396879-11-0 ControlWave Micro CPU Module (Industrial-Grade Hybrid Controller)

The 396879-11-0 ControlWave Micro CPU Module represents Emerson's next-generation solution for distributed process automation, merging programmable logic controller (PLC) intelligence with remote terminal unit (RTU) communication capabilities in a single compact platform. Built around a robust 150 MHz ARM processor architecture with 16 MB Flash memory and dual Ethernet connectivity, this controller addresses the critical demands of oil & gas pipeline networks, municipal water infrastructure, power substations, and manufacturing facilities requiring 24/7 uptime.

Designed for engineers managing geographically dispersed assets, the 396879-11-0 eliminates the complexity of maintaining separate PLC and RTU systems while delivering protocol flexibility that bridges legacy SCADA networks with modern IIoT platforms. Whether you're retrofitting aging Bristol Babcock installations or deploying greenfield automation projects, this CPU module provides the computational power and communication versatility to future-proof your control architecture.

With certifications spanning ATEX Zone 2, IECEx, and CSA standards, plus an operating temperature range from -40°C to +70°C, the 396879-11-0 thrives in harsh industrial environments where conventional controllers fail—from Arctic wellheads to desert refineries—while consuming just 240 mA for solar-powered remote site compatibility.

Core Features & Benefits

→ Dual 10/100 Mbps Ethernet Ports: Redundant network architecture ensures continuous SCADA communication even during cable failures or switch maintenance, eliminating single points of failure in mission-critical applications. Supports ring topology for self-healing networks.

✓ Multi-Protocol Native Support: Simultaneously operates Modbus RTU/TCP, DNP3 (IEEE 1815), OPC DA/UA, and BSAP protocols without external gateways, reducing hardware costs by 30-40% while simplifying system integration across multi-vendor environments.

→ 11 Configurable Serial Ports: Unprecedented serial I/O capacity enables direct connection to legacy field devices, RTUs, and instrumentation without protocol converters. Optional integrated modem supports dial-up backup communication for remote sites.

✓ Extended Temperature Performance: Industrial-grade components rated for -40°C to +70°C operation maintain full processing speed and accuracy across extreme climates, eliminating thermal derating and ensuring consistent control loop performance.

→ 16 MB Flash + 4 MB SRAM: Generous memory allocation supports complex control logic, historical data buffering during communication outages, and firmware updates without program loss. Ideal for batch process recipes and alarm event logging.

✓ Low Power Consumption (240 mA @ 24 VDC): Energy-efficient design extends battery backup runtime during power outages and enables solar-powered installations in off-grid locations, reducing operational costs for remote monitoring applications.

Typical Application Scenarios

Oil & Gas Pipeline Automation: Deployed at remote pump stations and metering skids, the 396879-11-0 executes PID control for pressure regulation while transmitting flow totalizer data to central SCADA via DNP3. Dual Ethernet ports connect to redundant fiber optic networks, ensuring leak detection alarms reach operators even during network failures. Solves the challenge of integrating legacy Modbus flowmeters with modern DNP3 masters without costly protocol gateways.

Municipal Water Treatment: Controls chemical dosing pumps, filtration backwash sequences, and UV disinfection systems while logging water quality parameters (pH, turbidity, chlorine residual) to OPC historians. The 11 serial ports interface directly with legacy SCADA RTUs, eliminating the need for separate data concentrators. Delivers 99.9% uptime for regulatory compliance reporting.

Power Substation Automation: Manages circuit breaker control, capacitor bank switching, and transformer monitoring in utility substations. DNP3 protocol support ensures seamless integration with utility SCADA systems per IEEE C37.1 standards. Extended temperature rating eliminates the need for climate-controlled enclosures, reducing installation costs by $5,000-$8,000 per site.

Manufacturing Process Control: Orchestrates batch mixing operations, conveyor interlocks, and environmental monitoring (temperature, humidity, dust levels) in food processing and pharmaceutical plants. Modbus TCP connectivity links to HMI panels and MES systems for real-time production tracking. Compact DIN rail mounting saves 60% panel space versus traditional PLC/RTU combinations.

Legacy System Modernization: Provides a migration path for aging Bristol Babcock and ControlWave networks, maintaining BSAP protocol compatibility while adding Ethernet/IP and OPC UA capabilities for Industry 4.0 initiatives. Reduces retrofit engineering time by 50% through backward-compatible I/O addressing.

Technical Parameters & Selection Guide

Selection Criteria: Choose the 396879-11-0 when your application requires simultaneous PLC control logic execution and multi-protocol RTU communication in a single device. This module is optimal for distributed control systems with 50-500 I/O points spread across multiple locations. For applications exceeding 500 I/O points or requiring redundant CPU configurations, consult our engineering team for ControlWave Designer system architecture planning.

Extended Functions

IIoT Integration Capabilities: The 396879-11-0 supports OPC UA server functionality, enabling direct connectivity to cloud-based analytics platforms (AWS IoT, Azure IoT Hub, ThingWorx) without middleware. Publish process variables, alarm states, and diagnostic data to enterprise historians for predictive maintenance and energy optimization initiatives.

Advanced Diagnostics: Built-in web server provides real-time CPU utilization, memory usage, and communication statistics accessible via standard web browsers. SNMP trap support integrates with network management systems (Nagios, PRTG) for proactive fault detection before process disruptions occur.

Customization Options: Factory-configurable firmware variants support specialized applications including gas flow calculation (AGA-7/8), custody transfer metering, and SIL-rated safety logic. Contact our technical sales team for custom protocol development or industry-specific function blocks.

Delivery & Service Assurance

Lead Time: Standard configurations ship within 3-5 business days from our certified distribution center. Custom firmware variants require 2-3 weeks for factory programming and testing. Expedited shipping available for emergency replacements.

Warranty Coverage: 24-month manufacturer warranty covers defects in materials and workmanship. Extended warranty plans available for critical infrastructure applications requiring 5-year coverage with advance replacement service.

Technical Support: Pre-sales application engineering assistance included at no charge—our team helps with I/O mapping, network architecture design, and protocol configuration. Post-delivery support includes phone/email troubleshooting and remote diagnostics via VPN connectivity.

Documentation Package: Each module ships with installation manual, quick start guide, Modbus register map, DNP3 point list template, and ControlWave Designer software license. CAD drawings (DWG/PDF) and 3D STEP models available for panel layout planning.

Frequently Asked Questions

Q: Can the 396879-11-0 replace an existing Allen-Bradley ControlLogix PLC in a Modbus TCP network?
A: Yes, the module natively supports Modbus TCP client/server modes and can execute IEC 61131-3 ladder logic programmed via ControlWave Designer. Migration tools are available to convert RSLogix 5000 programs to ControlWave format, though manual validation is recommended for complex motion control or safety-rated logic.

Q: What is the maximum distance for serial communication using the RS-485 ports?
A: RS-485 serial ports support up to 1,200 meters (4,000 feet) at 9,600 baud using twisted-pair cable (Belden 3105A or equivalent). For longer distances, use fiber optic converters or Ethernet-based distributed I/O to maintain signal integrity.

Q: How much energy savings can I expect compared to traditional PLC/RTU combinations?
A: The 396879-11-0 consumes approximately 5.8 watts (240 mA @ 24 VDC) versus 15-20 watts for separate PLC and RTU devices, representing 60-70% power reduction. For solar-powered sites, this translates to smaller battery banks and reduced panel wattage requirements.

Q: Does this CPU module require special installation tools or training?
A: Standard installation uses a flathead screwdriver for DIN rail mounting and Phoenix Contact-style terminal blocks for wiring. Programming requires ControlWave Designer software (Windows-based) with training available through Emerson University online courses. Basic PLC programming knowledge (ladder logic, function blocks) is recommended.

Q: Can I monitor and configure the controller remotely over cellular networks?
A: Yes, the dual Ethernet ports support VPN connectivity via industrial cellular routers (Sierra Wireless, Digi). The integrated web server and OPC UA interface enable secure remote access for configuration changes, firmware updates, and real-time diagnostics without site visits.

Q: Is the 396879-11-0 compatible with existing ControlWave I/O racks and expansion modules?
A: Fully compatible with the entire ControlWave Micro I/O family including analog input modules (396509-05-3), digital I/O modules (396351-03-4), and specialty modules for temperature, vibration, and flow measurement. Supports up to 11 distributed I/O racks via serial communication.

Start Your Automation Project Today

Ready to modernize your control system with proven hybrid PLC/RTU technology? Our application engineers are standing by to review your I/O requirements, network topology, and protocol specifications. Request a detailed quotation including recommended I/O modules, programming software licenses, and installation support packages tailored to your project timeline.

Contact our technical sales team: Share your system architecture drawings and functional requirements for a complimentary feasibility assessment within 24 hours.

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