuration, run internal diagnostics, read and reset system status. It further allows the programming software to read, write and download the ControlWave.
The Secure Data Advantage
ControlWave sets a new standard for providing intelligent control at the point where control is needed.
Whether you need control on the plant floor or at a remte site in the "middle of nowhere", ControlWave is the solution for control, communication and secure data to help you make the right operating decisions.
Bristol ® ControlWave ® PAC
ControlWave was designed to provide the optimum level of data security using a distributed database architecture. All data including time & date stamped alarms, alarm limits, and historical data are stored locally in each industrially rugged ControlWave, thereby distributing your data integrity risk. To firther ensure that the data is always current and historically accurate, the historical data is stored in non-volatile flash memory within ControlWave.
Historical data is even maintained during and after program downloading.
When historical data is collected from ControlWave, it is converted and appended to .CSV and/or ODBC compliant databases but does not destroy the original historical data stored in ControlWave, thus providing a flexible and secure historical data system that is clearly recognized as a benefit to virtually every industrial application.
The Bridge Between Systems
Continuing our tradition of introducing innovative new solutions while maintaining compatibility with existing systems, Emerson again provides a migration path for existing customers by bridging the new
ControlWave system with Network 3000 systems already in place. The network bridge is enabled by employing the open architecture technologies afforded by TCP/IP and OPC in both networks.
TCP/IP allows seamless Ethernet connectivity to both networks as well as the corporate Intranet so both ControlWave and Network 3000 controllers can reside and communicate on the same LAN. Emerson’s Bristol OpenBSI OPC Server facilitates the merging of the two networks for technical, engineering and operator data access. The data source, configuration and path are completely transparent to the OPC client. Real-time data can also be passed between the two communication networks, making this a total Plant Automation Management Solution.
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Product Data Document
420DS-1k
July 16, 2007 - Page 15
Bristol ® ControlWave ® PAC
8-I/O Module - ControlWave - Mounting Dimensions
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Bristol ® ControlWave ® PAC
4-I/O Module - ControlWave - Mounting Dimensions
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Bristol ® ControlWave ® PAC
2-I/O Module - ControlWave - Mounting Dimensions
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Product Data Document
420DS-1k
July 16, 2007 - Page 18
4.00
TYP 1.80
6.71
Bristol ® ControlWave ® PAC
B A C
6.74
1.48
2.36
TYP
6.98
A
4.91
19 Inch Rack Mount Configuration
For 8 I/O Assembly
DETAIL
A
End Panel Mounting
.22
.57
.28
.32
.46
.32
ASSEMBLY
8 I/O Modules
DIM.
18.31
A
4 I/O Modules
2 I/O Modules
10.98
7.31
DIM.
18.98
B
11.65
7.98
DIM.
17.70
C
10.37
6.70
.82
All Dimensions Are In Inches
ControlWave Installation Drawing
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Bristol ® ControlWave ® PAC
ControlWave Base Unit
DESCRIPTION PART NO.
ControlWave main and I/O Expansion rack Chassis (Holds PSSM, CPU and 2, 4, or 8 I/O modules)
Select either the ControlWave CPU or I/O Expansion rack CPU.
0 I/O slot chassis Panel mount 396463-01-0
2 I/O slot chassis
4 I/O slot chassis
Panel mount or 19” rackmount
Panel mount or 19” rackmount
8 I/O slot chassis Panel mount or 19” rackmount
Internal Power Supply Sequencer Module (PSSM)
12 V input power PSSM
24 V input power PSSM
396356-03-6
396356-02-8
396356-01-0
396351-02-6
396351-01-8
24 V input power PSSM used with Redundant I/O system. See Page 5
CPU (See Note 1) Comm Port Configurations (Note 3)
CPU with 16 MB of RAM 1 - ENET & 2 - RS 232
CPU with 16 MB of RAM 1 - ENET & 3 - RS 232 & 1 - RS 485 (Note 2)
CPU with 16 MB of RAM 1 - ENET & 2 - RS 232 & 2 - RS 485 (Note 2)
CPU with 16 MB of RAM 3 - ENET & 3 - RS 232 & 1 - RS 485 (Note 2)
CPU with 16 MB of RAM 3 - ENET & 2 - RS 232 & 2 - RS 485 (Note 2)
I/O Expansion Rack CPU Comm Port Configurations (Note 3)
Comm CPU 2 - RS232 & 1 - ENET
Comm CPU 1 RS 232, 1 - RS 485 & 1 - ENET
396351-03-4
396359-01-9
396359-06-0
396359-07-8
396359-05-1
396359-12-4
396458-01-7
396458-02-5
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Product Data Document
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Bristol ® ControlWave ® PAC
ControlWave Base Unit (Continued)
DESCRIPTION
Local Termination I/O Modules
16 AI 4-20 mA Internally or Externally powered AI
PART NO.
16 AI
8 AI
8 AI
6 TC
4 RTD
8 AO
8 AO
4 AO
1-5 V & ext. powered 4-20 (with 250 ohm on input)
4-20 mA Internally or Externally powered AI
1-5 V & ext. powered 4-20 (with 250 ohm on input)
B, R, S, J, E, K, T, C, N, + 10 mV
2, 3, or 4 wire platinum RTD
4-20 mA
1-5 V
4-20 mA
396352-01-4
396352-02-2
396352-03-0
396352-04-9
396877-01-0
396878-01-6
396353-01-0
396353-02-9
32 DI
16 DI
Selectable Internally or Externally powered Dry Contact
Selectable Internally or Externally powered Dry Contact
32 DO
16 DO
12 UDI (HighSpeed
Counter)
Open Drain - 500 mA current capability, 30 mS filter
Open Drain - 500 mA current capability, 30 mS filter
Both 12 and 6 UDI High speed counters come with selectable
6 UDI (HighSpeed Counter) debounce (enabled/disable) @ (0-10 KHz) Low or High speed
396353-03-7
396357-01-6
396357-02-4
396358-01-2
396358-02-0
396362-01-0
396362-02-8
Notes
Note 1: CE approval requires the CE Accessories kits.
Note 2: RS485 Comm port 3 is RJ45. RS 485 ports have 500 V isolation
Note 3: The I/O Expansion Rack CPU interfaces to the main ControlWave Chassis CPU via Ethernet
Note 4: For conformal coating add -C suffix to each part number.
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Product Data Document
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Bristol ® ControlWave ® PAC
ControlWave I/O Modules and Termination Blocks
DESCRIPTION
Remote Termination I/O Modules (PC 850)
16 AI 4-20 mA Internally or Externally powered AI
16 AI
8 AI
1-5 V & ext. powered 4-20 (with 250 ohm on input)
4-20 mA Internally or Externally powered AI
8 AI
6 TC
4 RTD
1-5 V & ext. powered 4-20 (with 250 ohm on input)
B, R, S, J, E, K, T, C, N, + 10 mV
2, 3, or 4 wire platinum RTD
8 AO
8 AO
4 AO
32 DI
4-20 mA
1-5 V
4-20 mA
Selectable Internally or Externally powered Dry Contact
16 DI
32 DO
Selectable Internally or Externally powered Dry Contact
Open Drain - 500 mA current capability, 30 mS filter
16 DO Open Drain - 500 mA current capability, 30 mS filter
12 UDI (High Speed Counter) Both 12 and 6 UDI High speed counters come with selectable
6 UDI (High Speed Counter) debounce (enabled/disable) @ (0-10 KHz) Low or High speed counters. Inputs are 24VDC only.
PART NO.
Remote Terminal Blocks - (replacement fuses & relays can be found on spares page) (PC 851)
4 point AI (Note 1) No fuse 396391-01-0
4 point AI Fused 396391-02-8
2 point AO (Note 1)
2 point AO
No fuse
Fused
396391-01-0
396391-02-8
8 point DI
8 point DI
8 point DI - 120 Vac
8 point DI - 120 Vac
No fuse
Fused
No fuse (for internally powered DI module)
No fuse (for externally powered DI module)
396292-01-6
395622-02-6
395622-04-2
395622-01-8
8 point DO
8 point DO
8 point DO
3 point UDI
3 point UDI (Note 2)
No fuse
Fused
6 Amp Relay - No fuse
No fuse
No fuse protection
396292-01-6
395622-03-4
395622-00-0
396391-01-0
396391-02-8
396352-11-1
396352-12-0
396352-13-8
396352-14-6
396877-02-8
396878-02-4
396353-11-8
396353-12-6
396353-13-4
396357-11-3
396357-12-1
396358-11-0
396358-12-8
396362-11-7
396362-12-5
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Product Data Document
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Bristol ® ControlWave ® PAC
ControlWave I/O Modules and Termination Blocks (Cont’d)
DESCRIPTION
Remote Terminal Blocks (one cable required for each terminal block) (PC 851)
39” Term Cable
6.5 ft.” Term Cable
13 ft. Term Cable
Note 1: Sheild termination connection for AI & AO Remote Terminal blocks
recommend (P/N 395722-01-2) AO requires one and the AI requires two.
Note 2: Fuses do not offer protection for UDI points.
PART NO.
396389-01-5
396389-02-3
396389-03-1
395722-01-2
ControlWave Redundancy
CWREDCPU - A - BC - D
CODE DESCRIPTION CWREDCPU CODE
Redundant unit includes: Chassis, 2-PSSM, 2-CPU, Redundancy Switch Panel and serial communication cables from the CPUs to the Switch Panel. I/O is located in the Expansion Rack
A Internal Power Supply Sequencer Module
10 PSSM Power Supply +24 VDC input power
A
1
PSSM
BC Dual Redundant CPUs
20 CPU
CPU
CPU
D Chassis & Switcher Assembly
30 With Cables, Panel Mount
Power Supply +12 VDC input power
Comm Port Configurations CWREDCPUCP
(2) RS 232, (1) ETHERNET
(2) RS 232, (2) RS-485, (1) ETHERNET
(2) RS 232, (2) RS-485, (3) ETHERNET
CWREDCHASI
(2) RS-232, (2) RS-485
2
BC
01
07
12
D
2
© 2007 Remote Automation Solutions, division of Emerson Process Management. All rights reserved.
Bristol, Inc., Bristol Babcock Ltd, Bristol Canada, BBI SA de CV and the Flow Computer Division , are wholly owned subsidiaries of Emerson Electric Co. doing business as Remote Automation Solutions (“RAS”), a division of Emerson Process Management. FloBoss, ROCLINK, Bristol, Bristol Babcock, ControlWave, TeleFlow and Helicoid are trademarks of RAS. AMS,
PlantWeb and the PlantWeb logo are marks of Emerson Electric Co. The Emerson logo is a trademark and service mark of the Emerson Electric Co. All other marks are property of their respective owners.
The contents of this publication are presented for informational purposes only. While every effort has been made to ensure informational accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. RAS reserves the right to modify or improve the designs or specifications of such products at any time without notice. All sales are governed by RAS’ terms and conditions which are available upon request. RAS does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any RAS product remains solely with the purchaser and end-user.
Emerson Process Management
Remote Automation Solutions
Watertown, CT 06795 USA
Mississauga, ON 06795 Canada
Worcester WR3 8YB UK
T 1 (860) 945-2200
T 1 (905) 362-0880
T 44 (1) 905-856950
Website: www.EmersonProcess.com/Remote
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Key features
Open architecture for easy integration
Modular design for easy expansion
Advanced networking capabilities
Extensive library of basic IEC 61131-3 functions and function blocks
Frequently asked questions
The main benefit of using the ControlWave ExpressPAC is its ability to provide a complete automation solution for a wide range of process control applications.
Some of the key features of the ControlWave ExpressPAC include its open architecture, modular design, advanced networking capabilities, and extensive library of basic IEC 61131-3 functions and function blocks.
The ControlWave ExpressPAC is suitable for a wide range of process control applications, from small RTU systems to large plant-wide control systems.
