Emerson Bristol ControlWave LP Operation manual

Product Data Document
420DS-4c
July 19, 2007 - Page 1
Bristol®ControlWave®LP
Website: www.EmersonProcess.com/Remote
Remote Automation Solutions
Low Power High Performance Process
Automation Controller
Bristol® ControlWave® LP, from Emerson Process
Management, is a low power high performance pro-
cess 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 ap-
plications, 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 environ-
ments. Above all, Emerson has developed this inno-
vative 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 programmabil-
ity of ControlWave Designer IEC 61131 compliant
software, and communicates via standard BSAP, as
well as other industry standard protocols.
The ControlWave LP is available in an open chassis
assembly for mounting to a panel or within an enclo-
sure. 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.
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
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 oper-
ated 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 ap-
plications using solar panels and battery backup.
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Product Data Document
420DS-4c
July 19, 2007 - Page 2 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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 C37.90-
1978
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 termi-
nations 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
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 opera-
tion. The output voltages are electrically isolated
(500 VDC) and are regulated at 24V.
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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
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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Product Data Document
420DS-4c
July 19, 2007 - Page 3 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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
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 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
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%
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Product Data Document
420DS-4c
July 19, 2007 - Page 4 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
‘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)
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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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 Packaging
Physical Size: Mounting Plate is 12.5 inches
high x 8.5 inches wide. Unit is 3.5 inches deep.
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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 -

Product Data Document
420DS-4c
July 19, 2007 - Page 5 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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, engi-
neering 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
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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 pro-
gramming 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.

Product Data Document
420DS-4c
July 19, 2007 - Page 6 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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 com-
munication interface, written as a Windows 98/NT &
2000 communication server API through which other
client applications communicate with the Bristol net-
works. OpenBSI supports both serial BSAP protocol
and Ethernet Internet Protocol communication to
ControlWave and Network 3000 RTUs and control-
lers. 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.
OpenBSI Utilities
OpenBSI Utilities provide a full set of communica-
tion 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
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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 simpli-
fying 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g-
ured, 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.
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NetView - Network conguration
and application LaunchPad

Product Data Document
420DS-4c
July 19, 2007 - Page 7 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
Conguration Wizard simplies Network setup
Local Conguration Wizard allows local commu-
nication 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.
DataView for Real-time data display
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gu-
ration 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 commu-
nication access to ControlWave are provided for en-
gineers to develop their own custom web pages us-
ing any standard package such as Microsoft®Front-
Page. 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 stan-
dards, which allow plug and play with any ActiveX
container, using Microsoft ActiveX container tech-
nology such as Visual Basic, HTML web pages, and
Microsoft Excel
The set of available ActiveX Controls provides the
basic functions necessary to communicate and col-
lect data from ControlWave.
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.
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Product Data Document
420DS-4c
July 19, 2007 - Page 8 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
The IP compliant ControlWave opens the door for
owner controlled access via Web Pages. Any ge-
neric 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 sys-
tem 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-
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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 histori-
cal archive in addition to the real-time alarm report-
ing system. This le is also collected through Open-
BSI 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.
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 tech-
nologies 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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Generic Web
Page
Data Server
Control
Wave

Product Data Document
420DS-4c
July 19, 2007 - Page 9 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
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
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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
ControlWave
BSAP
Modbus
ControlWave Open Network Connectivity
By embracing the open system network technolo-
gies 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 exter-
nal customers.

Product Data Document
420DS-4c
July 19, 2007 - Page 10 Bristol®ControlWave®LP
Remote Automation Solutions
Website: www.EmersonProcess.com/Remote
Communication Protocols
Like all Emerson products, ControlWave supports
BSAP (Bristol Standard Asynchronous Protocol),
Modbus, DF1 and serial ASCII as standard func-
tions. These protocols are implemented in ash-
ware 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 provid-
ing 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 con-
troller 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 propri-
etary in that Emerson does not charge a license fee
and makes the protocol and documentation avail-
able to anyone.
While BSAP is an open protocol, the added func-
tionality of the messages passed provide much
more capability than is found other networks.
Global time-synchronization
Time-stamped Alarm reporting
Historical archive data transfer
Audit le transfer
On-line program editing
Diagnostics
Communication statistics
Modbus - Modbus is often considered a de-facto
standard protocol because broad usage as ei-
ther 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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Slave, Serial and TCP/IP Open Modbus. In addi-
tion 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 inter-
face 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 typi-
cally with third party serial ASCII devices. This
protocol can be used to interface with such devices
and message boards, card readers and many mea-
surement devices.
Multi-User Security Access
Security is an essential element of any open
system, particularly those with Internet access.
ControlWave employs a User Name/Password ac-
cess system protected by a 56-bit encryption tech-
nique 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.
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