Product Data Document 420DS-4c July 19, 2007 - Page 1 ® ® Bristol ControlWave LP 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 Hardware Features by minimizing the time required for installation and configuration. • Ultra Low Power 486 based processor provides high performance with low power consumption. The ControlWave LP complements the ControlWave and Network 3000 family of process automation • Five asynchronous serial communication ports controllers and RTU’s. The ControlWave LP is • Fixed I/O with optional expansion I/O compact in size and offers the full programmabil- ity of ControlWave Designer IEC 61131 compliant • Field device power supply built in software, and communicates via standard BSAP, as well as other industry standard protocols. • Small size • Wide temperature range (-40ºC to +70ºC) The ControlWave LP is available in an open chassis Class I, Div. 2 hazardous location and assembly for mounting to a panel or within an enclo- CE approval 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 field I/O connections to the ControlWave LP are readily Low Power Performance available via quick disconnect terminals located on the sides of the chassis. 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. Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 2 Bristol ControlWave LP • Fused with power-on switch. Specifications • Master Clear and Power Fail Indication CPU • Power sequencer for auto power recovery • Intel Ultra Low Power 486SX 32 bit processor • Power supply isolation: 500 VDC -25 MHz • Surge Suppression: 500 VDC MOV PSGND • Data Storage Memory: 2 MB SRAM battery to CHASSIS 32 V Transient suppressor across backed memory VIN + to PSGND Meets ANSI/IEEE C37.90- • Historical Archive Memory: Stored in either 1978 flash or battery backed SRAM Low Power Mode • Code/ Instruction Memory: 4 MB on-board FLASH ControlWave LP power consumption is highly • BIOS: 512 Kbytes Boot-Block FLASH dependent on the actual application program and whether or not you are using internal loop power to field devices. Communication • Four RS-232 serial communication ports with Typical power consumption range: 150 to 200 mA standard PC/AT 9-pin male D-sub connectors, @ 24 Vdc supporting baud rates up to 115.2 KB Fixed Multifunction Input/Output Board • One selectable RS 232 or RS 485 serial communication port with standard PC/AT 9-pin The Fixed Multifunction Input/Output Board (FMI/ male D-sub connector, supporting baud rates up OB) contains four I/O modules with pluggable termi- to 115.2 KB nations and a PC-104 Interface for interconnection • RS 485 port has line pull-ups and termination of fixed and expansion I/O subsystems. The board resistor also provides for electrical isolation to field devices, surge suppression, and LED indicators for Discrete • Modem control on all ports. I/O, CPU, and communications functions. The four I/O modules are fixed as follows: • One 10 Base-T Ethernet port with RJ45 connector - Optional. • 16 Discrete Inputs • Isolation: Ethernet port isolated to 500 Vdc • 8 Discrete Outputs • 4 High Speed Counters Power Supply/Sequencer Board • 8 Analog Inputs • Input Power: 12 or 24 VDC input: 10 to 22 VDC or 22 to 30 VDC Two on-board Field Power Supplies are provided: • Plugs into Multifunction Motherboard one for DI and HSC operation and one for AI opera- tion. The output voltages are electrically isolated • Provides system isolated + 5 VDC & +/- 12 VDC (500 VDC) and are regulated at 24V. power Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 3 Bristol ControlWave LP ControlWave LP Analog Input Module Fixed I/O Subsystem • Number of Points: 8 ControlWave LP Discrete Input Module • Input Configuration: Isolated Voltage Input: 1-5V • Number of Points: 16 Fixed • Isolated Current Input: 4-20 mA • Input Voltage Range: 12V or 24V • Powered Current Loop: 4-20 mA • Input Filtering: 1 millisecond or 30 milliseconds • Accuracy: 0.1 % of span @ 25 deg. C 0.2 % of • Input Configuration: Contact Closure, internally span –20 deg.C to + 70 deg. C 0.3 % of span or externally sourced on a point by point basis. –40 deg.C to + 70 deg. C Jumper Configurable • Isolated Voltage/Current: 38 VDC referenced to • Input Current: 2.5 mA +/- 10% isolated common • ‘1’ State Voltage: 90 % of input voltage range • Powered Current Loop: 0 V referenced to isolated common When a field supply common • ‘0’ State Voltage: 10 % of input voltage range is connectesd to the AI system the isolated common is connected to the field supply • Interrupt Generation: On change of state common transition on a point by point basis • Input Filtering: 300 milliseconds to 99.75% of • Bus Access: Sixteen bit wide signal input. • Electrical isolation: 1500 VDC • Channel Settling Time: 300 microseconds • Electrical isolation: 1500 VDC • Conversion Time: 200 microseconds • Surge suppression: 500Vdc MOV to chassis 38 • On Board References: 1V, 5V - optional VDC MOV across input and to Field Common Meets ANSI/IEEE C37.90-1978 • Surge Suppression: 500Vdc MOV isolated common to chassis 38 VDC MOV across input • Terminations: Pluggable, maximum wire size is signals and (-) input to chassis Meets ANSI/ 16 gauge IEEE C37.90-1978 • Status indication: 16 LED’s (one per point) • Terminations: Pluggable, maximum wire size is 16 gauge ControlWave LP Discrete Output Module • Bus Access: 16 Bits Wide • Number of Points: 8 • Output Type: Open Drain ControlWave LP High Speed Counter Module • Max Operating Voltage: 38 VDC • Number of points: 4 • Max. Operating Freq: 20 Hz • Input Voltage Range: 12V or 24V • Sink Current: 100 mA Maximum • Input Filtering: 10 KHz max. • Electrical Isolation: 1500 VDC • Input Filtering: 20 microseconds • Surge Suppression: 500Vdc MOV isolated • Input Configuration: Set/Reset inputs, contact common to chassis 38 VDC MOV across input closure, externally sourced on point by point signals and (-) input to chassis Meets ANSI/ basis with jumper configurtion. IEEE C37.90-1978 • Input Current: 2.5 mA +/- 10% • Terminations: Pluggable, maximum wire size is 16 gauge • Bus Access: 16 Bits Wide Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 4 Bristol ControlWave LP Two Wire Three Wire Two Wire Transmitter Transmitter Transmitter AI In + AI In + 1 AI + AI In + AI + 1 AI + 1 AI - 2 AI In - AI - 2 AI In - 2 AI - AI In - 3 AI + _ + AI + 3 AI + 3 24 4 AI - 24 Vdc AI - Vdc 4 AI - 4 1 - 5 Vdc 4 - 20 mA AI for externally 4 - 20 mA externally powered powered internally powered transmitter transmitter transmitter • ‘1’ State Voltage: 90 % of input voltage range Environmental Specifications o o • ‘0’ State Voltage: 10 % of input voltage range • Operating Temperature: -40 C to + 70 C o o (-40 F to + 158 F) • Bus Access: 16-bits wide o o • Storage Temperature: -40 C to + 85 C • Max Accumulator Value: 65536 o o (-40 F to + 185 F) • Electrical Isolation: 1500 VDC • Relative Humidity: 15 – 95 Noncondensing • Surge Suppression: 500Vdc MOV to Chasis 38 • Vibration: 10-150 Hz at 1.0G VDC MOV across input and to Field Common Meets ANSI/IEEE C37.90-1978 150-2000 Hz at 0.5G • Terminations: Pluggable, maximum wire size is • RFI Susceptibility: 3V/M at 80-1000 MHz per 16 gauge EN50082-2 • Status indication: 4 LED’s (one per point) ControlWave LP Packaging ControlWave LP Analog Output Module (Optional) • Physical Size: Mounting Plate is 12.5 inches high x 8.5 inches wide. Unit is 3.5 inches deep. • Number of Points: 4 • Output configurations: 1-5 VDC & 4-20 mA (Individually configured) • Power Loop: 9 to 30 VDC for 4-20 mA AO 10 to 30 VDC for 1-5 VDC AO o • Accuracy: 0.1% of span @ + 25 C o 0.2% of span @ -20 to 70 C o 0.3% of span @ -40 to 85 C • 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 Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 5 Bristol ControlWave LP By adhering to such industry standards as Ethernet, ControlWave LP Software ® TCP/IP, Microsoft Windows , COM/DCOM, OLE and Active X, ControlWave is able to achieve the highest Open Standards For Programming, Network degree of openness in control system architecture Configuration and Communication. and bring you the optimal process efficiency and productivity you need to ensure a successful system Only Bristol ControlWave, from Emerson Process implementation. To minimize your engineering and Management, brings you the perfect combination of development time, we have adopted the best pro- industry standards to minimize your learning, engi- gramming standard available in IEC 61131-3. IEC neering and implementation costs. The intelligent 61131-3 compliant programming is supported by tool suites add an extra dimension to the overall the ControlWave Designer configuration generation umbrella we call OpenBSI (Open Bristol System tools, offering all five IEC 61131-3 process languag- Interface). es for batch or continuous control, and ladder logic and sequential languages for discrete control, as • ControlWave Designer - Programming well as high level languages for maximum flexibility. Software, I/O Configuration Wizard, and I/O Additionally, ControlWave is loaded with custom- Simulator ized function blocks to simplify the configuration of • TechTools – Diagnostics, Application complicated industrial, water & wastewater, and oil Downloader, Real-Time ActiveX controls and & gas, and industrial control system applications. 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 Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 6 Bristol ControlWave LP • Allows network configuration through NetView OpenBSI • PC and Network communication diagnostics Simply Creative • OPC Server for interfacing to most HMI software OpenBSI (Open Bristol System Interface) is a set of network setup, communication diagnostic, and • Data Collector and Scheduler Utilities Collects data viewing utilities that provide access to both historical data on request or scheduled basis ControlWave and Network 3000 controllers and RTUs. OpenBSI is the only product available in the NetView is the basic configuration and application industry to bring such unique functionality and ease interface for all network operations. NetView uses of use to the network level. At the core is the com- a tree structure for network graphical display in the munication interface, written as a Windows 98/NT & Windows Explorer style. Network nodes can be 2000 communication server API through which other added on-line by simply dragging the node Icon into client applications communicate with the Bristol net- the tree. This invokes a configuration Wizard simpli- works. OpenBSI supports both serial BSAP protocol fying network setup. Through the NetView Wizard, and Ethernet Internet Protocol communication to the necessary network parameters are entered for ControlWave and Network 3000 RTUs and control- node and IP address, alarm and message routing, lers. Above this communication layer are a group and network communication media. Once config- of applications known as OpenBSI Utilities. These ured, selecting any node allows direct access to the client utilities communicate through the server to common OpenBSI utilities to reprogram, download a collect and manage data gathered from the network, new application to the node, review communication generate files based on collected historical data, statistics, view real-time data through DataViewer, collect alarms, and monitor and control OpenBSI and edit controller/RTU properties. 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 configuration files, 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 NetView - Network configuration • Communication engine for PC applications and application LaunchPad • 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 Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 7 Bristol ControlWave LP Local Configuration Wizard allows local commu- TechTools – OPC Server & ActiveX nication with any attached ControlWave controller Controls or RTU to download system flashware upgrades, configure cold download parameters, and configure The Technicians Toolkits consist of a set of configu- IP and soft-switch parameters. ration wizards and standard web pages which are used to configure 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 benefits TechTools brings to Configuration Wizard simplifies Network setup you is our use of open standards such as ActiveX Controls. AcitveX is another of the Microsoft stan- DataView is an on-line utility for ControlWave and dards, which allow plug and play with any ActiveX Network 3000 nodes used to collect and display container, using Microsoft ActiveX container tech- several types of process data, including signal nology such as Visual Basic, HTML web pages, and values, data array values, signal lists, and audit Microsoft Excel trail information. Operators have the ability to alter signal values. Multiple DataView windows may be The set of available ActiveX Controls provides the open simultaneously. 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. • Configuration Info – works with a standard page that displays and allows the user to change RTU Configuration information. DataView for Real-time data display Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 8 Bristol ControlWave LP sheet and database reports. If data is missed due Page Generic Web to a communication failure, it is collected when the communication is reestablished and the PC histori- cal database is backfilled 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 file stored in ControlWave Flash memory containing significant 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 file is also collected through Open- BSI and presented as a text file in the PC. This Data Server • Archive Collection – collection and storage to disk of the ControlWave archive data • Audit Collection - collection and storage to disk of the ControlWave audit data. Wave Control • Exports data files to third party, .CSV & ODBC applications The IP compliant ControlWave opens the door for • DDE compliant for use with other popular owner controlled access via Web Pages. Any ge- Windows applications neric web page builder can be employed to create user defined pages to access ControlWave. The OPC Server web pages are populated with these pre-configured Active X controls. With industry demand for open standards, ControlWave answers the call by embracing tech- Software Required nologies that open the door for maximizing your efficiency and productivity. The OPC standard was • Microsoft’s Internet Explorer developed by the OPC Foundation comprised of hardware and software suppliers from the process • Emerson’s Bristol Active X Controls control community. OPC allows the engineer to • Emerson’s Bristol Data Server select best in class hardware and software with con- fidence in their interoperability. Our OpenBSI OPC Server was among the first to comply with the OPC Foundation alarm and event server specification. OpenBSI Utilities • OPC Data Access 1.0a & 2.0 compatible High Historical Data Integrity • Windows 98/NT & 2000 The ControlWave Historical Data Collection sys- • Compatible with both ControlWave and Network tem provides time-stamped historical data storage 3000 systems in ControlWave nonvolatile Flash memory. The historical data is collected, through OpenBSI, on a • 32 bit multi-threading, multi-processor design schedule or demand basis and converted to .CSV • Automatic database builder and ODBE compliant file formats for use spread- Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 9 Bristol ControlWave LP • Integrated real-time data monitor ControlWave Open Network Connectivity • Supports OPC Browse interface By embracing the open system network technolo- gies available through TCP/IP, Ethernet, OPC, and • Supports both serial comm and IP Ethernet Microsoft™ DNA, as well as pseudo standards such connections as Modbus and Open Modbus, ControlWave can • Supports COM/DCOM & OLE Automation provide a total Process Automation Management Solution for in-plant LAN based networks and Wide • Primary and Background polling scheme Area Network SCADA systems. • OPC Alarm & Event Server support 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 floor technician, operator, engineer, supervisor and corporate management, even exter- nal customers. Plant Automation Management Solution Corporate Mainframe Corporate Intranet Ethernet TCP/IP Remote Workstation Engineer Operator and Engineering Workstations WAN Router Laptop OpenBSI Customer OPC Server Router Ethernet TCP/IP Plant Control Network Open Modbus ControlWave Laptop Router DPC 3335 Network 3000 Modbus I/O Network Ethernet Serial Hub Modbus BSAP Open Modbus TCP/IP DPC 3330 RTU 3310 RTU 3305 TeleRTU ControlWave ControlWave ControlWave Remote Ethernet I/O Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 10 Bristol ControlWave LP Communication Protocols Slave, Serial and TCP/IP Open Modbus. In addi- tion there are consideration regarding supported Like all Emerson products, ControlWave supports function codes, floating point values and byte order. BSAP (Bristol Standard Asynchronous Protocol), Emerson’s Bristol products supports the following: Modbus, DF1 and serial ASCII as standard func- • Modbus serial and TCP/IP Open Modbus tions. These protocols are implemented in flash- (Ethernet) ware so no additional hardware is required to use any one or a combination of all protocols. • Master and Slave All of Emerson’s Bristol Network 3000 and • Modbus RTU and ASCII ControlWave RTU and controller products support • Modes 1 - 7, 8, 15 & 16 BSAP protocol. BSAP is widely accepted as provid- ing exceptional data integrity and greatly simpli- • IP modes 51, 52 & 53 fies communication between controllers. BSAP is provided with interfaces for Master/Slave, vertical • Integer and IEEE 4 byte floating point 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 Allen Bradley DF-1 slave to master. DF-1 protocol is the primary mechanism to inter- BSAP meets the definition of an industry-standard, face to Allen Bradley PLCs and interface devices. open-architecture protocol because if conforms to ControlWave and Network 3000 both support DF-1 ISO standards 2629, 1745 and 2111, it is not propri- half-duplex master protocol. etary in that Emerson does not charge a license fee and makes the protocol and documentation avail- able to anyone. Generic Serial Protocol While BSAP is an open protocol, the added func- The Generic Serial Protocol is a Master and Slave tionality of the messages passed provide much protocol used to send and receive messages typi- more capability than is found other networks. cally with third party serial ASCII devices. This protocol can be used to interface with such devices • Global time-synchronization and message boards, card readers and many mea- • Time-stamped Alarm reporting surement devices. • Historical archive data transfer • Audit file transfer Multi-User Security Access • On-line program editing Security is an essential element of any open system, particularly those with Internet access. • Diagnostics ControlWave employs a User Name/Password ac- • Communication statistics cess system protected by a 56-bit encryption tech- nique through the TCP connection. There can be up Modbus - Modbus is often considered a de-facto to thirty-two users, who sign-in using their name and standard protocol because broad usage as ei- password. Both the name and the password can be ther the primary or a secondary offering in many up to sixteen characters. measurement and control related products. Even with its common use, Modbus protocol actually has many variations. Consider Modbus RTU and Modbus ASCII, Master & Remote Automation Solutions Website: www.EmersonProcess.com/Remote Product Data Document 420DS-4c ® ® July 19, 2007 - Page 11 Bristol ControlWave LP The security system provides for up to sixty-four When historical data is collected from ControlWave, access rights to read and write data values and files it is converted and appended to .CSV and/or ODBC via FTP, access and configure historical and audit compliant databases but does not destroy the origi- data information, edit configuration, run internal nal historical data stored in ControlWave. Thus, a diagnostics, read and reset system status. It further flexible and secure historical data system is clearly allows the programming software to read, write and recognized as a benefit to virtually every industrial download the ControlWave. application. The Secure Data Advantage The Bridge Between Systems ControlWave sets a new standard for providing in- Continuing our tradition of introducing innovative telligent control at the point where control is needed. new solutions while maintaining compatibility with Whether you need control on the plant floor or at a existing systems, Emerson again provides a migra- remote site in the “middle of nowhere” ControlWave tion path for existing customers by bridging the new is the solution for control, communication and ControlWave system with Network 3000 systems secure data to help you make the right operating already in place. The network bridge is enabled decisions. by employing the open architecture technologies afforded by TCP/IP and OPC in both networks. ControlWave was designed to provide the optimum TCP/IP allows seamless Ethernet connectivity to level of data security using a distributed database both networks as well as the corporate Intranet so architecture. All data including time & date stamped both ControlWave and Network 3000 controllers alarms, alarm limits, and historical data are stored can reside and communicate on the same LAN. locally in each industrially rugged ControlWave, Emerson’s Bristol OpenBSI OPC Server facilitates thereby distributing your data integrity risk. To the merging of the two networks for technical, engi- further ensure that the data is always current and neering and operator data access. The data source, historically accurate, the historical data is stored configuration and path are completely transparent to in non-volatile flash memory within ControlWave. the OPC client. Real-time data can also be passed Historical data is even maintained during and after between the two communication networks making program downloading. this a total Plant Automation Management Solution. © 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 Auto- mation 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 war- ranties 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 T 1 (860) 945-2200 Mississauga, ON 06795 Canada T 1 (905) 362-0880 Worcester WR3 8YB UK T 44 (1) 905-856950 Website: www.EmersonProcess.com/Remote