Data Sheet
Ovation™ Controller
Upgrade
Model OCR1100 Features
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Decreases overall size and power requirements
in comparison to model OCR161 (same as
OCR400)
Maintains same OCR400 form factor size and fit
Enhanced on-board port capabilities
Quadruples memory and expandability
Eliminates need for fans
Increases process rates by 20% over OCR400
and 70% over OCR161
Provides more efficient primary-to-backup
synchronization
Allows more combinations of I/O through one
interface
Supports up to 8 remote nodes
Increases connectivity for bus technology,
increased channel capacity I/O and third-party
I/O
Uses LEDs indicators for improved diagnostics
Upgrade Benefits
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Provides seamless migration through the
retention of several characteristics
Reuses current power supply scheme
Full interchangeability of I/O modules irrespective
of the type of packaging
Uses same engineering tools for configuration
and maintenance
Fits same controller backplane as the OCR400
Introduction
Emerson’s Ovation™ control system makes use of
industry standard components that easily incorporate
new operating systems, hardware platforms and
network topologies. Continuous evolution is a basic
Ovation design characteristic that enables the system
to stay current with the rapidly advancing technology
of today’s world.
The Ovation system features a powerful controller
for secure, mission-critical operations required to
operate the most advanced power, water and
wastewater plants in the industry.
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OCR1100 requires Ovation 3.5 or newer
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The Ovation controller executes simple or complex
modulating and sequential control strategies,
performs data acquisition functions and interfaces to
the Ovation network and various I/O sub-systems.
The current Ovation controller, model OCR1100,
offers new features and increased functionality
beyond the capabilities of previous Ovation controller
models. The OCR1100 is a direct replacement for the
OCR400, fitting the same form factor1. This provides
an easy upgrade path with minimal hardware
replacement and required downtime.
Ovation™ Controller Upgrade
Technology enhancements have made significant
improvements to the Ovation controller possible.
Currently available processors have increased
speed, reduced power consumption and decreased
heat generation allowing for fanless operation.
Network interfacing technologies, such as media
support, have also been incorporated into the
OCR1100 controller.
Enhancements to the controller’s real-time operating
system include new security features and support for
additional hardware capabilities. Controller I/O
interface capabilities have increased to allow a larger
number of I/O interface types and protocols to be
supported by the controller without adding additional
hardware.
Data Sheet
The Upgrade Process
The Ovation OCR1100 controller is supported in
Ovation 3.5 level systems and above for Microsoft
Windows® systems only. Contact your Emerson
Service Sales representative for controller support
with other Ovation system levels.
Saving any control or database configuration
implemented on an OCR400 or OCR161 controller
requires a simple process to ensure proper operation
on the OCR1100 model:
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Benefits of Upgrading
Ovation’s evolving controller technology provides
increased speeds as well as RAM and Flash memory
for faster processing of complex tasks.
The OCR1100 offers advanced functionality and
improvements to internal software components and
I/O interface modules while maintaining the
capabilities of previous controller models, including
the original hardware I/O bus connection.
Enhancements have also been made to the Ovation
engineering tools, such as the control builder, to
support the OCR1100 and OCR400 platforms in
Ovation 3.5 and above.
Lifecycle Planning
Lifecycle planning identifies future paths for upgrades
and extensions of existing systems. The use of
commercial off-the-shelf products reduces initial
costs, but as with any solution, requires continued
investments to keep pace with changing technology.
Emerson’s Evergreen program is an economical way
to plan for ongoing changes driven by the quick
evolution of the computer technologies used in
today’s process control systems.
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Upgrade the Ovation system to the current
release level that supports the OCR1100
Modify the database controller configuration to
identify the new controller model
Download the controller to complete the transition
This field-proven and reliable process allows for a
quick migration without changing the validated control
schemes already in use. Current Ovation releases
support the concurrent use of the OCR1100 and
OCR400 (with 128 Mb memory) controller models to
allow for a transition to occur over a user-defined
time.
The OCR1100 power and monitoring connection
design is plug-compatible with that of the OCR161
and OCR400, so the same Ovation redundant power
supply system can be used. The OCR1100’s Ovation
I/O bus connection is also the same as the OCR400’s
and OCR161’s.
Upgrading an OCR161
The recommended migration path for an OCR161 is to
upgrade directly to the OCR1100. The OCR1100
requires an Ovation system software level of 3.5 or
newer.
Upgrading to the latest Ovation software ensures your
system is compatible with the latest available
technologies and features, including the OCR1100 and
the accompanying controller software that incorporates
new security functions.
Ovation™ Controller Upgrade
Upgrading an OCR400
The recommended upgrade path for an existing
OCR400 is replace both processor modules of an
OCR400 redundant controller pair with OCR1100
processor modules. The upgrade requires an Ovation
3.5 or newer system level. It is possible to retain
current OCR400’s with Ovation 3.5 and newer;
however, they must have 128 MB memory processors.
If the OCR400 processors do not meet the memory
requirements, it is recommended to upgrade the
OCR400 controllers to OCR1100 controllers.
OCR1100 Connection to QLine I/O
The OCR1100 controller seamlessly interfaces to the
Q-Line I/O bus using dedicated RJ45 communication.
This is the same method used with the OCR400.
Data Sheet
Two Q-Line I/O cards, one connected to each
controller, provide the connections to the Q-Line I/O
bus to simplify and increase the reliability of the local
Q-Line I/O interface. The Q-Line I/O cards occupy the
QBE or 13th slot in the upper and lower Q-crates in a
WDPF A or Ax cabinet.
Summary
The OCR1100 controller is a functional replacement for
its predecessors, the OCR400 and the OCR161. It
provides an upgraded platform for control and I/O
interface connectivity now and the ability to obtain
future functionality.
The Ovation controller upgrade maintains previous
investments in control, graphics and process
engineering. The OCR1100 controller continues the
legacy established by the OCR161 and OCR400,
which has been characterized by uncompromised
reliability and ever-expanding capabilities.
Improvements and Characteristics
Summary of Improvements when Upgrading to an OCR1100 Controller
Size
▪ Maintains the same space requirement of the OCR400 which in turn occupies 40% of
OCR161 space
▪ Height reduced by 60%; width remains the same compared to the OCR161
Power requirements
Reduced 50% to 75% over OCR161
Fans
None required
I/O interfaces
A single unit now provides interfaces to all I/O types
I/O connectivity
Supports:
▪ Local and remote Ovation standard I/O
▪ Local and remote Ovation increased channel capacity I/O
▪ Local and remote WDPF Q-Line
▪ Local Fieldbus and Ethernet link controller I/O
▪ Other simultaneous combination (with one I/O interface module)
Remote I/O
Supports up to 8 Ovation remote I/O nodes (equivalent to a single PCRR capability used with the
OCR161)
Flash memory
1 Gb; increased from 32 Mb on the OCR161
RAM
Doubled to 256 Mb from 128 Mb (OCR400) and from 32 Mb (OCR161)
Processing
Intel-based 1.1 GHz processor that replaces Celeron P4 at 400 MHz (OCR400) and Pentium P1
at 266 MHz (OCR161)
Speed
20% improvement over OCR400 and 70% over OCR161, with capabilities to run complex control
schemes and advanced control algorithms
Displays
LED status indicators (the same as the OCR400 which replaced the OCR161 alphanumeric
display)
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Ovation™ Controller Upgrade
Data Sheet
Summary of Improvements when Upgrading to an OCR1100 Controller
Memory layout
More contiguous memory up to 50 mS to support simpler, increased efficiency primary-to-backup
synchronization
Ethernet
connectivity ports
4 Ethernet network port connections on board with 10/100/1000 base hardware
▪ 2 media type options available:
- Four RJ45 copper ports – same as the OCR400 (OCR1100 G01)
- One RJ45 copper and three SFP fiber ports (OCR1100 G02)
▪ N1 3rd party Cu or SFP fiber third-party communications link (optional)
▪ N2 Cu or SFP fiber is used to single attach to the Ovation network (required)
▪ N3 Cu or SFP fiber used for dual attach to the Ovation network (optional)
▪ N4 Cu only - used for high speed controller synchronization and redundancy failover
(required)
▪ A mix of copper and fiber network media can only be supported using the four RJ45 port
version (OCR1100 G01) with media converters on the network links
Memory
synchronization
Usage options:
▪ A mix of copper and fiber network media can only be supported using the four RJ45 port
version (OCR1100 G01) with media converters on the network links
▪ Dedicated connection capability with faster failover to backup, to decrease likelihood of
bumping the process
▪ Ovation network
Upgrading to an OCR1100 Controller Preserves Previous Investments with Minimal Changes
Power connections
The controller’s connections to Ovation I/O and the power supply system remain the same,
making an upgrade to the OCR1100 seamless
Power supply
The 24 V redundant power supply and power distribution system has been redesigned and now
includes fanless power supplies. The redesigned power scheme retains the same connections
as the old design. This is a recommended upgrade to increase power supply reliability, which
can degrade with age. However, because the connections remain the same, the existing
supplies can be retained if deemed reliable.
I/O base
The I/O base system has been extended while retaining the same I/O bus connections allowing
them to be intermixed as needed for the particular types of I/O, modularity and terminations:
▪ The 2-slot I/O base into which the Ovation I/O modules are installed remains unchanged
which results in full interchangeability of I/O modules
▪ A secured 2-slot I/O base with secured connectors allows the use of prefabricated cables to
external termination blocks used in marshaling cabinet applications
▪ A 4-slot I/O base is used with Ovation increased channel capacity I/O; these are necessary
to handle the increased field terminations
Internal electronic
boards
Electronics modules (emods), personality modules (pmods) and drawing numbers of all the
existing I/O modules have not been changed. Additional modules are continually added to the
Ovation I/O system with the most recent additions increasing the channel capacities.
▪ It is recommended that when power requirements are verified when adding I/O modules
▪ It is recommended to verify controller IOIC capabilities before adding new I/O modules
Environmental
ratings
Remains at 0 to 60°C
User interface
The user interface and engineering tools for Ovation controllers remains unchanged: The
Ovation Developer Studio’s graphic and control builders, are used to create database, graphics
and control sheets just as in previous Ovation releases
©2017-2018 Emerson. All rights reserved. The Emerson logo is a trademark and service mark of Emerson Electric Co. Ovation ™ is a mark of one of the Emerson Automation Solutions
family of business units. All other marks are the property of their respective owners. The contents of this publication are presented for information purposes only, and while effort has been
made to ensure their 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. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at
any time without notice.
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