Emerson Bristol ControlWave PAC, ControlWave PAC Technical Specifications
Technical Specifications
December 2010
ControlWave® PAC
Process Automation Controller
CWPAC
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 costeffective 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 +70ºC)
Class I, Div. 2 hazardous location and CE
approval
Open industry standards for programming,
configuration, and communication
Base Unit
The ControlWave PAC base unit is constructed of a
stainless steel 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 memory. The CPU module is
available with the following on-board 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.
ControlWave PAC
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
D301303X012
Technical Specifications
CWPAC
Page 2
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
Coils
Inputs and Outputs
Input and output (I/O) modules are designed to
maximize usability while minimizing installation,
maintenance, and system down-time costs. A pulldown 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 two-wire 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 prewired 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 8slot 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
Technical Specifications CWPAC:RDN.
Key Switch
The ControlWave PAC is available with a threeposition 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.
Technical Specifications
CWPAC
Page 3
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.
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.
Theses 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 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.
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