Emerson Process Management Bristol ControlWave ExpressPAC User Manual
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 1
Bristol® ControlWave
SCADA RTU Package
Bristol® ControlWave® ExpressPAC, from Emerson
Process Management, is a highly integrated preengineered package solution that combines the new
ControlWave Express SCADA RTU with a variety of
options commonly required in SCADA applications.
These include a compact Nema 4X rated enclosure,
power supply and solar panel options with battery
backup, operator display/keypad input options, and
wireless communication options. Standardization
eliminates the need for in-house panel and packaging design and fabrication resulting in lower initial
installation cost. This also standardizes the maintenance effort to reduce the long term cost of ownership.
As an integrated RTU in a SCADA system,
ControlWave ExpressPAC has the unique attributes
required for wide area networks, without sacricing
process control performance.
Pre-engineered SCADA RTU package solution •
reduces integration and maintenance costs
Multiple serial communication ports for network, •
local and multi-vendor connectivity
Built-in BSAP, Modbus & DNP protocols for •
broad network compatibility
®
ExpressPAC
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
Natural Gas: Gas well, storage and plunger lift
control
Report-By-Exception for communication •
efciency
Modbus Store and Forward capability for •
geographic exibility with radio networks
Ultra low power modes minimizes cost of solar/•
battery power systems
Wide operating temperature range for remote •
outdoor locations
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
Features
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/OI congurations•
4 Digital inputs•
2 Digital outputs•
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 2
Bristol® ControlWave ExpressPAC
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•
ControlWave ExpressPAC
Integrated Solution
ControlWave ExpressPAC is delivered in a compact,
Lexan enclosure that includes the RTU electronics, optional operator display/keypad, battery/solar
power system and a broad selection of modem and
radio communications options.
Features – Package
Dimensions, Lexan Housing: 15.77” H x 7.8” W •
x 9” D (40.1cm X 19.8cm X 22.9cm)
Nema Rating: Nema 3R (Nema 4x except with a •
battery vent)
Mounting: Pipe-mounted, or wall-mounted •
tuning parameters, and outputs used in a measurement or control application. Status bits include
the alarm state, alarm acknowledge, control, and
manual (Auto/Man). Providing access to such variable information allows the user complete control
over the process operation.
The standard LCD provides 4 line x 20 character
display with either a two-button read-only or 25-button read-write keypad. Both display/keypad assemblies have the same “footprint” on the front door.
Features – Display/Keypads
4 line by 20 character backlit liquid crystal •
display
Adjustable display contrast•
Membrane keys with tactile feedback•
Self-adhesive overlay mounts to the enclosure •
door or panel (ControlWave ExpressPAC is
delivered with this assembly installed on the
door)
Easy conguration via ACCOL III Function Block•
Scrolling display mode•
Solar Panel Mounting: All solar panels are •
delivered with all hardware necessary for 2”
pipe or mast-mounting
Integrated LCD Display/Keypad Option
ControlWave ExpressPAC offers a convenient local
operator interface. The 2-button display allows an
operator to view site, conguration and process
data. The screens are organized in a series of lists.
The operator can select a list and then manually
scroll through the data. Additionally, a “scroll list”
can be dened. The ControlWave ExpressPAC can
be set to automatically sequence through this list.
The 25-button Display/Keypad performs the same
functions and additionally allows the operator to
view and modify ControlWave ExpressPAC inputs,
process variables, calculated variables, setpoints,
Shown, above, is the LCD with 25-button keypad.
The 2-button version is similar but includes only
two “arrow” buttons to sequence through lists.
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 3
Bristol® ControlWave ExpressPAC
Adjustable timer turns off display when not in •
use
Specications – Display/Keypads
Window size: 1.1” H x 3.1”W (2.8cm x 7.9cm)•
Character size: 4mm H x 3mm W•
Dimensions: 7.4”H x 5.5”W (18.8cm x 14.4cm)•
Power consumption: 2.5 mA @ 3.3V (0.008 •
watts)
Operating Temperature: -4 to 158ºF (-20 to •
70ºC)
Scalability
ControlWave ExpressPAC 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.
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.
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
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
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.
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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 process measurement & control applications. Further,
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 4
Bristol® ControlWave ExpressPAC
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•
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.
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
Historical Archive memory: Stored in ash•
Optional solar power regulator•
LED status indicators – Watchdog and CPU Idle •
LEDs
One RJ45 connector for interface to •
ControlWave LCD Display/Keypad
Power Input
5.4 to 16 Vdc power input with 14 MHz CPU •
- Surge suppression 16 V transorb
9.0 to 30.0 Vdc power input with 33 MHz CPU •
- Surge suppression 30 V transorb
Power-fail detection and recovery sequencer•
Battery voltage monitor•
Reverse voltage protection•
Environmental Specications
Operating Temperature range:•
40 to 70ºC (-40 to 158ºF), 85ºC storage
-20 to 70ºC (-4 to 158ºF) with display/ keypad
-20 to 60ºC (-4 to 140ºF) with Lead Acid Cell
Batteries
Relative Humidity:• 15-95% non-condensing
Vibration:• 2.0g for 10-150 Hz – 1.0g for 150Hz
to 2000Hz
RFI Susceptibility:• 3V/m – 80 MHz to 1000Mhz
(EN50082-2)
Electrostatic Discharge:• Meets IEC EN
60001-4-2, EN 61326
CPU RFI
Immunity: ENV 50140 Radio-frequency •
Electromagnetic eld amplitude modulated EMC •
Emissions: EN 55022:1998 Class A ITE •
emissions requirements (EU)
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
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
ICES-003 Issue 3 Class A Digital Apparatus •
emissions requirements (Canada)
AS/NZS3548:1995/CISPR Class A ITE •
emissions requirements (Australia)
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 5
Bristol® ControlWave ExpressPAC
I/O RFI Susceptibility:
3V/m – 80 MHz to 1000Mhz (IEC 1000-4-3)
Hazardous Area Approvals
Approved as non-incendive for operation in •
Class I, Division 2
Class I, Division 1 approval pending for a •
subset of congurations
ControlWave ExpressPAC is approved by UL as an
instrument. This certication does not allow installation of any other hardware, not indicated by the
model number, in the instrument enclosure. Wiring
to and from the I/O, communication and power connections inside the enclosure, per the ControlWave
ExpressPAC manual, are, of course, allowed.
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
Features
Convenient pluggable local •
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
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
DIO plus AIO card: 0.021 watt
ControlWave ExpressPAC Process I/O
ControlWave Express I/O module is designed to
maximize usability while minimizing installation and
maintenance.
The I/O module 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•
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
Used as Pulse Input:
Frequency Range: 0-10 kHz •
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
Product Data Document
420DS-7d / D301312X012
January 29, 2009 - Page 6
Bristol® ControlWave ExpressPAC
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
Ambient temperature effect on RTD •
measurement: ±0.01°C / °C 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)
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
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
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 25ºC•
0.2% of span -40 ºC to 70 ºC•
Power consumption: •
Not applicable
Analog Output
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)
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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
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