October 19, 2007 - Page 1 Bristol ControlWave Redundant Control Redundant systems are offered for critical processes and harsh applications that require maximum operational readiness and system availability. Bristol ControlWave Redundant Systems, from Emerson Process Management, are designed to prevent a single point of failure from shutting down the system. ControlWave offers two levels of redundant operation in order to achieve the optimum level of reliability required by the application. Many applications require the level of reliability provided by the cost effective ControlWave Redundant Process Control and Communication system. Other, even more critical applications may require the higher system availability provided by the ControlWave Redundant I/O system. These designs deliver redundant systems that provide high availability, reliability, and safety. ControlWave Process Control and Communications Redundant System Dual CPUs, Dual Power Supply Sequencers Automatic Failure Detection Automatic Switchover to Hot Standby Controller High Reliability No Single Point of Failure Communication Channel Switching Alarm and Historical Data Backup No programming required for redundancy data transfer Upgrade programs on the fly Convenient Packaging Process Control and Communications Redundancy CPU Hot Standby In the event of a failure of the primary CPU, the system will automatically switch to the Hot Standby backup CPU. All process control and communication functions are automatically switched to the backup. This method offers a high degree of control reliability and system availability at the most economical cost. In addition to process data and control functions, ControlWave also updates the Standby CPU with all time-stamped alarm and historical information, automatically at the end of each program cycle. Unlike traditional redundant systems, ControlWave was designed with these functions built-in. There is no programming required to implement the redundant control program, alarm, or historical data backup. Even interfacing to a host PC is easily accomplished without programming by simply assigning a primary and secondary IP address. ControlWave I/O Expansion Racks are used for the process interface. A Redundant ControlWave system includes a chassis that houses Primary and Standby CPU s and PSSM s. The chassis also houses the ControlWave
October 19, 2007 - Page 2 CPU and Communications Redundancy Switch (CCRS) Module. The CCRS Module allows automatic and manual selection of the primary controller CPU in case of hardware failure, and will additionally switch up to four serial communication ports to the selected primary CPU of the pair. Availability of multiple power sources within the CCRS insures system viability. The CCRS operator switches and LED for control and visual indication of the redundant system operation and status. A/B Primary Controller Select Switch Two position switch used to select the primary CPU from the redundant pair A/B Mode Select Switch Three-position key switch used to select whether primary CPU is forced or automatically determined Serial Communication Port Switching Selects communication ports from the on-line controller.(relay Contact Ratings: 1A@30 VDC) On-Line Status Outputs Independent A-Online and B-Online status outputs indicate which CPU module is currently selected as primary and is on-line. Two isolated relay contacts are provided via a front panel pluggable terminal block.(relay Contact Ratings: 1A @30 VDC) Status Display Panel A On-Line LED (Green) A Fail LED (Red) Control Logic Power Status LED (Red/Green) B On-Line LED (Green) B Fail LED (Red) A/B Power Status LED (Red/ Green)
October 19, 2007 - Page 3 ControlWave Redundant I/O System The ControlWave Redundant I/O system can provide redundant I/O reliability for local I/O modules located in the controller chassis or I/O modules located in an expansion chassis. In either case, I/O switching offers several benefits. Dual CPUs, Dual Power Supply Sequencers Automatic Failure Detection Automatic Switchover to Hot Standby Controller Switchover to backup on any I/O failure High Reliability No Single Point of Failure Communication Channel Switching Alarm and Historical Data Backup No programming required for redundancy data transfer Upgrade programs on the fly Each I/O Switch Module is connected to identical I/O modules in two ControlWave racks via mass terminated cables, eliminating the need for costly point to point wiring. The ControlWave I/O Redundancy Switch Module monitors the A/B select watchdog signals and selects one of the two ControlWave chassis as the on-line unit. Analog inputs, digital inputs, and high speed counter inputs are routed to the ControlWave I/O racks without any switching mechanisms. Digital outputs use MOSFETS to switch the field power supply source and return. The analog output switches contain reed relays to switch between ControlWave I/O modules outputs.
October 19, 2007 - Page 4 The digital output switches use power MOSFETs to switch the field power supply source and return. The individual outputs are diode OR d. Externally powered digital input switches have current limiting circuitry for each input. The current limiting circuit will protect the ControlWave I/O channel transorbs and also limit the current to a shorted digital input channel. Internally sourced digital input switches contain a diode/transorb arrangement. If a transorb fails on the ControlWave rack, a diode will isolate the channel. Redundant Switchover Control All ControlWave redundant configurations use the same mechanism for failure detection and switchover. System and user configured failure detection both trigger a switchover to the backup unit. System failures are detected without specific user programming. System Failures: An application program running in the CPU crashes, due to a hardware or software fault All tasks are suspended for more than a userconfigurable number of milliseconds A task watchdog occurs Hardware failures such memory or processor User Configured Failures: For even greater flexibility, virtually any user-created logic for detection of a particular failure (e.g. local I/O, communication failure, etc.) may be configured to activate a switchover via a ControlWave Designer REDUN_SWITCH function block. Determination of on-line and failure status for both redundant CPU modules is performed by triple redundant programmable logic devices whose outputs feed 2 of 3 majority voting blocks. Each programmable logic device block monitors the CPU module status, Switch Panel switch settings and internal logic states, and will generate on-line and failure status for both redundant CPU modules. Database Backup In general, data is only transferred from the Primary unit to the Backup unit if it has changed. Among the types of data transferred are: Any changed process I/O variables All variables marked as RETAIN in the user s project Any data in the static memory area Certain function block parameters that are retained Changes to certain port configuration information, e.g., on-line baud rate changes, etc. Changes to user account definitions (usernames, passwords) Any newly generated alarms plus any changed alarm states from alarm function blocks Historical data (audit records, archive files) Specifications Redundancy Switch Module: Electrical Isolation and environmental specification are the same as for ControlWave. Switch Panel Fault Tolerant Operating Logic and Voting Hardware
October 19, 2007 - Page 5 2007, 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 specifications 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 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
October 19, 2007 - Page 6 Redundant Controller Model Specifications Model Number: CWREDCPU - A - B C - D CWREDCPU CODE DESCRIPTION CWREDCPU CODE Redundant unit includes: Chassis, 2-PSSM, 2-CPU, Redundancy Switch Panel and serial communication cables from the CPUs to the Switch Panel. I/O is located in the Expansion Rack A Internal Power Supply Sequencer Module A 10 PSSM Power Supply +24 VDC input power 1 BC PSSM Power Supply +12 VDC input power 2 Dual Redundant CPUs Comm Port Configurations CWREDCPUCP BC 20 CPU (2) RS 232, (1) Ethernet 01 CPU (2) RS 232, (2) RS-485, (1) Ethernet 07 CPU (2) RS 232, (2) RS-485, (3) Ethernet 12 D Chassis & Switcher Assembly CWREDCHASI D 30 With Cables, Panel (2) RS-232, (2) RS-485 2 Mount
October 19, 2007 - Page 7 Model Number: CWREDIO - A - B C - D E - F G - H I - J K - L M - N O - P Q CWREDIO Redundant I/O System Model Specifications CODE DESCRIPTION XCWREDCPU CODE Redundant unit includes: Chassis, 2-PSSM, Redundancy Switch Panel and serial communication cables from the CPUs to the Switch Panel. A Chassis, PS & CPU Switcher Assembly (Note 1) A Switch Assy (2)RS232, 2 (2) RS232 & (2) RS485 ports 2 BC I/O Switcher (Slot 1) (Note 2 & 3) XCWREDIO BC Local Terminations Includes cables from I/O module to switcher None Empty slot 00 Digital Input Internally or Externally sourced 01 Analog Input 4-20 ma input 02 Analog Input 1-5 Vdc input 03 Digital Output 04 Analog Output 4-20 ma input or 1-5 Vdc 05 Remote Terminations Includes cables from I/O module to switcher None Empty slot 00 Digital Input Internally or Externally sourced 06 Analog Input 4-20 ma input 07 Analog Input 1-5 Vdc input 08 Digital Output 09 Analog Output 4-20 ma input or 1-5 Vdc 10 DE-PQ I/O Switcher (Slot 2-8) Repeat selections for slots 2-8 DE-PQ Note 1: Use PSSM PN 396351-03-4 in the ControlWave base controllers and I/O Expansion racks. Note 2: Use ONLY Remote Termination I/O modules in the ControlWave base controllers and I/O Expansion Racks. Note 3: All I/O switchers support the double density I/O modules.