Product Data Document
420DS-6d / D301311X012
June 2011 - Page 1
ControlWave® Express
SCADA RTU
ControlWave® Express SCADA RTU, from Emerson Process Management, provides exceptional
performance and unique functionality for applications requiring low installation cost, very low power
consumption, and space efciency.
As an integrated RTU in a SCADA system,
ControlWave Express has the unique attributes
required for wide area networks, without sacricing
process control performance.
Multiple serial communication ports for network, •
local and multi-vendor connectivity
Built-in BSAP, Modbus & DNP protocols for •
broad network compatibility
Features
Report-By-Exception for communication •
efciency
Modbus Store and Forward capability for •
geographic exibility with radio networks
Ultra low power modes for solar applications •
and reduced solar panel and battery costs
Wide operating temperature range for remote •
outdoor locations
Application Suitability
Based on years of experience in water, gas and
SCADA related industries, ControlWave Express
has the technology, functional benets and open
architecture to excel in many applications.
Water distribution: Pump, tank, well and reservoir
control
Wastewater: Lift station and storm water monitoring
and control
Natural Gas: Gas well, storage and plunger lift
control
ARM processor provides exceptional •
performance and low power consumption
IEC 61131-3 programming with ACCOL III •
process control function block library
Optional 100/10 MB Ethernet port•
Three serial communication ports •
Flexible xed I/O congurations•
4 Digital inputs•
2 Digital outputs•
2 selectable Digital inputs/outputs•
2 selectable Digital inputs/counters•
2 selectable Digital/Pulse inputs on CPU•
3 optional Analog inputs•
1 optional Analog output•
Wide temperature range (-40 to +70ºC)•
Class I, Div. 2 hazardous location and CE •
approval
Open standards for programming, network •
conguration and communication
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Product Data Document
420DS-6d / D301311X012
June 2011 - Page 2
ControlWave® Express
Scalability
ControlWave Express can also be combined seamlessly with other members in the ControlWave family
of products. For remote applications requiring more
I/O exibility, ControlWave Micro provides a modular
RTU/PLC expandable up to 14 I/O modules.
For natural gas well site and measurement station
automation, ControlWave single and multi-run ow
computers share a common architecture with the
ControlWave family of products and all meet API
21.1 requirements for multiple meter runs.
For in-plant control applications, ControlWave and
ControlWave Micro are powerful, exible PLCs.
ControlWave offers the greatest local and remote
I/O expansion to hundreds of I/O points, up to three
Ethernet ports for network segmentation, plus CPU,
communication and I/O redundancy capability.
The combined benets of the ControlWave family
of products integrates your wide area network with
your local area network.
Open Standards For Programming, Net-
work Conguration 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 efciency
and productivity needed to ensure a successful
system implementation.
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.
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-ops, 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 benet 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 & waste and pro-
cess measurement & control applications. Further,
ACCOL III is designed to take full advantage of the
signicant features offered by ControlWave.
Briey, this library includes function blocks for:
Average, Compare, Totalize•
Scheduling & Sequencing•
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 ve
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PID & Lead/Lag•
AGA gas ow 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.
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 3
ControlWave® Express
Specications
CPU
32-bit ARM processor: 14 & 33 MHz CPUs•
Sleep mode for low power applications •
Real time clock/memory battery backup: 9000 •
hours
Program execution and Data Memory : 2 MB •
battery backed SRAM memory
Data and le storage memory: 8 MB Flash for •
Program source, historical Archive and Audit
storage
Optional solar power regulator•
LED status indicators – 6 failure status LEDs, •
Watchdog and CPU Idle and communication
LEDs
Communication
Two RS-232 and one selectable RS-232/RS-•
485 serial communication port supporting baud
rates up to 115.2 KB
One optional 100/10 Base-T Ethernet port with •
RJ45 connector
One RJ45 connector for interface to •
ControlWave LCD display/keypads
Housing
Mounting base plate: 10.75” H x 5.5” H x 2.0”D •
(27.3 cm x 14.0 cm x 5.0 cm)
Mounting: Flat or edge panel mounting, or •
optional DIN mount
Environmental Specications
Operating Temperature range• :
-40 to 70oC (-40 to 158oF), storage up to 85oC
Relative Humidity• :
15-95% non-condensing
Vibration• :
1.0g for 10-150 Hz - 0.5g for 150Hz to 2000Hz
Hazardous Area Approvals• :
non-incendive for operation in Class I, Division 2
CPU RFI
Immunity: ENV 50140 Radio-frequency •
electromagnetic eld amplitude modulated EMC •
Emissions: EN 55022:1998 Class A ITE •
emissions requirements (EU)
ICES-003 Issue 3 Class A Digital Apparatus •
emissions requirements (Canada)
AS/NZS3548:1995/CISPR Class A ITE •
emissions requirements (Australia)
Power Input
5.4 to 16 Vdc power input with 14 MHz CPU •
- Surge suppression 16 V transorb
11.4 to 28.0 Vdc power input with 33 MHz CPU •
- Surge suppression 30 V transorb
Power-fail detection and recovery sequencer•
Battery voltage monitor•
Reverse voltage protection•
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I/O RFI Susceptibility
3V/m – 80 MHz to 1000Mhz (IEC 1000-4-3)•
Power consumption
14 MHz CPU: 0.036 watt
33 MHz CPU w/o Ethernet: 0.12 watt
33 MHz CPU with Ethernet: 1.0 watt
DIO card: 0.018 watt
DIO plus AIO card: 0.021 watt
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 4
ControlWave® Express
ControlWave Express Process I/O
ControlWave Express I/O module is designed to
maximize usability while minimizing installation and
maintenance.
The I/O module (bottom card) provides a mix of
analog and digital inputs and outputs that are a
perfect t for small RTU applications.
2 DI/PI (on CPU)•
1 RTD input on 14 MHz CPU•
4 DI•
2 DO•
2 selectable DI or DO•
2 selectable DI or HSC•
Optional 3 AI or 3 AI and 1 AO•
1 second for 2 DI/PI inputs on CPU board•
Surge protection: Meets C37.90-1978 •
30 Vdc transorb between signal and ground•
Terminations are pluggable and accept a •
maximum wire size of 16 gauge
Power consumption is stated for each I/O •
module type measured at the input supply and
does not include loop power
Pulse/Digital Inputs
Inputs located on base CPU board•
Number of points: up to 2 non-interrupting •
inputs
Internally sourced, dry contact single ended •
inputs
Scan rate: Once per second•
Input lter: 20 microSec•
Voltage Range: Internally sourced dry contact •
input - 3.3 Vdc
On state: >1.6 V, Off state <1.3V •
Input current : 200 µA for low power applications •
Power consumption: •
200 µA input, all inputs ON: 0.002 watt
Features
Convenient pluggable local terminations•
All conguration jumpers and switches •
accessible without disassembly of circuit boards
Termination points for external loop power •
supply
Specications
All I/O
I/O access: 50 ms with 33 MHz CPU, 250 ms •
with 14 MHz CPU
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Used as Pulse Input:
Frequency Range: 0-10 kHz •
Debounce: None•
Accumulator: 16 bit •
RTD Input
Input available on 14 MHz Ultra Low Power •
CPU only
Specications are for the interface only, not including the RTD probe or wiring
RTD Conversion Accuracy: ± 0.1°C, or ± 0.1% •
of reading, whichever is greater
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 5
ControlWave® Express
Ambient temperature effect on RTD •
measurement: ±0.01°C / ºC max
Long Term Stability at Constant Conditions: •
±0.25ºC / month max
Digital Inputs
Number of points: up to 4 dedicated DI and 4 •
selectable DI (2 DI/DO, 2 DI/HSC)
Non-interrupting inputs•
Internally sourced, dry contact single ended •
inputs
Input Voltage Range: Internally sourced dry •
contact input - 3.3 Vdc
On state: >1.6 V, Off state <1.3V •
Input current :•
4 DI selectable 60 µA for low power applications
or 2 mA for in-plant noise immunity
2 DI/DO selectable 200 µA or 2.2 mA
2 DI/HSC selectable 200 µA or 2.2 mA
Input ltering: 15 ms time constant (contact •
bounce)
Power consumption: •
All 8 inputs ON: 0.005 watt
(4 inputs @ 66 µA and 4 @ 200 µA)
All 8 inputs ON: 0.075 watt
(4 inputs @ 2 mA and 4 @ 2.2 mA)
Analog Inputs
Number points: 3 AI optional •
AI Resolution: 14 bit •
Input Conguration: Externally sourced. Single–•
ended inputs - jumper selectable 4–20 mA or
1–5 Vdc. Terminal block connections provided
for external source.
Input Impedance: 1 megΩ - 1 5 Vdc;•
250 Ω - 4-20 mA
Input Filtering: 12 Hz•
Channel Settling Time: 600 ms to be within •
0.01% of input signal
Input accuracy:•
0.1% of span at 25 oC
0.2% of span -40 oC to 70 2 oC
Power consumption: •
Not applicable
Analog Output
Number of Channels: 1 AO optional•
Output congurations: Selectable externally •
sourced 4-20 mA or 1-5 Vdc:
250 ohm with 12 V external source
650 ohm with 24 V external source
1-5 Vdc @ 5mA max., 11 to 30 Vdc external
source
Digital Outputs
Number of points: 2 dedicated, 2 selectable DO •
(2 DI/DO)
Output type: solid state open drain MOSFET•
Operating voltage range: 10 - 31Vdc•
Maximum operating frequency: 20 Hz•
Current sink capability: 400 mA at 16 V (6 V •
system), 400 mA at 30 V (12/24 V system)
Power consumption:•
Not applicable to DOs
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D/A resolution: 12 bit•
Accuracy: •
0.1% of span @ 25 oC for current output; 0.1%
+ 3% of span @ 25 oC for voltage
0.3% of span @ -40 to 70 oC for current 0.3% +
3% of span @ -40 to 70 oC for voltage
Power consumption – 1 output: •
Analog current output: 0.1 watt
Analog voltage output: 0.1 watt
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 6
ControlWave® Express
High Speed Counters
Number of points: 2 selectable as HSC or DI•
Frequency Range: 0-10 kHz •
Input Voltage Range:•
Internally sourced: 3.3 Vdc
Externally sourced: 3 Vdc to 24 Vdc
On state: >1.65 V, Off state <1.65 V •
Input lter: 20 microSec for 10 kHz •
1 ms for 300 Hz LSC
Input current : selectable 200 µA for low •
power applications or 2.2 mA for in-plant noise
immunity
Accumulator: 16 bit •
Power consumption: •
200 µA input, all inputs ON: 0.004 watt
2.2 mA input, all inputs ON: 0.039 watt
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 ControlWave controllers, ow computers 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 the Bristol networks.
OpenBSI Utilities
Above this communication layer are a group of ap-
plications known as OpenBSI Utilities. These client
utilities communicate through the server to collect
and manage data gathered from the network, gen-
erate les based on collected historical data, collect
alarms, and monitor and control OpenBSI commu-
nications.
Communication engine for PC applications•
Supports ControlWave serial and IP protocols•
RS 232, Dial-line, cellular, radio, satellite, and •
Ethernet connections
Provides on-line download & signal variable •
changes
Allows network conguration 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 conguration 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
OpenBSI supports both serial BSAP protocol
and Ethernet Internet Protocol communication to
ControlWave controllers, ow computers and RTUs.
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Netview - Network conguration
and application Launchpad
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 7
ControlWave® Express
added on-line by simply dragging the node Icon into
the tree. This invokes a conguration 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 congured, 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.
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
Conguration Wizard simplies Network setup
Local Conguration Wizard allows local commu-
nication with any attached ControlWave controller
or RTU to download system ashware upgrades,
congure cold download parameters, and congure
IP and soft-switch parameters.
DataView for Real-time data display
WebBSI - WebBSI is a powerful and exible soft-
ware product bringing web technology to all 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 ControlWave prod-
ucts through a set of supplied HTML web pages.
Real-time ActiveX Controls
One of the many benets OpenBSI brings to you is
our use of open standards such as ActiveX Con-
trols. AcitveX is another of the Microsoft standards,
which allow plug and play with any ActiveX container, using Microsoft ActiveX container technol-
ogy such as Visual Basic, HTML web pages, and
Microsoft Excel
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Product Data Document
420DS-6d / D301311X012
June 2011 - Page 8
ControlWave® Express
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
Conguration Info – works with a standard page •
that displays and allows the user to change
RTU Conguration information
Historical• – Collect and view historical archive
and audit les
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 dened pages to access ControlWave. The
web pages are populated with these pre-congured
ActiveX controls.
Required Software
backlled with the missing data. This distributed historical database architecture provides the greatest
data reliability and integrity during communication or
PC failure.
Another important historical feature is the Audit
storage and collection system. The Audit Trail is a
le stored in ControlWave ash memory containing
signicant events and time-stamped alarms. The
alarms stored in the Audit system provide a historical archive in addition to the real-time alarm report-
ing system.
This le is also collected through OpenBSI and
presented as a text le in the PC. This functionality
is extremely useful in providing an event trail during
communication or PC downtime or other system
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 les to third party, .CSV & •
ODBC applications
DDE compliant for use with other popular •
Windows applications
Microsoft Internet Explorer•
Bristol ActiveX controls•
OpenBSI LocalView or NetView•
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 ash memory. The historical data
is collected, through OpenBSI on a scheduled or
demand basis and converted to .CSV and ODBC
compliant le formats for use in spreadsheets and
reports. If data is missed due to a communication
failure, it is collected when the communication is
reestablished and the PC historical database is
OPC Server
With industry demand for open standards,
ControlWave answers the call by embracing tech-
nologies that open the door for maximizing your
efciency 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 specication.
OPC Data Access 1.0a & 2.0 compatible•
WindowsXP•
Compatible with ControlWave tems•
32 bit multi-threading, multi-processor design•
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Product Data Document
420DS-6d / D301311X012
June 2011 - Page 9
ControlWave® Express
Automatic database builder •
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•
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 oor technician, operator, engineer,
supervisor and corporate management, even exter-
nal customers.
Communication Protocols
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.
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 denition 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-
able to anyone.
While BSAP is an open protocol, the added functionality of the messages provide much more capa-
bility than is found in other networks.
Global time-synchronization•
Time-stamped Alarm reporting•
Historical archive data transfer•
Audit le transfer•
On-line program editing•
Diagnostics•
Communication statistics•
Modbus Protocol
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, oating point values and byte order.
Bristol products support the following:
Modbus serial and TCP/IP Open Modbus •
(Ethernet)
BSAP Protocol
BSAP is widely accepted as providing exceptional
data integrity and greatly simplies communication
between controllers. BSAP is provided with interfac-
es for Master/Slave, vertical networks, and Client/
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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 •
Product Data Document
420DS-6d / D301311X012
June 2011 - Page 10
ControlWave® Express
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 and message boards, card
readers and many measurement 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 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 les
via FTP, access and congure historical and audit
data information, edit conguration, 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 in-
telligent control at the point where control is needed.
Whether you need control on the plant oor or at a
remote site in the “middle of nowhere” ControlWave
is the solution for control, communication and
secure data to help you make the right operating
decisions.
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
further ensure that the data is always current and
historically accurate, the historical data is stored
in non-volatile ash 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 pro-
viding a exible and secure historical data system
that is clearly recognized as a benet 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, engi-
neering and operator data access. The data source,
conguration 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-6d / D301311X012
June 2011 - Page 11
ControlWave® Express
© 2009-2011 Remote Automation Solutions, division of Emerson Process Management. All rights reserved.
Bristol, Inc., Bristol Canada, BBI SA de CV, the Flow Computer Division, and Emerson Process Management Ltd, Remote Automation Solutions division (UK) , are wholly owned subsidiaries of Emerson Electric Co. doing business as Remote Automation Solutions, a division of Emerson Process Management. FloBoss, ROCLINK, Bristol, Bristol Babcock, ControlWave,
TeleFlow and Helicoid are trademarks of Remote Automation Solutions. 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. Remote Automation Solutions reserves the right to modify or
improve the designs or specications of such products at any time without notice. All sales are governed by Remote Automation Solutions’ terms and conditions which are available upon
request. Remote Automation Solutions does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
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Emerson Process Management
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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
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