Emerson Bristol ControlWave PAC User Manual

CWPAC Product Data Sheet

D301303X012 October 2012

ControlWave® PAC
Process Automation Controller

The ControlWave® PAC is a highly adaptable Process
Automation Controller with exceptional networking
capability. Designed with an emphasis on scalability and
modularity, the ControlWave PAC can be configured to
maximize the performance of a wide range of control
systems. Emerson has developed this innovative controller
to provide cost-effective solutions by minimizing the time
required for installation and configuration.

The ControlWave PAC combines the elements of a PLC and
an RTU without compromising the unique features and
capabilities of each device. The ControlWave PAC provides a
modular architecture, expandable I/O capacity, and
Ethernet networking capability that introduces the
possibilities of open architecture for emerging
communication standards and provides a simple solution for
existing networks.

Features

 Powerful, high-performance processor
 Up to three 10/100 MB Ethernet ports
 Up to four serial communication ports
 4- and 8-slot I/O base unit
 Hot-swappable I/O
 Security key-lock
 Analog outputs maintain last/preset value on CPU

watchdog

 Discrete outputs maintain last or zero value on CPU

watchdog

 Wide temperature range (-40 to +70°C)
 Class I, Div. 2 hazardous location and CE approval
 Open industry standards for programming,

configuration, and communication

memory. The CPU module is available with the following on­board communication port configurations:

 One Ethernet port and two RS-232 ports
 One Ethernet port, three RS-232 ports, and one RS-485

port

 Three Ethernet ports, three RS-232 ports, and one

RS-485 port

 Three Ethernet ports, two RS-232 ports, and two

RS-485 ports

Power Modules

The power module is installed in the first slot of the
ControlWave PAC base unit and provides power to the rest
of the device. Two power modules are available including:

 24 volt input power supply sequencer module
 24 volt redundant power supply sequencer module

Open Network Connectivity

By embracing the open systems network technologies
available through TCP/IP, Ethernet, OPC, and Microsoft DNA
(as well as pseudo standards such as Modbus and Open
Modbus) the ControlWave PAC provides a total process
automation management solution for in-plant LAN-based
and wide area network SCADA systems. Access to real-time
data and operating conditions, historical data, maintenance,
and performance data stored in the ControlWave PAC is
available to the global network.

Base Unit

The ControlWave PAC base unit is constructed of an
aluminum housing that contains the CPU, power supply,
and is available with a 4 or 8 I/O slots. These slots are used to
add optional I/O modules.

CPU Options

The ControlWave PAC has a 100 MHz CPU module that
contains 2 MB of SRAM, 64 MB of SDRAM, and 32 MB of flash

Remote Automation Solutions

ControlWave PAC

CWPAC October 2012

Communications

The ControlWave PAC supports up to seven communication
ports. The base CPU module has two RS-232 serial ports and
one Ethernet port. Two additional RS-232 or RS-485 serial
ports and two additional Ethernet ports are optional.

Communication Protocols

ControlWave PAC supports BSAP (Bristol Standard
Asynchronous Protocol), Modbus, DF1, CIP, DNP3, and serial
ASCII communication protocols as standard features.
ControlWave PAC also supports the following Modbus
protocols:

 Modbus serial and TCP/IP Open Modbus (Ethernet)
 Master and Slave
 Modbus RTU and ASCII
 Function Codes 1–7, 8, 15, and 16
 Integer and IEEE 4-byte floating point

Inputs and Outputs

Input and output (I/O) modules are designed to maximize
usability while minimizing installation, maintenance, and
system down-time costs. A pull-down door provides front
panel wiring terminal access for technicians. The bezel and
the terminations can be easily removed from the I/O
module to make wiring even easier. In addition, a wide
range of applications is supported by the availability of both
local terminations and remote DIN-rail terminations.

To minimize field wiring and eliminate the need for
marshalling strips, the analog input (AI) and discrete input
(DI) modules are capable of supplying loop power to two­wire transmitters and dry contacts.

Status indicators offer instant visual notification of I/O
conditions. Each I/O module has a two-color Pass/Fail LED
that displays the online diagnostic status. Discrete I/O
modules provide status LEDs for each point on the module.
AI modules provide two LEDs on each input point to indicate
input under/over range conditions.

The ControlWave PAC supports a wide variety of I/O
modules. Available I/O modules include:

 Analog Input (AI) module with 8 or 16 points
 Analog Output (AO) module with 8 points
 Discrete Input (DI) module with 16 or 32 points
 Discrete Output (DO) module with 16 or 32 points
 Resistance Temperature Detector (RTD) module with 4

points

 Thermocouple (TC) module with 6 points
 UDI Counter module with 6 points

Note: Modules are hot-swappable. All I/O is frozen for 300

milliseconds when any module is replaced.

Remote Termination Modules

The remote termination option for the ControlWave PAC
modules provides a convenient alternative to the standard
direct connect termination. All remote termination modules
are standard DIN-rail mountable, and connect to the I/O
module with pre-wired connector cables. To simplify
installation, all I/O modules use the same cable.

I/O Expansion Rack

The I/O Expansion Rack allows for the addition of I/O
modules to multiple local and remote mounted racks. The
I/O Expansion Rack consists of a 4- or 8-slot ControlWave
chassis. This chassis contains an Ethernet communication
engine dedicated to communications between the main
processor and the I/O Expansion Rack. The communication
engine also supports battery backed RAM to retain output
values during short power outages.

The I/O Expansion Rack is connected to the main
ControlWave via an Ethernet physical link using TCP/IP. The
process control application program resides in the main
ControlWave. The main ControlWave controls both local I/O
as well as the I/O located in the I/O Expansion Rack.

ControlWave Redundant Systems

Redundant systems are ideal for use in critical processes and
harsh applications that require maximum operational
readiness and system availability. The ControlWave PAC
redundant systems are designed to prevent a single point of
failure from shutting down the entire system. Two types of
redundant systems are available for the ControlWave PAC:
the redundant process control and communications system,
and the redundant input/output (I/O) system. For more
information on the ControlWave PAC redundant systems,
refer to Product Data Sheet CWPAC:RDN.

Key Switch

The ControlWave PAC is available with a three-position front
panel key switch. The front panel key switch provides a high
level of manual security by controlling three modes of
operation.

In Run Mode, the ControlWave PAC rejects any attempt to
download or modify the running program, either locally or
over the network.

In Remote Mode, the ControlWave PAC allows downloading
and online program modification through the network
provided the security access requirements have been met.
Local download and online modification of the running
program is prohibited.

In Local Mode, the ControlWave PAC allows download and
online modification through either the network connection
or through a local serial communication port provided the
security access requirements have been met.

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October 2012

Multi-User Security Access

The ControlWave PAC employs a user name/password
access system protected by a 56-bit encryption technique
through the TCP connection. There can be up to 240 users
who sign in with their user name and password. Both the
user name and the password can be up to sixteen characters
in length.

You can customize the security level for each user based on
64 access rights including the ability to read and write data
values and files via FTP, access and configure historical and
audit data information, edit configuration, run internal
diagnostics, and read and reset system status.

Data Reliability

The ControlWave PAC is designed to provide the optimum
level of data reliability using a distributed database
architecture. All data, including time stamped alarms, alarm
limits, and historical data is stored locally in non-volatile
flash memory in each ControlWave PAC.

When historical data is collected from the ControlWave
PAC, it is converted and appended to a .CSV and ODBC
compliant database. The original historical data is not
changed and is stored in the device flash memory.

Historical Data Collection

The ControlWave Historical Data Collection system provides
time-stamped historical data storage in ControlWave flash
memory. The historical data is collected through OpenBSI
software on a scheduled or on-demand basis. After the data
is collected, it is converted to CSV and ODBC compliant file
formats for use in spreadsheets and reports. If any data is
missed due to a communication failure, it is collected and
the PC historical database is backfilled when the
communication is reestablished. This distributed historical
database architecture provides data reliability and integrity
during communication or PC failure.

Another important historical feature is the audit system. The
audit logs are files stored in ControlWave flash memory that
contain significant events and time-stamped alarms. In
addition to the real-time alarm reporting system, the alarms
stored in the audit alarm log provide a reportable historical
alarm archive.

These files are collected through OpenBSI software and
presented as text files in the PC. This functionality is
extremely useful in providing an event trail during
communication interruption, PC downtime, or other system
problem.

OpenBSI

Emerson’s OpenBSI (Open Bristol System Interface) is an
optional set of network setup, communication, diagnostic,
and data viewing software utilities for use with ControlWave
RTUs, flow computers, and controllers. At the core of
OpenBSI is the communication interface. The interface is

CWPAC

written as a Windows communication server API through
which other client applications communicate. OpenBSI
supports both serial BSAP protocol and Ethernet IP
communication to ControlWave devices.

ControlWave Designer

ControlWave Designer is an optional, fully IEC 61131-3
compliant programming environment for the ControlWave
PAC. ControlWave Designer includes all five IEC 61131-3
process languages for batch, continuous, and discrete
control. These languages are: 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-flops, counters, and timers
 Ladder diagram functions – coils and contacts, etc.
 Numerical, arithmetic, and Boolean functions – Sine,

Cosine, Add, Sub, Square Root, And, Or, etc.

 Selection and 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
ACCOL III function block library. ACCOL III includes over sixty
function blocks valuable for use in oil and gas, water and
waste, and process measurement and control applications.
ACCOL III is designed to take full advantage of the significant
features offered by ControlWave.

The library consists of many function blocks including:

 Average, Compare, Totalize
 Scheduling and Sequencing
 PID and Lead/Lag
 AGA Gas Flow and Liquids Calculations
 File Handling

ObjectServer

ObjectServer is an optional OPC-compliant server that
provides direct communication to the ControlWave family
of controllers, RTUs, PLCs, and flow computers through the
OpenBSI Communications Interface. ObjectServer supports
serial multi-drop, remote telemetry, and Ethernet
communication networks. Unlike traditional OPC servers,
ObjectServer provides reliable access to RTUs that are
connected via low-bandwidth, high-latency, and poor­quality networks such as radio, satellite, and cellular
modems.

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