Emerson Process Management Bristol ControlWave PAC User Manual
Product Data Document
420DS-1k
July 16, 2007 - Page 1
Bristol® ControlWave® PAC
Process Automation Controller
Bristol® ControlWave® PAC, from Emerson Process Management, is a highly adaptable, high
performance Process Automation Controller with
exceptional networking capability to provide a
complete Process Automation Management Solution. Designed with a great emphasis on scalability
and modularity, ControlWave can be congured to
maximize the performance of a wide range of control systems, from small or mid-size applications to
large ones. Additionally, due to its small form factor
and rugged industrial design, ControlWave offers an
outstanding ability to match the requirements of the
most demanding process plant and SCADA system
environments. Above all, Emerson has developed
this innovative controller to provide cost-effective
solutions by minimizing the time required for instal-
lation and conguration.
Through this new open architecture, ControlWave
provides an ideal hybrid union of PLC, RTU and
DCS without compromising the unique features
and capabilities of each product. Consequently, the
ControlWave Process Automation Controller not
only introduces the great possibilities of an open
architecture for emerging communication standards,
but it also provides a simple solution for existing
networks. From its conception, ControlWave was intended as a very exible system capable of satisfying the requirements of local, expanded, remote and
distributed I/O combinations. It is widely accepted
as a scalable platform because it can be used for
small applications using a single rack, but it can
also be expanded to large applications spanning an
entire plant.
Hardware Features
586 based processor provides unparalleled
•
performance
Up to three 100/10 MB Ethernet ports
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Ethernet remote I/O
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Up to four serial communication ports
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2, 4, and 8 I/O slot panel mount chassis, panel
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or 19” rack mount on 8 slot chassis
Single and double density I/O modules
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Hot Swap I/O replacement
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Security key-lock to prevent unauthorized
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access
Internal loop power for I/O simplies installation
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AOs maintain last/preset value on CPU
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Watchdog
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DOs maintain last or zero value on CPU
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Watchdog
Wide temperature range (-40 to +70ºC)
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Class I, Div. 2 hazardous location and CE
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approval
Open, industry standards for programming,
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conguration and communication
Product Data Document
420DS-1k
July 16, 2007 - Page 2
Bristol® ControlWave® PAC
Scalability
ControlWave PAC meets the needs of a wide range
of applications, from a unit controller RTU to a
powerful plant process control system through its
modular architecture, large I/O capacity and Ethernet networking capability.
For smaller I/O congurations, the low power
ControlWave Micro and Express are ideal RTU
packages with all of the same software capabilities
of their ControlWave PAC big brother.
ControlWave Micro is a compact modular RTU/PLC
hybrid, providing up to eleven serial communication
ports and optional built-in 100/10 Base-T Ethernet
ports. Built-in spread spectrum radio and dial-line
modem options reduce integration cost, enhance
communication exibility and provide communication back-up.
The base unit is used to house the power system,
CPU and 2 or 6 I/O modules. The base is expandable up to fourteen I/O slots through 2,4 or 8 slot
plug-on I/O expansion bases.
ControlWave Express is a very compact, low prole
SCADA RTU with a xed I/O point count. Extremely
low power consumption makes ControlWave Express highly suitable for many remote sites common
in water, wastewater, and natural gas applications
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
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Ladder diagram functions - coils and contacts,
•
etc.
Numerical, Arithmetic & Boolean functions
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- Sine, Cosine, Add, Sub, Square Root, And, Or,
etc.
Selection & Comparison - Min, Max, Greater
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than, Equal, Less than, etc.
Type conversions - Integer to Real, Boolean to
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Word, etc.
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 archi-
tecture and bring the optimal process efciency and
productivity needed to ensure a successful system
implementation.
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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 func-
tion blocks valuable for use in oil & gas, water and
wastewater and process 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
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Scheduling & Sequencing
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Product Data Document
420DS-1k
July 16, 2007 - Page 3
PID & Lead/Lag
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AGA gas ow and liquids calculations
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File handling
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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
Bristol® ControlWave® PAC
Ethernet ports with RJ45 connectors
Isolation: Ethernet ports isolated to 500 Vdc
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Power Supply and Chassis
12 or 24 Vdc power
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Power-fail detection and recovery sequencer
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System LEDs for: Active , Fail, & Power OK
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Power supply isolation: 500 Vdc
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ISA bus for I/O system (supports Hot Swap I/O)
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able to drive 8 local chassis I/O modules
CPU
AMD Elan 520 processor: 586 CPU-100 Mhz
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Data Memory: 2 MB SRAM battery backed
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memory
Historical Archive memory: Stored in either ash
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or battery backed SRAM
Code/ Instruction Memory: 16 MB on-board
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Flash
Synchronous Dynamic memory: 4 MB (66MHz
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SDRAM coupled to a 32-bit bus)
PCI bus for communication expansion module
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2-digit ‘Port 80’ display for booting and run-time
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diagnostics
Key-lock security switch
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Communication
Two RS-232 serial communication ports with
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standard PC/AT 9-pin male D-sub connectors
on CPU module, both supporting baud rates up
to 115.2 KB
Two expansion RS 232 or RS 485 serial
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communication ports: up to 115.2 KB
1 standard PC/AT 9-pin D-sub Connector and 1
RJ45 8-pin connector
Isolation: RS 485 serial communication ports
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isolated to 500 Vdc
Up to three independent 100/10 Base-T
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2 – I/O slot chassis: Panel Mount 7.97”W x
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6.97”H x 4.96”D (202.43W x177.03H x 125.98D)
4 – I/O slot chassis: Panel Mount 11.84”W
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x 6.97”H x 4.96”D (300.73W x 177.03H x
125.98D)
8 – I/O slot chassis: Panel Mount or 19” Rack
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Mount 18.96”W x 6.97”H x 4.96”D (481.58W x
177.03H x 125.98D)
Environmental Specications
Industrial operational temperature limits
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(-40 to + 70oC)
Humidity: 0-95% (non-condensing)
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Vibration limits: 1.0 g acceleration over 10-150
•
Hz; 0.5 g acceleration over 150-2000 Hz
ControlWave Local I/O
ControlWave ‘Process Friendly’ local I/O modules
are designed to maximize usability while minimizing installation, maintenance, and system downtime
costs. A pull-down door provides front panel wiring
terminal access for technicians. The bezel and even
the terminations can be easily removed from the
I/O card to make wiring even easier. In addition, the
availability of both local direct and remote DIN rail
terminations conveniently accommodates a wide
range of applications.
To minimize eld wiring and eliminate the need for
marshalling strips, the analog input and digital input
modules are capable of supplying loop power to two
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Product Data Document
420DS-1k
July 16, 2007 - Page 4
Bristol® ControlWave® PAC
wire transmitters and dry contacts. For maximum
channel-to-channel isolation, externally powered
analog and digital inputs may be selected.
Status-at-a-glance indicators offer instant visual
notication of I/O system problems. Each I/O
module has a bi-color Pass/Fail LED to display the
on-line diagnostic status. Digital I/O status LED’s
are provided for each point. Analog Input modules
have a unique feature. Each input point has two
LEDs to indicate input under/over range conditions
due to open and shorted eld devices. The green
LED, when lit, indicates the input is in a normal
range. The Red LED, when lit, indicates the input is
under or over range, typically meaning it is open or
shorted.
Features
Convenient ‘Process Friendly’ pluggable
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local and remote wiring terminations simplify
installation
Status-at-a-glance LED indicators
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Single and Double density I/O count available
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for all modules provide application exibility
Loop powered inputs minimize wiring costs
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Easy access pull-down door with terminal wiring
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labels
Hot Swap I/O replacement
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All I/O modules are enclosed in a rugged
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aluminum shell
Analog outputs congurable for ‘Hold last value,
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Fail-Safe state or preset value’
Discrete outputs congurable ‘Hold last value or
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fail to zero’
Specications
All I/O
Surge protection meets C37.90-1978 and
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IEC 801-5
Terminations are pluggable and accept a
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maximum wire size of 14 gauge
‘HOT SWAP’ module replacement is supported.
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All I/O is frozen for 300 ms when any module is
replaced
Environmental Specications
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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
RFI Susceptibility: 3V/m – 80 MHz to 1000Mhz
(EN50082-2)
ControlWave Digital Input Module
Number of points: 16 or 32 – non-interrupting
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inputs
16-bit wide bus access
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Input Voltage Range: 24 Vdc nominal
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Input current : 5 mA nominal
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Optical isolation: 1500 V eld input to logic
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Surge suppression: 500Vdc MOV to chassis
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31 Vdc transorb between signal and isolated
ground
Input ltering: 30 ms time constant (contact
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bounce)
Dry contact or externally powered voltage
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inputs – 21 Vdc on-board isolated loop power
Product Data Document
420DS-1k
July 16, 2007 - Page 5
Bristol® ControlWave® PAC
supply for contacts
Power Consumption: 100 mA max @5V ( all
•
LED’s on)
Status indication: LED per point status and
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module OK/FAIL LED
ControlWave Digital Output Module
Number of points: 16 or 32
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16-bit wide bus access
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Output type: solid state open source MOSFET
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Operating voltage range: 10 - 31Vdc
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Maximum operating frequency: 20 Hz
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Current sink load capability: 500 mA at 31V
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Electrical isolation: 1500 Vdc
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Surge supression: 500 MOV to chassis
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31 Vdc transob between signal and isolated
ground
Status indicator: LED per point status and
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module OK/FAIL LED
Congurable Fail State ‘OFF’, or ‘Hold Last
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Value’
Input Impedance: > 1 megOhm for 1-5 Vdc,
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250 Ohm for 4-20 mA
Common Mode Rejection: 70 db
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Normal Mode Rejection: 26 db
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Input Filtering: 300 ms to 99.9% of input signal
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Channel Settling Time: 680 microseconds
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Conversion Time: 25 microseconds
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Accuracy:
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0.1% of span 25oC
0.2% of span -20 oC to 70 oC
0.3% of span -40 oC to 70 oC
Isolated Voltage Common Mode Range: 31 Vdc
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to isolated common
LED Indicators : Normal, Over-range/Under-
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range, module FAIL/OK
On board References: 1V, 5V
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On-board isolated loop supply for internally
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powered AI
Surge Supression: 31 Vdc transorb across input
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signals and (-) input to chassis
500Vdc MOV isolated common to chassis
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Power consumption: 143 mA max @ 5 Vdc (all
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LEDs ON)
ControlWave Analog Input Module
Number of Channels: 8 or 16
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A/D Resolution: 14 bit
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Input Conguration: Isolated voltage input: 500
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V per card to chassis 31 V per channel when
externally sourced
Internally or externally sourced current
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Input:Single-ended inputs 4-20 mA
Voltage Input: Isolated Differential inputs
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1-5 V dc
Externally sourced current loop with 1–5
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V input module and 250 ohm resistor
across the input terminals or 4-20 mA
input module
Thermocouple Input Module
Number of Channels: 6 AI
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Input type: B, R, S, J, E, K, T, C, N, +/- 10 mV
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AI Resolution: 16 bit
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Input Conguration: Differential thermocouple
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Voltage input Impedance: 10 megΩ
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Channel data acquisition: 50 microsec
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Conversion Time: 66 millisec for all 6 inputs
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Input Accuracy: Varies by thermocouple type
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0.025% of span at 25°C for 10 mV input
0.95% of span -25°C to 70°C for 10 mV input
Common Mode Rejection: 120 db
•
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Product Data Document
420DS-1k
July 16, 2007 - Page 6
Normal Mode Rejection: 80 db
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Electrical Isolation: 500 Vdc channel to channel
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and channel to bus
Surge Suppression: 180 Vdc transorb between
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signal and ground meets IEEE 472.1978
Cold Junction Compensation: RTD sensor on
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terminal block
Local or remote terminations
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Power Consumption - 6 inputs:
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TC analog input: 0.96 watt
RTD Input Module
Number of Channels: 4 AI
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Input Type; 2, 3, or 4 wire RTD
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AI Resolution: 16 bit
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Voltage Input Impedance: 9.6 KΩ
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Channel Data Acquisition: 50 microsec
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Conversion Time: 3 wire - 266 ms, 4 wire - 200
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ms, for all 4 inputs
Input Accuracy:
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+/- 0.5°C at 25°C
+/- 1.0°C at -40°C to 70°C
Common Mode Rejection: 120 db
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Normal Mode Rejection: 80 db
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Electrical Isolation: 500 Vdc channel to channel
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and channel to bus
Surge Suppression: 12 Vdc transorb between
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signal and ground meets IEEE 472.1978
Local or remote terminations
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Power Consumption - 4 inputs:
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RTD analog input: 0.6 watt
ControlWave Analog Output Module
Number of Channels: 4 or 8
•
Bristol® ControlWave® PAC
Output congurations: 4-20 mA (650 max. drive)
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D/A resolution: 12 bit
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Accuracy:
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0.1% of span @ 25oC for current output
0.2% of span @ -20 to 70 oC for current output
0.3% of span @ -40 to 70 oC for current output
Electrical Isolation from the power system by an
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opto-coupler and a dc/dc converter.
Settling time: 1 ms
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FAIL and OK module status LED
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Surge Supression: 31 Vdc transorb across
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output signals and (-) output to common
Power Consumption: 91 mA max. @5 V (all
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LEDs ON)
500Vdc MOV isolated common to chassis
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Congurable Output Fail State (hold last value,
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zero (-5%), to specied value)
ControlWave Universal Digital Input Module and
Counter (UDI)
Number of points: 6 or 12
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Polled DI and High Speed Counter or Low
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Speed Counter
Bus Access: 16-bits wide
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Frequency Range: 0-10 KHz
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Input Voltage Range: 12V, 24V
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Debounce circuitry factory set Enabled or
•
Disabled
Input Current: 5mA +/- 10%
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Each counter input can be congured as a
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polled input, Low Speed Counter, or High Speed
Counter (Roll-over on 65536, not software
resettable)
Input Filtering, Software congurable for:
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20 micro seconds for high speed counter
1 milliseconds for low speed counter 30
milliseconds for contact closure interruptible DI
Loop power for dry contact inputs
•
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Product Data Document
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Electrical Isolation: 1500 Vdc to system logic
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and 500Vdc to chassis
Surge Suppression: 31 Vdc transorb across
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input and to eld common
Terminations: Pluggable, max wire size is
•
14 gauge. Set, reset, common and Shield
terminals per input
Status Indication: Status LED per input, module
•
PASS/FAIL LED
Remote Termination Modules
The remote termination option for ControlWave Local I/O modules provides a convenient alternative
to the standard direct connect termination. Remote
terminiations allow a concentration of electrical connections from one or more controllers to be located
in one area such as the rear of a 19" cabinet.
Bristol® ControlWave® PAC
All Remote Termination modules are standard DINrail mountable and connect to the I/O module with
from one to four pre-wired connector cables. To
simplify installation, all I/O modules use the same
cable.
Features
Removes electrical connections from the
•
controller
Passive terminations are DIN-rail mountable
•
Options for fusing, relays and 120 VAC I/O
•
A single common connector cable for all I/O
•
Up to 14 AWG wire with compression screw
•
terminals
Available Modules
AI: 4 points, no fuses
AI: 4 points, with fuses
AO: 2 points, no fuses
AO: 2 points, with fuses
DI: 24 Vdc - 8 points, no fuses
DI: 24 Vdc - 8 points, with fuses
DI: 120 VAC - 8 points
DO: 24 Vdc - 8 points, no fuse
DO: 24 Vdc - 8 points, with fuse
DO: 8 points - 6 Amp relay
Cable Lengths
18 inch cable
•
39 inch cable
•
6-1/2 foot cable
•
13 foot cable
•
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