Emerson Bristol ControlWave LP Operation manual

Product Data Document

420DS-4c

July 19, 2007 - Page 1

Bristol®ControlWave®LP

Website: www.EmersonProcess.com/Remote

Remote Automation Solutions

Low Power High Performance Process

Automation Controller

Bristol® ControlWave® LP, from Emerson Process

Management, is a low power high performance pro-

cess automation controller that performs complex

control strategies, collects, time stamps, and stores

data, and communicates in local, remote, and wide

area networks. ControlWave LP offers the features

of an RTU and an automation controller with DCS

functionality.

Designed for control and data acquisition ap-

plications, the ControlWave LP is easily installed

in"remote areas and offers one of the industries

widest operating temperature ranges. Additionally,

due to its small form factor and rugged industrial

design, ControlWave LP offers an outstanding ability

to match the requirements of the most demanding

process plant and remote SCADA system environ-

ments. Above all, Emerson has developed this inno-

vative controller to provide cost-effective solutions

by minimizing the time required for installation and

conguration.

The ControlWave LP complements the ControlWave

and Network 3000 family of process automation

controllers and RTU’s. The ControlWave LP is

compact in size and offers the full programmabil-

ity of ControlWave Designer IEC 61131 compliant

software, and communicates via standard BSAP, as

well as other industry standard protocols.

The ControlWave LP is available in an open chassis

assembly for mounting to a panel or within an enclo-

sure. The unit is a three-board assembly consisting

of a CPU board, a Multifunction Input/Output board,

and a Power Supply/Sequencer board. All eld

I/O connections to the ControlWave LP are readily

available via quick disconnect terminals located on

the sides of the chassis.

Hardware Features

Ultra Low Power 486 based processor provides

high performance with low power consumption.

Five asynchronous serial communication ports

Fixed I/O with optional expansion I/O

Field device power supply built in

Small size

Wide temperature range (-40ºC to +70ºC)

Class I, Div. 2 hazardous location and

CE approval

Low Power Performance

The ControlWave LP uses the Ultra Low Power

(ULP) Intel 486SX processor. The CPU is oper-

ated at 3.3 V to reduce power consumption. The

unit automatically goes into a low power, quiet

mode, during CPU idle time. These features make

ControlWave LP the logical choice for low power ap-

plications using solar panels and battery backup.

•

Product Data Document

420DS-4c

July 19, 2007 - Page 2 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

Fused with power-on switch.

Master Clear and Power Fail Indication

Power sequencer for auto power recovery

Power supply isolation: 500 VDC

Surge Suppression: 500 VDC MOV PSGND

to CHASSIS 32 V Transient suppressor across

VIN + to PSGND Meets ANSI/IEEE C37.90-

1978

Low Power Mode

ControlWave LP power consumption is highly

dependent on the actual application program and

whether or not you are using internal loop power to

eld devices.

Typical power consumption range: 150 to 200 mA

@ 24 Vdc

Fixed Multifunction Input/Output Board

The Fixed Multifunction Input/Output Board (FMI/

OB) contains four I/O modules with pluggable termi-

nations and a PC-104 Interface for interconnection

of xed and expansion I/O subsystems. The board

also provides for electrical isolation to eld devices,

surge suppression, and LED indicators for Discrete

I/O, CPU, and communications functions. The four

I/O modules are xed as follows:

16 Discrete Inputs

8 Discrete Outputs

4 High Speed Counters

8 Analog Inputs

Two on-board Field Power Supplies are provided:

one for DI and HSC operation and one for AI opera-

tion. The output voltages are electrically isolated

(500 VDC) and are regulated at 24V.

•

Specications

CPU

Intel Ultra Low Power 486SX 32 bit processor

-25 MHz

Data Storage Memory: 2 MB SRAM battery

backed memory

Historical Archive Memory: Stored in either

ash or battery backed SRAM

Code/ Instruction Memory: 4 MB on-board

FLASH

BIOS: 512 Kbytes Boot-Block FLASH

Communication

Four RS-232 serial communication ports with

standard PC/AT 9-pin male D-sub connectors,

supporting baud rates up to 115.2 KB

One selectable RS 232 or RS 485 serial

communication port with standard PC/AT 9-pin

male D-sub connector, supporting baud rates up

to 115.2 KB

RS 485 port has line pull-ups and termination

resistor

Modem control on all ports.

One 10 Base-T Ethernet port with RJ45

connector - Optional.

Isolation: Ethernet port isolated to 500 Vdc

Power Supply/Sequencer Board

Input Power: 12 or 24 VDC input: 10 to 22 VDC

or 22 to 30 VDC

Plugs into Multifunction Motherboard

Provides system isolated + 5 VDC & +/- 12 VDC

power

•

Product Data Document

420DS-4c

July 19, 2007 - Page 3 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

Fixed I/O Subsystem

ControlWave LP Discrete Input Module

Number of Points: 16 Fixed

Input Voltage Range: 12V or 24V

Input Filtering: 1 millisecond or 30 milliseconds

Input Conguration: Contact Closure, internally

or externally sourced on a point by point basis.

Jumper Congurable

Input Current: 2.5 mA +/- 10%

‘1’ State Voltage: 90 % of input voltage range

‘0’ State Voltage: 10 % of input voltage range

Interrupt Generation: On change of state

transition on a point by point basis

Bus Access: Sixteen bit wide

Electrical isolation: 1500 VDC

Surge suppression: 500Vdc MOV to chassis 38

VDC MOV across input and to Field Common

Meets ANSI/IEEE C37.90-1978

Terminations: Pluggable, maximum wire size is

16 gauge

Status indication: 16 LED’s (one per point)

ControlWave LP Discrete Output Module

Number of Points: 8

Output Type: Open Drain

Max Operating Voltage: 38 VDC

Max. Operating Freq: 20 Hz

Sink Current: 100 mA Maximum

Electrical Isolation: 1500 VDC

Surge Suppression: 500Vdc MOV isolated

common to chassis 38 VDC MOV across input

signals and (-) input to chassis Meets ANSI/

IEEE C37.90-1978

Terminations: Pluggable, maximum wire size is

16 gauge

Bus Access: 16 Bits Wide

•

ControlWave LP Analog Input Module

Number of Points: 8

Input Conguration: Isolated Voltage Input: 1-5V

Isolated Current Input: 4-20 mA

Powered Current Loop: 4-20 mA

Accuracy: 0.1 % of span @ 25 deg. C 0.2 % of

span –20 deg.C to + 70 deg. C 0.3 % of span

–40 deg.C to + 70 deg. C

Isolated Voltage/Current: 38 VDC referenced to

isolated common

Powered Current Loop: 0 V referenced to

isolated common When a eld supply common

is connectesd to the AI system the isolated

common is connected to the eld supply

common

Input Filtering: 300 milliseconds to 99.75% of

signal input.

Channel Settling Time: 300 microseconds

Conversion Time: 200 microseconds

On Board References: 1V, 5V - optional

Surge Suppression: 500Vdc MOV isolated

common to chassis 38 VDC MOV across input

signals and (-) input to chassis Meets ANSI/

IEEE C37.90-1978

Terminations: Pluggable, maximum wire size is

16 gauge

Bus Access: 16 Bits Wide

ControlWave LP High Speed Counter Module

Number of points: 4

Input Voltage Range: 12V or 24V

Input Filtering: 10 KHz max.

Input Filtering: 20 microseconds

Input Conguration: Set/Reset inputs, contact

closure, externally sourced on point by point

basis with jumper congurtion.

Input Current: 2.5 mA +/- 10%

•

Product Data Document

420DS-4c

July 19, 2007 - Page 4 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

‘1’ State Voltage: 90 % of input voltage range

‘0’ State Voltage: 10 % of input voltage range

Bus Access: 16-bits wide

Max Accumulator Value: 65536

Electrical Isolation: 1500 VDC

Surge Suppression: 500Vdc MOV to Chasis 38

VDC MOV across input and to Field Common

Meets ANSI/IEEE C37.90-1978

Terminations: Pluggable, maximum wire size is

16 gauge

Status indication: 4 LED’s (one per point)

ControlWave LP Analog Output Module

(Optional)

Number of Points: 4

Output congurations: 1-5 VDC & 4-20 mA

(Individually congured)

Power Loop: 9 to 30 VDC for 4-20 mA AO 10

to 30 VDC for 1-5 VDC AO

Accuracy: 0.1% of span @ + 25oC

0.2% of span @ -20 to 70 oC

0.3% of span @ -40 to 85 oC

Common Mode Voltage: 500 VDC (AO ground

to chassis)

Surge Suppression: 16 V Transorb across input

to AO Ground Meets ANSI/IEEE C37.90-1975

•

Environmental Specications

Operating Temperature: -40oC to + 70oC

(-40oF to + 158oF)

Storage Temperature: -40oC to + 85oC

(-40oF to + 185oF)

Relative Humidity: 15 – 95 Noncondensing

Vibration: 10-150 Hz at 1.0G

150-2000 Hz at 0.5G

RFI Susceptibility: 3V/M at 80-1000 MHz per

EN50082-2

ControlWave LP Packaging

Physical Size: Mounting Plate is 12.5 inches

high x 8.5 inches wide. Unit is 3.5 inches deep.

•

AI -

AI +

4 - 20 mA

internally powered

transmitter

AI + AI In +

AI In -

Two Wire

Transmitter

Vdc

AI In -

AI In +

4 - 20 mA

externally powered

transmitter

AI +

AI -

Two Wire

Transmitter

Three Wire

Transmitter

AI In +

AI In -

1 - 5 Vdc

AI for externally

powered

transmitter

24 Vdc

AI +

AI -

AI +

AI -

Product Data Document

420DS-4c

July 19, 2007 - Page 5 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

ControlWave LP Software

Open Standards For Programming, Network

Conguration and Communication.

Only Bristol ControlWave, from Emerson Process

Management, brings you the perfect combination of

industry standards to minimize your learning, engi-

neering and implementation costs. The intelligent

tool suites add an extra dimension to the overall

umbrella we call OpenBSI (Open Bristol System

Interface).

ControlWave Designer - Programming

Software, I/O Conguration Wizard, and I/O

Simulator

TechTools – Diagnostics, Application

Downloader, Real-Time ActiveX controls and

Setup Wizards

OpenBSI Essentials – NetView/LocalView,

DataView, HMI Database Builder, Real Time

Active X controls and optional OPC Server

HistTools – Historical Data Collector, Scheduler

and File Converter

•

By adhering to such industry standards as Ethernet,

TCP/IP, Microsoft Windows®, COM/DCOM, OLE and

Active X, ControlWave is able to achieve the highest

degree of openness in control system architecture

and bring you the optimal process efciency and

productivity you need to ensure a successful system

implementation. To minimize your engineering and

development time, we have adopted the best pro-

gramming standard available in IEC 61131-3. IEC

61131-3 compliant programming is supported by

the ControlWave Designer conguration generation

tools, offering all ve IEC 61131-3 process languag-

es for batch or continuous control, and ladder logic

and sequential languages for discrete control, as

well as high level languages for maximum exibility.

Additionally, ControlWave is loaded with custom-

ized function blocks to simplify the conguration of

complicated industrial, water & wastewater, and oil

& gas, and industrial control system applications.

Product Data Document

420DS-4c

July 19, 2007 - Page 6 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

OpenBSI

Simply Creative

OpenBSI (Open Bristol System Interface) is a set

of network setup, communication diagnostic, and

data viewing utilities that provide access to both

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 com-

munication interface, written as a Windows 98/NT &

2000 communication server API through which other

client applications communicate with the Bristol net-

works. OpenBSI supports both serial BSAP protocol

and Ethernet Internet Protocol communication to

ControlWave and Network 3000 RTUs and control-

lers. 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,

generate les based on collected historical data,

collect alarms, and monitor and control OpenBSI

communications.

OpenBSI Utilities

OpenBSI Utilities provide a full set of communica-

tion and data access capabilities for operators

directly connected to the ControlWave network as

well as remote operators connected through one

of the main operator PCs. The OpenBSI includes

utilities to easily create the OPC server database

from the ControlWave application conguration les,

then provide access to those variables to any OPC

compliant HMI product for operator display and

interaction with the ControlWave network. HistTools

– Historical collection and storage

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

Allows signal searches based on selective

criteria

•

Allows network conguration through NetView

PC and Network communication diagnostics

OPC Server for interfacing to most HMI

software

Data Collector and Scheduler Utilities Collects

historical data on request or scheduled basis

NetView is the basic conguration 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 conguration Wizard simpli-

fying 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 cong-

ured, 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.

•

NetView - Network conguration

and application LaunchPad

Product Data Document

420DS-4c

July 19, 2007 - Page 7 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

Conguration Wizard simplies Network setup

Local Conguration Wizard allows local commu-

nication with any attached ControlWave controller

or RTU to download system ashware upgrades,

congure cold download parameters, and congure

IP and soft-switch parameters.

DataView for Real-time data display

DataView is an on-line utility for ControlWave and

Network 3000 nodes 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.

TechTools – OPC Server & ActiveX

Controls

The Technicians Toolkits consist of a set of congu-

ration wizards and standard web pages which are

used to congure a newly installed ControlWave or

modify those parameters on an existing controller.

The key components of the Technicians Toolkit are:

WebBSI- A set of Active X controls allowing commu-

nication access to ControlWave are provided for en-

gineers to develop their own custom web pages us-

ing any standard package such as Microsoft®Front-

Page. Active X controls allow data to be viewed in

any compliant container (such as Microsoft Excel

and Word or Visual Basic), or a compliant web page

Browser such as Microsoft Internet Explorer.

Real-time ActiveX Controls

One of the many benets TechTools brings to

you is our use of open standards such as ActiveX

Controls. AcitveX is another of the Microsoft stan-

dards, which allow plug and play with any ActiveX

container, using Microsoft ActiveX container tech-

nology such as Visual Basic, HTML web pages, and

Microsoft Excel

The set of available ActiveX Controls provides the

basic functions necessary to communicate and col-

lect data from ControlWave.

ActiveX Controls

Security – 56-bit encryption - allows the user to

sign on to the RTU.

Signal Value – displays signal values in various

formats.

Comm Statistics – works with a standard

page that displays the RTU’s communication

statistics.

Conguration Info – works with a standard page

that displays and allows the user to change

RTU Conguration information.

•

Product Data Document

420DS-4c

July 19, 2007 - Page 8 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

The IP compliant ControlWave opens the door for

owner controlled access via Web Pages. Any ge-

neric web page builder can be employed to create

user dened pages to access ControlWave. The

web pages are populated with these pre-congured

Active X controls.

Software Required

Microsoft’s Internet Explorer

Emerson’s Bristol Active X Controls

Emerson’s Bristol Data Server

OpenBSI Utilities

High Historical Data Integrity

The ControlWave Historical Data Collection sys-

tem provides time-stamped historical data storage

in ControlWave nonvolatile Flash memory. The

historical data is collected, through OpenBSI, on a

schedule or demand basis and converted to .CSV

and ODBE compliant le formats for use spread-

•

sheet and database reports. If data is missed due

to a communication failure, it is collected when the

communication is reestablished and the PC histori-

cal database is backlled with the missing data.

This distributed historical database architecture

proveides the greatest data reliability and integrity

during communication or PC downtime.

Another important historical feature is the Audit

storage and collection system. The audit trail is a

le stored in ControlWave Flash memory containing

signicant events and time-stamped alarms. The

alarms stored in the Audit system provide a histori-

cal archive in addition to the real-time alarm report-

ing system. This le is also collected through Open-

BSI and presented as a text le in the PC. This

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 les to third party, .CSV & ODBC

applications

DDE compliant for use with other popular

Windows applications

OPC Server

With industry demand for open standards,

ControlWave answers the call by embracing tech-

nologies that open the door for maximizing your

efciency 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 con-

dence in their interoperability. Our OpenBSI OPC

Server was among the rst to comply with the OPC

Foundation alarm and event server specication.

OPC Data Access 1.0a & 2.0 compatible

Windows 98/NT & 2000

Compatible with both ControlWave and Network

3000 systems

32 bit multi-threading, multi-processor design

Automatic database builder

•

Generic Web

Page

Data Server

Control

Wave

Product Data Document

420DS-4c

July 19, 2007 - Page 9 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

Integrated real-time data monitor

Supports OPC Browse interface

Supports both serial comm and IP Ethernet

connections

Supports COM/DCOM & OLE Automation

Primary and Background polling scheme

OPC Alarm & Event Server support

•

Open Modbus TCP/IP

Corporate

Mainframe

Laptop

Hub

Router

Corporate Intranet

Plant Control Network

I/O Network

Ethernet TCP/IP

Open Modbus

Ethernet

Laptop

ControlWave

Remote Ethernet I/O ControlWave

Network 3000

OpenBSI

OPC Server

Remote

Workstation

DPC 3330

RTU 3310

RTU 3305

TeleRTU

ControlWave

DPC 3335

Operator and Engineering

Workstations

WAN

Plant Automation

Management Solution

Engineer

Customer

Serial

Modbus

ControlWave

BSAP

Modbus

ControlWave Open Network Connectivity

By embracing the open system network technolo-

gies 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 informa-

tion to the plant oor technician, operator, engineer,

supervisor and corporate management, even exter-

nal customers.

Product Data Document

420DS-4c

July 19, 2007 - Page 10 Bristol®ControlWave®LP

Remote Automation Solutions

Website: www.EmersonProcess.com/Remote

Communication Protocols

Like all Emerson products, ControlWave supports

BSAP (Bristol Standard Asynchronous Protocol),

Modbus, DF1 and serial ASCII as standard func-

tions. These protocols are implemented in ash-

ware so no additional hardware is required to use

any one or a combination of all protocols.

All of Emerson’s Bristol Network 3000 and

ControlWave RTU and controller products support

BSAP protocol. BSAP is widely accepted as provid-

ing exceptional data integrity and greatly simpli-

es 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 con-

troller that are easily passed from server to client or

slave to master.

BSAP meets the denition of an industry-standard,

open-architecture protocol because if conforms to

ISO standards 2629, 1745 and 2111, it is not propri-

etary in that Emerson does not charge a license fee

and makes the protocol and documentation avail-

able to anyone.

While BSAP is an open protocol, the added func-

tionality of the messages passed provide much

more capability than is found other networks.

Global time-synchronization

Time-stamped Alarm reporting

Historical archive data transfer

Audit le transfer

On-line program editing

Diagnostics

Communication statistics

Modbus - Modbus is often considered a de-facto

standard protocol because broad usage as ei-

ther 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 addi-

tion there are consideration regarding supported

function codes, oating point values and byte order.

Emerson’s Bristol products 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 oating point

Allen Bradley DF-1

DF-1 protocol is the primary mechanism to inter-

face to Allen Bradley PLCs and interface devices.

ControlWave and Network 3000 both support DF-1

half-duplex master protocol.

Generic Serial Protocol

The Generic Serial Protocol is a Master and Slave

protocol used to send and receive messages typi-

cally with third party serial ASCII devices. This

protocol can be used to interface with such devices

and message boards, card readers and many mea-

surement devices.

Multi-User Security Access

Security is an essential element of any open

system, particularly those with Internet access.

ControlWave employs a User Name/Password ac-

cess system protected by a 56-bit encryption tech-

nique 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.

•

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