Data Sheet
Ovation™ Controller
Upgrade
Model OCR1100 Features
▪ 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
Upgrade Benefits
▪ Allows more combinations of I/O through one
interface ▪ Provides seamless migration through the
▪ Supports up to 8 remote nodes retention of several characteristics
▪ Reuses current power supply scheme
▪ Increases connectivity for bus technology,
increased channel capacity I/O and third-party ▪ Full interchangeability of I/O modules irrespective
I/O of the type of packaging
▪ Uses LEDs indicators for improved diagnostics ▪ Uses same engineering tools for configuration
and maintenance
▪ Fits same controller backplane as the OCR400
Introduction
Emerson’s Ovation™ control system makes use of The Ovation controller executes simple or complex
industry standard components that easily incorporate modulating and sequential control strategies,
new operating systems, hardware platforms and performs data acquisition functions and interfaces to
network topologies. Continuous evolution is a basic the Ovation network and various I/O sub-systems.
Ovation design characteristic that enables the system
to stay current with the rapidly advancing technology The current Ovation controller, model OCR1100,
of today’s world. offers new features and increased functionality
beyond the capabilities of previous Ovation controller
The Ovation system features a powerful controller models. The OCR1100 is a direct replacement for the
for secure, mission-critical operations required to OCR400, fitting the same form factor1. This provides
operate the most advanced power, water and an easy upgrade path with minimal hardware
wastewater plants in the industry. replacement and required downtime.
1 OCR1100 requires Ovation 3.5 or newer
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Ovation™ Controller Upgrade Data Sheet
Technology enhancements have made significant
improvements to the Ovation controller possible. The Upgrade Process
Currently available processors have increased The Ovation OCR1100 controller is supported in
speed, reduced power consumption and decreased Ovation 3.5 level systems and above for Microsoft
heat generation allowing for fanless operation. Windows® systems only. Contact your Emerson
Service Sales representative for controller support
Network interfacing technologies, such as media with other Ovation system levels.
support, have also been incorporated into the
OCR1100 controller. Saving any control or database configuration
implemented on an OCR400 or OCR161 controller
Enhancements to the controller’s real-time operating requires a simple process to ensure proper operation
system include new security features and support for on the OCR1100 model:
additional hardware capabilities. Controller I/O
interface capabilities have increased to allow a larger ▪ Upgrade the Ovation system to the current
number of I/O interface types and protocols to be release level that supports the OCR1100
supported by the controller without adding additional ▪ Modify the database controller configuration to
hardware. identify the new controller model
▪ Download the controller to complete the transition
Benefits of Upgrading This field-proven and reliable process allows for a
quick migration without changing the validated control
Ovation’s evolving controller technology provides
schemes already in use. Current Ovation releases
increased speeds as well as RAM and Flash memory
support the concurrent use of the OCR1100 and
for faster processing of complex tasks.
OCR400 (with 128 Mb memory) controller models to
allow for a transition to occur over a user-defined
The OCR1100 offers advanced functionality and
time.
improvements to internal software components and
I/O interface modules while maintaining the
The OCR1100 power and monitoring connection
capabilities of previous controller models, including
design is plug-compatible with that of the OCR161
the original hardware I/O bus connection.
and OCR400, so the same Ovation redundant power
supply system can be used. The OCR1100’s Ovation
Enhancements have also been made to the Ovation
I/O bus connection is also the same as the OCR400’s
engineering tools, such as the control builder, to
and OCR161’s.
support the OCR1100 and OCR400 platforms in
Ovation 3.5 and above.
Upgrading an OCR161
Lifecycle Planning The recommended migration path for an OCR161 is to
upgrade directly to the OCR1100. The OCR1100
Lifecycle planning identifies future paths for upgrades
requires an Ovation system software level of 3.5 or
and extensions of existing systems. The use of
newer.
commercial off-the-shelf products reduces initial
costs, but as with any solution, requires continued
Upgrading to the latest Ovation software ensures your
investments to keep pace with changing technology.
system is compatible with the latest available
technologies and features, including the OCR1100 and
Emerson’s Evergreen program is an economical way
the accompanying controller software that incorporates
to plan for ongoing changes driven by the quick
new security functions.
evolution of the computer technologies used in
today’s process control systems.
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Ovation™ Controller Upgrade Data Sheet
Two Q-Line I/O cards, one connected to each
Upgrading an OCR400 controller, provide the connections to the Q-Line I/O
The recommended upgrade path for an existing bus to simplify and increase the reliability of the local
OCR400 is replace both processor modules of an Q-Line I/O interface. The Q-Line I/O cards occupy the
OCR400 redundant controller pair with OCR1100 QBE or 13th slot in the upper and lower Q-crates in a
processor modules. The upgrade requires an Ovation WDPF A or Ax cabinet.
3.5 or newer system level. It is possible to retain
current OCR400’s with Ovation 3.5 and newer; Summary
however, they must have 128 MB memory processors.
If the OCR400 processors do not meet the memory The OCR1100 controller is a functional replacement for
requirements, it is recommended to upgrade the its predecessors, the OCR400 and the OCR161. It
OCR400 controllers to OCR1100 controllers. provides an upgraded platform for control and I/O
interface connectivity now and the ability to obtain
future functionality.
OCR1100 Connection to Q-
Line I/O The Ovation controller upgrade maintains previous
investments in control, graphics and process
The OCR1100 controller seamlessly interfaces to the engineering. The OCR1100 controller continues the
Q-Line I/O bus using dedicated RJ45 communication. legacy established by the OCR161 and OCR400,
This is the same method used with the 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 4 Ethernet network port connections on board with 10/100/1000 base hardware
connectivity ports ▪ 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 Usage options:
synchronization ▪ 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 Electronics modules (emods), personality modules (pmods) and drawing numbers of all the
boards 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 Remains at 0 to 60°C
ratings
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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