Emerson Process Management Bristol ControlWave LP User Manual

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 pro­cess 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 ap­plications, 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 environ­ments. Above all, Emerson has developed this inno­vative controller to provide cost-effective solutions by minimizing the time required for installation and
conguration.
The ControlWave LP complements the ControlWave and Network 3000 family of process automation controllers and RTU’s. The ControlWave LP is compact in size and offers the full programmabil­ity of ControlWave Designer IEC 61131 compliant software, and communicates via standard BSAP, as well as other industry standard protocols.
Hardware Features
Ultra Low Power 486 based processor provides high performance with low power consumption.
Five asynchronous serial communication ports
Fixed I/O with optional expansion I/O
Field device power supply built in
Small size
The ControlWave LP is available in an open chassis assembly for mounting to a panel or within an enclo­sure. The unit is a three-board assembly consisting of a CPU board, a Multifunction Input/Output board,
and a Power Supply/Sequencer board. All eld
I/O connections to the ControlWave LP are readily available via quick disconnect terminals located on the sides of the chassis.
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Wide temperature range (-40ºC to +70ºC)
• Class I, Div. 2 hazardous location and CE approval
Low Power Performance
The ControlWave LP uses the Ultra Low Power (ULP) Intel 486SX processor. The CPU is oper­ated 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 ap­plications using solar panels and battery backup.
Product Data Document
420DS-4c July 19, 2007 - Page 2
Specications
CPU
Intel Ultra Low Power 486SX 32 bit processor
-25 MHz
Data Storage Memory: 2 MB SRAM battery
• backed memory
Historical Archive Memory: Stored in either
ash or battery backed SRAM
Code/ Instruction Memory: 4 MB on-board
• FLASH
BIOS: 512 Kbytes Boot-Block FLASH
Communication
Four RS-232 serial communication ports with
• standard PC/AT 9-pin male D-sub connectors, supporting baud rates up to 115.2 KB
One selectable RS 232 or RS 485 serial
• communication port with standard PC/AT 9-pin male D-sub connector, supporting baud rates up to 115.2 KB
RS 485 port has line pull-ups and termination
• resistor
Modem control on all ports.
One 10 Base-T Ethernet port with RJ45
• connector - Optional.
Isolation: Ethernet port isolated to 500 Vdc
Bristol® ControlWave® LP
Fused with power-on switch.
Master Clear and Power Fail Indication
Power sequencer for auto power recovery
Power supply isolation: 500 VDC
Surge Suppression: 500 VDC MOV PSGND
• to CHASSIS 32 V Transient suppressor across VIN + to PSGND Meets ANSI/IEEE C37.90­1978
Low Power Mode
ControlWave LP power consumption is highly dependent on the actual application program and whether or not you are using internal loop power to
eld devices.
Typical power consumption range: 150 to 200 mA @ 24 Vdc
Fixed Multifunction Input/Output Board
The Fixed Multifunction Input/Output Board (FMI/ OB) contains four I/O modules with pluggable termi­nations and a PC-104 Interface for interconnection
of xed and expansion I/O subsystems. The board also provides for electrical isolation to eld devices,
surge suppression, and LED indicators for Discrete I/O, CPU, and communications functions. The four
I/O modules are xed as follows:
16 Discrete Inputs
8 Discrete Outputs
Power Supply/Sequencer Board
Input Power: 12 or 24 VDC input: 10 to 22 VDC
• or 22 to 30 VDC
Plugs into Multifunction Motherboard
Provides system isolated + 5 VDC & +/- 12 VDC
• power
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4 High Speed Counters
8 Analog Inputs
Two on-board Field Power Supplies are provided: one for DI and HSC operation and one for AI opera­tion. The output voltages are electrically isolated (500 VDC) and are regulated at 24V.
Product Data Document
420DS-4c July 19, 2007 - Page 3
Bristol® ControlWave® LP
Fixed I/O Subsystem
ControlWave LP Discrete Input Module
Number of Points: 16 Fixed
Input Voltage Range: 12V or 24V
Input Filtering: 1 millisecond or 30 milliseconds
Input Conguration: Contact Closure, internally
• or externally sourced on a point by point basis.
Jumper Congurable
Input Current: 2.5 mA +/- 10%
‘1’ State Voltage: 90 % of input voltage range
‘0’ State Voltage: 10 % of input voltage range
Interrupt Generation: On change of state
• transition on a point by point basis
Bus Access: Sixteen bit wide
Electrical isolation: 1500 VDC
Electrical isolation: 1500 VDC
Surge suppression: 500Vdc MOV to chassis 38
• VDC MOV across input and to Field Common Meets ANSI/IEEE C37.90-1978
Terminations: Pluggable, maximum wire size is
• 16 gauge
Status indication: 16 LED’s (one per point)
ControlWave LP Discrete Output Module
Number of Points: 8
ControlWave LP Analog Input Module
Number of Points: 8
Input Conguration: Isolated Voltage Input: 1-5V
Isolated Current Input: 4-20 mA
Powered Current Loop: 4-20 mA
Accuracy: 0.1 % of span @ 25 deg. C 0.2 % of
• span –20 deg.C to + 70 deg. C 0.3 % of span –40 deg.C to + 70 deg. C
Isolated Voltage/Current: 38 VDC referenced to
• isolated common
Powered Current Loop: 0 V referenced to
isolated common When a eld supply common
is connectesd to the AI system the isolated
common is connected to the eld supply
common
Input Filtering: 300 milliseconds to 99.75% of
• signal input.
Channel Settling Time: 300 microseconds
Conversion Time: 200 microseconds
On Board References: 1V, 5V - optional
Surge Suppression: 500Vdc MOV isolated
• common to chassis 38 VDC MOV across input signals and (-) input to chassis Meets ANSI/ IEEE C37.90-1978
Terminations: Pluggable, maximum wire size is
• 16 gauge
Bus Access: 16 Bits Wide
Output Type: Open Drain
Max Operating Voltage: 38 VDC
Max. Operating Freq: 20 Hz
Sink Current: 100 mA Maximum
Electrical Isolation: 1500 VDC
Surge Suppression: 500Vdc MOV isolated
• common to chassis 38 VDC MOV across input signals and (-) input to chassis Meets ANSI/ IEEE C37.90-1978
Terminations: Pluggable, maximum wire size is
• 16 gauge
Bus Access: 16 Bits Wide
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ControlWave LP High Speed Counter Module
Number of points: 4
Input Voltage Range: 12V or 24V
Input Filtering: 10 KHz max.
Input Filtering: 20 microseconds
Input Conguration: Set/Reset inputs, contact
• closure, externally sourced on point by point
basis with jumper congurtion.
Input Current: 2.5 mA +/- 10%
Product Data Document
1
2
3
4
AI -
AI -
AI +
4 - 20 mA internally powered transmitter
AI +
AI In +
AI In -
Two Wire Transmitter
24 Vdc
AI In -
AI In +
4 - 20 mA externally powered transmitter
AI +
AI +
AI -
AI -
Two Wire Transmitter
1
2
3
4
1
2
3
4
Three Wire Transmitter
AI In +
AI In -
1 - 5 Vdc AI for externally powered transmitter
24 Vdc
+
_
AI +
AI -
AI +
AI -
420DS-4c July 19, 2007 - Page 4
‘1’ State Voltage: 90 % of input voltage range
‘0’ State Voltage: 10 % of input voltage range
Bus Access: 16-bits wide
Max Accumulator Value: 65536
Electrical Isolation: 1500 VDC
Surge Suppression: 500Vdc MOV to Chasis 38
• VDC MOV across input and to Field Common Meets ANSI/IEEE C37.90-1978
Terminations: Pluggable, maximum wire size is
• 16 gauge
Status indication: 4 LED’s (one per point)
Bristol® ControlWave® LP
Environmental Specications
Operating Temperature: -40oC to + 70oC
• (-40oF to + 158oF)
Storage Temperature: -40oC to + 85oC
• (-40oF to + 185oF)
Relative Humidity: 15 – 95 Noncondensing
Vibration: 10-150 Hz at 1.0G
150-2000 Hz at 0.5G
RFI Susceptibility: 3V/M at 80-1000 MHz per
• EN50082-2
ControlWave LP Analog Output Module (Optional)
Number of Points: 4
Output congurations: 1-5 VDC & 4-20 mA
(Individually congured)
Power Loop: 9 to 30 VDC for 4-20 mA AO 10
• to 30 VDC for 1-5 VDC AO
Accuracy: 0.1% of span @ + 25oC
0.2% of span @ -20 to 70 oC
0.3% of span @ -40 to 85 oC
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
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ControlWave LP Packaging
Physical Size: Mounting Plate is 12.5 inches
• high x 8.5 inches wide. Unit is 3.5 inches deep.
Product Data Document
420DS-4c July 19, 2007 - Page 5
Bristol® ControlWave® LP
ControlWave LP Software
Open Standards For Programming, Network
Conguration and Communication.
Only Bristol ControlWave, from Emerson Process Management, brings you the perfect combination of industry standards to minimize your learning, engi­neering and implementation costs. The intelligent tool suites add an extra dimension to the overall umbrella we call OpenBSI (Open Bristol System
Interface).
ControlWave Designer - Programming
Software, I/O Conguration Wizard, and I/O
Simulator
TechTools – Diagnostics, Application
Downloader, Real-Time ActiveX controls and 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
By adhering to such industry standards as Ethernet, TCP/IP, Microsoft Windows®, COM/DCOM, OLE and Active X, ControlWave is able to achieve the highest degree of openness in control system architecture
and bring you the optimal process efciency and
productivity you need to ensure a successful system implementation. To minimize your engineering and development time, we have adopted the best pro­gramming standard available in IEC 61131-3. IEC 61131-3 compliant programming is supported by
the ControlWave Designer conguration generation tools, offering all ve IEC 61131-3 process languag-
es for batch or continuous control, and ladder logic and sequential languages for discrete control, as
well as high level languages for maximum exibility.
Additionally, ControlWave is loaded with custom-
ized function blocks to simplify the conguration of
complicated industrial, water & wastewater, and oil & gas, and industrial control system applications.
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Product Data Document
420DS-4c July 19, 2007 - Page 6
OpenBSI
Simply Creative
OpenBSI (Open Bristol System Interface) is a set of network setup, communication diagnostic, and data viewing utilities that provide access to both ControlWave and Network 3000 controllers 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 98/NT & 2000 communication server API through which other client applications communicate with the Bristol net­works. OpenBSI supports both serial BSAP protocol and Ethernet Internet Protocol communication to ControlWave and Network 3000 RTUs and control­lers. Above this communication layer are a group of applications known as OpenBSI Utilities. These client utilities communicate through the server to collect and manage data gathered from the network,
generate les based on collected historical data,
collect alarms, and monitor and control OpenBSI communications.
Bristol® ControlWave® LP
Allows network conguration through NetView
PC and Network communication diagnostics
OPC Server for interfacing to most HMI software
Data Collector and Scheduler Utilities Collects
• historical data on request or scheduled basis
NetView is the basic conguration 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 added on-line by simply dragging the node Icon into the tree. This invokes a conguration 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 cong­ured, 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.
OpenBSI Utilities
OpenBSI Utilities provide a full set of communica­tion 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 conguration les,
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
Communication engine for PC applications
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
NetView - Network conguration
and application LaunchPad
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Product Data Document
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Bristol® ControlWave® LP
Local Conguration Wizard allows local commu­nication with any attached ControlWave controller
or RTU to download system ashware upgrades, congure cold download parameters, and congure
IP and soft-switch parameters.
Conguration Wizard simplies Network setup
DataView is an on-line utility for ControlWave and Network 3000 nodes 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.
TechTools – OPC Server & ActiveX Controls
The Technicians Toolkits consist of a set of congu­ration wizards and standard web pages which are
used to congure 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 commu­nication access to ControlWave are provided for en­gineers to develop their own custom web pages us­ing any standard package such as Microsoft® Front­Page. 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 benets TechTools brings to you is our use of open standards such as ActiveX Controls. AcitveX is another of the Microsoft stan­dards, which allow plug and play with any ActiveX container, using Microsoft ActiveX container tech­nology such as Visual Basic, HTML web pages, and Microsoft Excel
The set of available ActiveX Controls provides the basic functions necessary to communicate and col­lect data from ControlWave.
DataView for Real-time data display
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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.
Conguration Info – works with a standard page
• that displays and allows the user to change
RTU Conguration information.
Product Data Document
Generic Web
Page
Data Server
Control
Wave
420DS-4c July 19, 2007 - Page 8
Bristol® ControlWave® LP
sheet and database reports. If data is missed due to a communication failure, it is collected when the communication is reestablished and the PC histori-
cal database is backlled 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
le stored in ControlWave Flash memory containing signicant 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
Archive Collection – collection and storage to
• disk of the ControlWave archive data
Audit Collection - collection and storage to disk
• of the ControlWave audit data.
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 dened pages to access ControlWave. The web pages are populated with these pre-congured
Active X controls.
Software Required
Microsoft’s Internet Explorer
Emerson’s Bristol Active X Controls
Emerson’s Bristol Data Server
OpenBSI Utilities
High Historical Data Integrity
The ControlWave Historical Data Collection sys­tem provides time-stamped historical data storage in ControlWave nonvolatile Flash memory. The historical data is collected, through OpenBSI, on a schedule or demand basis and converted to .CSV
and ODBE compliant le formats for use spread-
Exports data les to third party, .CSV & ODBC
• applications
DDE compliant for use with other popular
• Windows applications
OPC Server
With industry demand for open standards, ControlWave answers the call by embracing tech­nologies that open the door for maximizing your
efciency 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 specication.
OPC Data Access 1.0a & 2.0 compatible
Windows 98/NT & 2000
Compatible with both ControlWave and Network
• 3000 systems
32 bit multi-threading, multi-processor design
Automatic database builder
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Product Data Document
Open Modbus TCP/IP
Corporate
Mainframe
Laptop
Hub
Router
Router
Router
Corporate Intranet
Plant Control Network
I/O Network
Ethernet TCP/IP
Ethernet TCP/IP
Open Modbus
Ethernet
Laptop
ControlWave
Remote Ethernet I/O
ControlWave
Network 3000
OpenBSI
OPC Server
Remote
Workstation
DPC 3330 RTU 3310 RTU 3305
TeleRTU
ControlWave
DPC 3335
Operator and Engineering
Workstations
WAN
Plant Automation
Management Solution
Engineer
Customer
Serial
Modbus
Control
Wave
BSAP
Modbus
420DS-4c July 19, 2007 - Page 9
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
Bristol® ControlWave® LP
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 informa-
tion to the plant oor technician, operator, engineer,
supervisor and corporate management, even exter­nal customers.
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Product Data Document
420DS-4c July 19, 2007 - Page 10
Bristol® ControlWave® LP
Communication Protocols
Like all Emerson products, ControlWave supports BSAP (Bristol Standard Asynchronous Protocol), Modbus, DF1 and serial ASCII as standard func­tions. These protocols are implemented in ash­ware so no additional hardware is required to use any one or a combination of all protocols.
All of Emerson’s Bristol Network 3000 and ControlWave RTU and controller products support BSAP protocol. BSAP is widely accepted as provid­ing exceptional data integrity and greatly simpli-
es communication between controllers. BSAP is
provided with interfaces for Master/Slave, vertical networks and Client/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 denition of an industry-standard,
open-architecture protocol because if 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 avail­able to anyone.
While BSAP is an open protocol, the added func­tionality of the messages passed provide much more capability than is found other networks.
Global time-synchronization
Time-stamped Alarm reporting
Historical archive data transfer
Slave, Serial and TCP/IP Open Modbus. In addi­tion there are consideration regarding supported
function codes, oating point values and byte order.
Emerson’s Bristol products supports the following:
Modbus serial and TCP/IP Open Modbus
• (Ethernet)
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
Allen Bradley DF-1
DF-1 protocol is the primary mechanism to inter­face to Allen Bradley PLCs and interface devices. ControlWave and Network 3000 both support DF-1 half-duplex master protocol.
Generic Serial Protocol
The Generic Serial Protocol is a 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.
Audit le transfer
On-line program editing
Diagnostics
Communication statistics
Modbus - Modbus is often considered a de-facto standard protocol because 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 &
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Multi-User Security Access
Security is an essential element of any open system, particularly those with Internet access. ControlWave employs a User Name/Password ac­cess 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.
Product Data Document
420DS-4c July 19, 2007 - Page 11
Bristol® ControlWave® LP
The security system provides for up to sixty-four
access rights to read and write data values and les via FTP, access and congure historical and audit data information, edit conguration, 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 in­telligent 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, a
exible and secure historical data system is clearly recognized as a benet 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, engi­neering and operator data access. The data source,
conguration 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.
© 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 Auto­mation 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 war­ranties 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
specications 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
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