ControlEdge TPN R688.1 Enhanced Logic Manager Module User Guide

June 12, 2024
ControlEdge

ControlEdge TPN R688.1 Enhanced Logic Manager Module

ControlEdge-TPN-R688.1-Enhanced-Logic-Manager-
Module

Product Information

  • Product Name: TPN R690.1 ControlEdge PLC R172.1.15.1 (R172.1 HF1)
  • User Guide: Enhanced Logic Manager Module with ControlEdge PLC User’s Guide
  • Document Number: TNDOC-X573-en-690.1E
  • Release Date: August 2022

Table of Contents:

  • 1. Introduction
  • 1.1 Revision history
  • 1.1.1 Related documents
  • 1.2 Overview
  • 1.2.1 Purpose
  • 1.2.2 Scope
  • 1.2.3 Abbreviations
  • 1.3 Solution Overview
  • 1.3.1 Modernization
  • 1.3.2 Benefits
  • 1.3.3 The Solution
  • 1.4 Hardware and Software Requirements
  • 1.4.1 Supported Software Release
  • 1.4.2 Hardware Requirements
  • 1.4.3 Model Numbers
  • 2. ELMM WITH CONTROLEDGE PLC PLANNING AND DESIGN
  • 2.1 Planning Considerations
  • 2.2 Network Planning

Product Usage Instructions

Planning and Design:

  1. Consider the planning considerations mentioned in section 2.1 of the user guide.
  2. For network planning, refer to section 2.2 for detailed information.

Please note that this response provides a summary of the product information and usage instructions based on the given text-extract from the user manual. For complete and accurate information, please refer to the actual user guide provided with the product.

TPN R690.1 ControlEdge PLC R172.1.15.1 (R172.1 HF1)
Enhanced Logic Manager Module with ControlEdge PLC User’s Guide
TNDOC-X573-en-690.1E August 2022

DISCLAIMER
This document contains Honeywell proprietary information. Information contained herein is to be used solely for the purpose submitted, and no part of this document or its contents shall be reproduced, published, or disclosed to a third party without the express permission of Honeywell International Sàrl. While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a purpose and makes no express warranties except as may be stated in its written agreement with and for its customer. In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The information and specifications in this document are subject to change without notice. Copyright 2022- Honeywell International Sàrl.

1 Introduction

1.1 Revision history

Revision Date A April 2019

Description Initial release of the document.

B November 2019 Removed section “ELMM with ControlEdge PLC FTE Switchover operations”.

C November 2020 Updated section “PLC Inputs Outputs” to include 621-0020R, 621-0025R, and 6216551R modules.

D February 2021

Updated to include information as per ControlEdge PLC R170 changes/enhancements.

E August 2022

Updated to include information as per ControlEdge PLC R172.1.15.1 (R172.1 HF1) changes/enhancements.

1.1.1 Related documents
Sl. No. 1 2 3
4 5 6 7 8

Document Name UCN Planning Guide ControlEdge PLC and ControlEdge RTU Getting Started Guide ControlEdge 900 Platform Hardware Planning and Installation Guide Engineer’s Reference Manual LM Service manual Data Entity Builder Manual Logic Manager Service (LM13-685) Experion Network Best Practices

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Sl. No. 9 10 11 12 13 14 15

Document Name Universal Control Network Planning UN02501 Universal Control Network Installation UN20500 Fault Tolerant Ethernet Installation and Service Guide Fault Tolerant Ethernet Bridge Implementation Guide ControlEdge Builder User Guide ControlEdge Builder Software Installation User’s Guide Ladder Logic Migration User’s Guide

1.2 Overview
1.2.1 Purpose
This document provides necessary information to plan, install, configure, operate, and troubleshoot the Enhanced Logic Manager Module (ELMM) with ControlEdge® PLC. Instructions specific to ELMM are provided in this document. The referenced documents must be consulted to perform certain tasks mentioned in this document.

1.2.2 Scope

This document covers the information needed to replace Logic Manager (LM) with ELMM. This includes planning information about activities to be performed on existing LM modules before you shut them down
1. Disassemble the LM hardware
2. Replace the LM cabinet
3. Connect the new ELMM with ControlEdge PLC that come pre-loaded in the ControlEdge PLC cabinet
4. Power up and configure ELMM to continue working with the restored checkpoints
5. Configure ControlEdge PLC logic.

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IO wiring and reconfiguration of I/O is beyond the scope of this document. Contact Honeywell Project Engineering for planning IO wiring and reconfiguration.
ELMM with ControlEdge PLC is not supported in a nonredundant configuration.
ATTENTION

1.2.3

Abbreviations
The following table lists the various acronyms and abbreviations used in this document.

Acronyms DEB .EB files EHPM ELMM ENIM

Meaning Data Entity Builder Entity Builder files Enhanced High­Performance Process Manager Enhanced Logic Manager Module Enhanced Network Interface Module

EUCN

Enhanced Universal Control Network

FOE FTE IOP LCN LM

Fiber Optic Extender Fault Tolerant Ethernet Input/Output Processor (module) Local Control Network Logic Manager

MAC

Media Access Control

NIM

Network Interface Module

UCN PMIO AM

Universal Control Network Process Manager IO Application Module

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Acronyms APM
Audit
CPM EPM SIOM

Meaning Advanced Process Manager Module System Audit Tool: The AUDIT overlay is called from the Command Processor and produces output identical to LVRLOG Control Processor Module Expansion Processor Module Serial Input/Output Module

1.3 Solution Overview
1.3.1 Modernization

1.3.2 Benefits

Enhanced Logic Manager Module with ControlEdge PLC is for users who want to modernize and migrate Logic Managers on their TDC 3000, TPS or Experion TPS systems with an IEC 61131-3 based controller. The existing IPC/LCS 620 controller and I/O module is replaced with the ControlEdge 900 Platform controllers and I/O module, improving control performance while offering greater flexibility and lower costs.
Migrating from the obsolete LM platform to an Experion PKS hardware platform with the latest ControlEdge PLC ensures facilities of better lifecycle support. Additional benefits include:
· Replace obsolete IPC620 processor along with its I/O module by the ControlEdge PLC along with its I/O module.
· Replace the LMM by the ControlEdge PLC and enable connectivity to EUCN network by adding EUCN protocol support on the PLC.
· Convert all the ladder logics in the IPC620 processor to its equivalent ladder logics/function blocks on the ControlEdge PLC.
· Retain the user’s intellectual property and user experience intact, by allowing a restore of existing checkpoint, thereby enabling the usage of all existing graphics, trends, and control groups.

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1.3.3 The Solution
The solution includes two major components:
1. ELMM 2. ControlEdge PLC with ControlEdge 900 I/O modules or UIOs
3. LM Ladder Logic Migration Tool
4. ControlEdge Builder Honeywell’s Enhanced Logic Manager Module with ControlEdge PLC hosts all LMM functions. The ControlEdge PLC replaces the LM’s IPC 620 controller and uses a proprietary tool called LM Ladder Logic Migration Tool to migrate the LM database and ladder programs to ControlEdge PLC function blocks. The ELMM is virtualized and operates on the ControlEdge PLC platform. ControlEdge Builder is used to configure ELMM with ControlEdge.
ELMM is connected to the Enhanced Universal Control Network (UCN over FTE) and Experion technology. You can also migrate the Logic Manager database to ControlEdge PLC ladder logic/function blocks, retain TPN graphics and AM applications, and even retain peer access to HPMs.
Note: This solution only supports off-process migration and requires shutdown. The backward migration from ELMM with ControlEdge PLC to ELMM is not supported.
The below illustration depicts the ELMM with ControlEdge PLC architecture.

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1.4 Hardware and Software Requirements

1.4.1 Supported Software Release

Software TPN

Requirement TPN688.1 or later

ControlEdge PLC R152.1 or later

ControlEdge Builder R152.1 or later

LM Ladder Logic Migration Tool

R200.1

1.4.2

Hardware Requirements

The following list provides hardware components required to set up an ELMM system. Based on your existing LM configuration, hardware requirements will vary depending on the existing installation . At a minimum, you will need:

Hardware

Description/Model Number

ELMM with ControlEdge PLC is supported only for ControlEdge PLC
redundant ControlEdge PLC.

ENIM/ENB

You must have ENIM/ENB based network.

Honeywell FTEcompliant EUCN with spare ports on an L2 switch

One redundant pair is a minimum requirement. FTE A and FTE B L2 switch is required to connect ControlEdge PLC controller to connect on L2 FTE network.

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Cables

·

Grounding cables

·

Power cables

·

FTE cables

Note: If you are retaining the field wiring, use the additional Weidmuller connector or third-party connector with custom cable.

1.4.3 Model Numbers
Model Number Description
900RR0-0200 Redundant CPM Rack
900R04-0200 I/O Rack (4-slot)
900R08R-0200 I/O Rack (8-slot) can include either a redundant power supply or non-redundant power supply. A Power Status Module (PSM) is required with redundant power supplies. The diagram shows the rack with a redundant power supply. The model number of the rack with a non-redundant power supply is 900R08-0200.
900R12R-0200 I/O Rack (12-slot) can include either a redundant power supply or non-redundant power supply. A Power Status Module (PSM) is required with redundant power supplies. The diagram shows the rack with a redundant power supply. The model number of the rack with a non-redundant power supply is 900R12-0200.
SP-CELMMP ELMM With ControlEdge License Redn/NR

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2 ELMM with ControlEdge PLC Planning and Design
2.1 Planning Considerations
Implementing an ELMM solution begins by planning for the following:
· Network topology: Understand how ELMM with ControlEdge PLC connects to EUCN. For information about ControlEdge PLC I/O, see ControlEdge 900 Platform Hardware Planning and Installation Guide.
· EUCN Planning: ELMM connects to EUCN (UCN over FTE). See UCN Planning Guide for more details.
· Back migration from ControlEdge PLC to Classic LM or C300: Backward migration from ControlEdge PLC to Classic LM or C300 is not supported.
· ELMM with ControlEdge PLC: The number of modules needed based on your requirements, or based on the number of LM processors being replaced. ELMM with ControlEdge PLC supports redundancy. Plan the number of controllers and ELMMs required if you want redundancy, or if the LMs being replaced are redundant.
· I/O: ControlEdge 900 I/O
· IO Network Topology: ELMM with ControlEdge PLC supports both Star, Ring, and DLR topologies like PLCs do. For more information on topologies, see Section “I/O Network Topology” in the ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).
· Process wiring techniques: Study the wiring and grounding requirements of PLC cabinet, ControlEdge PLC I/O, and Remote I/O, if any.
· Additional customer responsibilities: In general, you are responsible for preparing your facility as outlined in this guide and references to other guides provided. In addition:
o Install this equipment in accordance with applicable statutory requirements such as National Electrical Code (NEC), ANSI/NFPA 70, or the Canadian Electrical Code (CEC), C22.1.
o Furnish and install (at your expense and sole responsibility) all internal building wiring (including power and signal cables) in accordance applicable standards such as NEC or the CEC.

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o Install any power and signal cables according to the applicable standards such as NEC, CEC, and other local regulations and requirements.
· Note: If the Control Edge PLC is used as a replacement for LM/IPC620 by enabling the “EUCN Protocol” and “Modbus Slave” options, then, the MODBUS Slave protocol cannot be used for any external or third-party communication. If the Control Edge PLC is used as an ELMM, no other external MODBUS devices can be connected or configured. All other protocols are supported.
2.2 Network Planning
Level 1 nodes are the heart of the control system. This network segment contains ENIM, EHPM, SM, and ENB.
Level 2 nodes are the primary server, view and advanced control nodes for the process control system. Examples of Level 2 nodes include ACE, ACE-T, ES-T, ESVT, E-APP, PHD, and TCMI. These nodes are essential for operation of the process, but not as critical to control as the Level 1 nodes.
The following illustration depicts the ELMM with ControlEdge PLC network topology.
To communicate with the EUCN network, ELMM with ControlEdge PLCs are connected to FTE L2 network switches which in turn are connected to ENIMs.

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ControlEdge PLCs on an FTE network connect to Experion-qualified FTE L2 network switches. ControlEdge PLC has a built-in firewall, so a separate Control Firewall switch is not required. For more information, see Experion Best Practices Document.

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2.3 Site Selection

2.3.1 Space assessment for PLC hardware

LM cabinet dimensions

Dual Access Cabinet

Height (mm) Width (mm)

2100

800

Single Access Cabinet

Height (mm) Width (mm)

2000

800

LM rack size Full Rack Size Height (mm) 266.7

Width (mm) 482.6

Half Rack Size

Height (mm) Width (mm)

266.7

301.2

Depth (mm) 800
Depth (mm) 500
Depth (mm) 188
Depth (mm) 188

Follow the guidelines mandated at your site for mounting ControlEdge PLC racks in an existing LM cabinet. In addition, consider the following:
New I/O modules can be mounted in the space of removed LM processor racks. Three 12-slot ControlEdge PLC racks can be mounted as shown in the following figure. A LM rack has 14 slots including one slot each for a power supply module, communication module, and, EDM, and 10 slots for IO modules (maximum). this totals to 40 slots of IO in the cabinet. Three 12-slot IO racks of ControlEdge are needed to replace LM I/O modules.
The racks are mounted on a bracket which will bring the IO rack by 100 mm to the front to conveniently use the space over cable trays on both the ends. Take care to ensure the access and visibility of the cables behind the bracket are not hindered. As the higher density ControlEdge IO modules are mapped

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against the LM I/O modules, this reduces the count of new IO modules required, resulting in an option of 8-slot ControlEdge IO racks. This will also eliminate the need for a bracket.
The other cabinets will have a maximum of two racks and finding additional space for two new IO racks will not be a problem. Take care that the earthing is not disconnected on the introduction of a bracket. The routing and the space of the existing power cables can be reused.
There are two possible scenarios for installing ControlEdge IO modules in an existing LM cabinet as follows:
· Scenario 1 (existing IO racks having four spare slots) ­ in this scenario, there are four spare slots to install IO modules in an existing rack, the remaining 36 can be accommodated in the three racks added to the cabinet as shown in the following figure.
· Scenario 2 (existing IO racks having three or fewer spare slots) ­ in this scenario, as the higher density ControlEdge IO modules are mapped against the LM IO modules, for example, 16 ControlEdge modules in place of 8 LM IO modules, this reduces the count of new IO modules required and so the IO modules can be accommodated in the same cabinet.

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Honeywell recommends you to use third party cable connectors, with the aid of cable connectors, the problem of replacing older PLC systems with ELMM can be solved easily and safely, you can maintain the existing field cabling.

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2.4 PLC Inputs Outputs

Module Type LM module

AI

621-0020R

LM module description
Universal Analog Input Module

ControlEdge Channels Equivalent

16

900A01-0202

ControlEdge Description
Universal Analog Input -RTD, TC, V

Channels Notes

Sensor type and PV low

range must be

configured suitably for

8

4 – 20 mA.

Resistance

Temperature

AI

621-0025R Detector Module 8

Universal Analog 900A01-0202 Input -RTD, TC, V 8

Sensor type and PV low range must be configured suitably for 4 – 20 mA.

4-20 mA Isolated

AI

621-0022-AR Analog Input

8

Universal Analog 900A01-0202 Input -RTD, TC, V 8

Sensor type and PV low range must be configured suitably for 4 – 20 mA.

0-10 V Isolated

AI

621-0022-VR Analog Input

8

Universal Analog 900A01-0202 Input -RTD, TC, V 8

Sensor type and PV low range must be configured suitably for 0 – 10V.

4-20 mA Analog

AO

621-0010-AR Output

4

Analog Output

900B01-0301 Module

4

4-20 mA needs low range configuration.

0-10 V Analog

AO

621-0010-VR Output

4

Analog Output

900B01-0301 Module

4

Voltage output needs conversion from mA with suitable load resistor.

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ELMM WITH CONTROLEDGE PLC PLANNING AND DESIGN

Module Type LM module
Counter 621-0307RC

LM module description
High-Speed Counter module with PFQ

ControlEdge Channels Equivalent

4

PFQ 900K01

ControlEdge Description

Channels Notes

Pulse &

Frequency Input,

Pulse Output

4

12-24VDC

DI

621-4500R Source Input

8

Digital Input 24

900G32-0101 VDC

32

115 VAC Discrete

DI

621-1180

Input

32

Digital Input

900G03-0202 120/240 VAC

16

115 VAC/VDC

DI

621-1100R Discrete Input

8

Digital Input

900G03-0202 120/240 VAC

16

115 VAC/VDC

Isolated Discrete

DI

621-1101R Input

6

Digital Input

120/240 VAC-

125VDC

(individually

900G04-0101 isolated)

16

Group the channels as per signals, for example, start, stop, and trip status of the same motor together. This will eliminate isolation need.

115 VAC Discrete

DI

621-1160R Input

16

Digital Input

900G03-0202 120/240 VAC

16

24 VAC/VDC

DI

621-1500R Discrete Input

8

Digital Input 24

900G32-0101 VDC

32

24 VDC Sink Fast

Response

DI

621-3552R Discrete Input

16

Digital Input 24

900G32-0101 VDC

32

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ELMM WITH CONTROLEDGE PLC PLANNING AND DESIGN

Module Type LM module

DI

621-3560R

DI

621-1250R

DI

621-3580

DI

621-3580R

D0

621-6500R

DO

621-6503R

DO

621-0007R

DO

621-2100R

LM module description
12-24 VDC Sink Discrete Input

ControlEdge Channels Equivalent

16

900G32-0101

ControlEdge Description
Digital Input 1224 VDC

Channels Notes 32

240 VAC Discrete

Input

16

Digital Input

900G03-0202 120/240 VAC

16

24Vdc Discrete

input

32

Digital Input 24

900G32-0101 VDC

32

12-24Vdc

Discrete input

32

Digital Input 12-

900G32-0101 24 VDC

32

Discrete Output

24 VDC

8

Digital Output 24

900H32-0102 VDC

32

24 Vdc Source Self-Protected Discrete Output 8

Digital Output 24

900H32-0102 VDC

32

Reed Relay

Output

6

Relay Output

900H01-0202 Module

8

115 VAC Discrete

Output

8

Digital Output

900H03-0202 120/240 VAC

8

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ELMM WITH CONTROLEDGE PLC PLANNING AND DESIGN

Module Type LM module

DO

621-2101R

DO

621-2150R

DO

621-6550R

DO

621-2102R

DO

621-2200R

DO

621-6575

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621-6551R

LM module description

ControlEdge Channels Equivalent

ControlEdge Description

115 VAC Isolated Discrete Output 6

Digital Output 900H03-0202 120/240 VAC

Channels Notes

Group the channels as

per signals, for example,

start, stop, and trip

command of the same

motor together. This will

eliminate isolation need.

Use relay module if

channel isolation is still

8

a need.

115 VAC Discrete

Output

16

Digital Output

900H03-0202 120/240 VAC

8

24 VDC Source Discrete Output 16

Digital Output 24

900H32-0202 VDC

32

115 VAC SelfProtected Discrete Output 8

Digital Output

900H03-0202 120/240 VAC

8

230 VAC Discrete

Output

8

Digital Output

900H03-0202 120/240 VAC

8

24Vdc Discrete

output

32

Digital Output 24 900H32-0102 VDC

If current ratings are more ­ use relay module 621-0007R.

Low Power

Discrete Output

24 VDC

16

Digital Output 24

900H32-0102 VDC

32

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ELMM WITH CONTROLEDGE PLC PLANNING AND DESIGN

2.5 Process wiring techniques

2.5.1

Cabling considerations for ControlEdge PLC Components
See the section “Wiring and Cabling” in ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

2.5.2

Grounding requirements
See the section “Wiring and Cabling” in ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

2.5.3

Power entry guidelines for PLC
See the section “Power Supply” in ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en).

2.6 Estimated Time
The estimated time required to install ControlEdge PLC is 8 hours. The estimated time does not include system reconfiguration or startup time. It also does not take into consideration time required for IO wiring and reconfiguration of I/O.

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3 ELMM with ControlEdge PLC Installation

3.1 Overview
Before ELMM installation can begin, you must disassemble existing LM equipment and safely transport it away from the site. Exercise caution to power down equipment ­ cabinet, card files, I/O, remote IO racks – and follow all instructions provided in this guide and the guides referenced herein when uninstalling LM equipment.
Label field wiring with new module and channel identification prior to removal. Some IO modules have terminal blocks with friction fit connectors. Others have screw terminals. Determine if the field wiring is of appropriate size and length for the new module connections.

3.1.1

Overview of tasks
After a plan to replace LM with ELMM is in place, begin to shut down and disassemble LM hardware. The sequence of steps to power down and disassemble LM hardware is provided here.

Step Action
1 Prepare the LM for shutdown. Record the existing UCN address information for NIMs and LMs in section “Appendix A: EUCN Configuration Data Checklist” on page 160 for reference purposes.

2 Checkpoint LMs in HM and Emulated Drive.

3 Record the switch settings of the existing LM for future reference.

4 Generate ladder logic files.

5 Generate EB files for LM box using Node-specific configuration page and for all the points in the respective configuration pages.

6 Shutdown LM from Native Window.

7 Power down LM hardware and remove wiring.

8 Remove card files and modules from the cabinet.

9 Remove the cabinet.

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3.1.2

Preparing the LM for shutdown
Ensure the following checklist items are completed to prepare the LM for shutdown.

Item

Reference

Record the existing UCN address information for NIMs and LMs, and LM node numbers in section “Appendix A: EUCN Configuration Data Checklist” on page 160 for reference purposes.

Checkpoint and take a backup of LM checkpoint files.

See Section “Checkpointing” of Engineer’s Reference Manual (SW09605) for more details.

Generate EB files for LM box using Node-specific configuration page and for all the points in the respective configuration pages.

Record DIP switch settings on the existing LMs for future reference.

Record the DIP switch settings on the Serial IO Module.

Generate LM I/O configuration details (.xls or .csv).

Generate and save Ladder logic files (.PRN).

Repeat the earlier task for all LMs on the UCN.

See Section “Checkpointing” of Engineer’s Reference Manual (SW09605) for more details.

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3.1.3

Checkpoint LM
Data checkpointing is performed to maintain up-to-date device settings in the event a device is taken out of service. Prior to replacing LM with ELMM, checkpoint NIM and LM to save existing data.

It is always recommended that you preserve the LM checkpoint in an Emulated Drive.
ATTENTION

The following diagram gives a snapshot of the checkpointing process.

See Section 21 of the Engineer’s Reference Manual for more details.

3.1.4

Record Current LM Card File Configuration
It is important you record the switch settings of the existing LM for future reference. Ensure you complete this activity before disassembling the LM hardware.

See chapter 2 of the LM Service manual LM13500 for information about switch settings on the LM card file.

3.1.5 Generate Ladder Logic files
Generate and save the following files before shutting down the LM.

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ELMM WITH CONTROLEDGE PLC INSTALLATION

· PRN file
· Label File
· Force List (Force function and data change function are not supported for ELMM with ControlEdge PLC)
See the Data Entity Builder Manual (SW11-611) and the 620 WinLoader, Version 5.4, User Manual for additional information.

3.1.6

Generate UCN & Node specific EB files
See the Data Entity Builder Manual (SW11-611) for additional information about Print entities.

Generate EB files for LM box using Node-specific configuration page and for all the points in the respective configuration pages.

See Appendix D (for Exception Building) and Appendix E (for Creating Exception Build Files from IDFs) of the System Startup Guide CD-ROM (SW11600).

3.1.7 Shut down LM from Native Window
After checkpointing LMs and backing up ladder logic and EB files, proceed to shutdown LMs.
From an R6xx LCN station ­ for instance, US, GUS, ES-T, or PCUS, perform the following procedure to shut down the R6xx LM. For information about Displays, see the Logic Manager Service (LM13-685).
The following tasks must be performed in the given order for a safe and successful shutdown of LM.

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Step Action Depress the (System Status) key on the system console
1 to invoke the System Status display.

Choose the NIM node in the display grid that the LM is resident on

2

and then select the NTWK/HWY STATUS target to invoke the UCN

Status display.

Choose the LM of interest on the display grid and then select the 3
DETAIL STATUS target on the UCN Status display.

For redundant nodes, perform steps 4 and 5. For a non-redundant node, skip to step 6.

Choose the secondary LM (Status shows BACKUP) and then select 4
RUN STATES target.

Choose the SHUTDOWN target and execute the command by

5

selecting the ENTER target. The secondary LM enters the ALIVE

state.

Choose the primary LM (Status shows OK) and then select RUN 6
STATES target.

Choose the IDLE target and execute the command by selecting the 7
ENTER target. The LM enters the IDLE state.

Choose the SHUTDOWN target and execute the command by 8
selecting the ENTER target. The LM enters the ALIVE state.

3.1.8

Power-off LM
You can now proceed to shut down the LM by isolating power to the LM hardware and cabinet. To isolate power, remove power from a particular LM card file by placing the power breakers in the off-position.

Typically, the Logic Manager card files are installed in the single or dual access cabinets as depicted in the following diagram. The redundant IPC 620 processors sit at the top of the cabinet followed by the Serial IO card files underneath. Follow a bottom-up approach when isolating power to the LM system. Power is isolated to the bottom most IO card file followed by the one above it and so on. When isolating power to the IPC 620 processors, shut down the secondary processor before the primary. If remote IO racks are present, isolate power and remove the Serial Link cable.

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Assumptions and Cautions Before you work on any electronic equipment, read and follow the safety guidelines to help protect the system from potential damage and ensure personal safety.
· Only qualified personnel must perform this upgrade.
TIP
· When disconnecting a cable, pull on its connector or on its strain-relief loop, not on the cable itself. As you pull connectors apart, keep them evenly aligned to avoid bending any connector pins. Ensure that both connectors are correctly oriented and aligned.
To guard against electrical shock, always turn off any electronic equipment before removing any covers or boards.
ELECTRICAL SHOCK

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ELMM WITH CONTROLEDGE PLC INSTALLATION
Electrostatic Discharge Protection
Handle components and cards with care. Do not touch the components or contacts on a card. Hold a card by its edges or by its mounting bracket. ESD While removing, handling, and installing Logic Manager System HAZARD components, it is extremely important that you wear an Electrostatic Discharge (ESD) wrist strap that is properly connected to ground. Be sure power to the equipment is off. Slip the strap on your wrist like a wristwatch and connect its clip to the ground bus located inside the front, left side of the cabinet. Wearing an approved ESD wrist strap does not increase the danger of electrical shock.

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ELMM WITH CONTROLEDGE PLC INSTALLATION
ESD Wrist strap Connection in the Logic Manager Cabinet Be sure to store any electronic component in a static-safe carrying pouch whenever it is not in use. An ESD kit is available through Honeywell. Contact your Honeywell representative and ask for part number 30185-H.

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ELMM WITH CONTROLEDGE PLC INSTALLATION
3.1.9 Remove LM hardware
LM hardware removal can proceed in one of two ways. 1. Disassemble IO files from each IO card file and then remove the card files. 2. Remove the card files directly.
If you plan to reuse cables, tag them and safely store them so they can be identified. Identity Components for Disassembly
· Logic Manager Processor Card File · Logic Manager Redundant Processor Card File · I/O Card Files · Remote IO racks · Power cables · IO cables · UCN cables · UCN taps Disassembly Procedure Use the following procedure to disassemble the LM hardware.

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Step Action

Shut down power supply to the LM processor, LM redundant processor, and all IO racks (local and remote).

1

Tip: Make sure no LED is lit up in any of the racks signifying power

has been isolated from the racks. Use proper voltage measurement

device to verify that there is no potential/voltage in the module which

is being replaced.

Disconnect the power cables to remove power from the LM Processor card file, LM Redundant Processor card file, and I/O Card Files.

2

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Disconnect the I/O Link Interface cables from the card files. Note that some IO modules have terminal blocks with friction fit connectors while others have screw terminals. The I/O Link Interface cables can be reused.
3
Remove any unused UCN drop cables, taps, and tap mounting brackets.
4

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Loosen, but do not remove the four screws holding the card file to its support.
5

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Grasp the card file firmly and lift it about 1 cm (1/2 in.) to release the 6
file into your hands.

If you have remote IO racks, isolate power and remove the Serial Link cable. 7 Note: See Logic Manager Service Guide LM13-400 for more details on Remote IO racks and Serial link cable configuration.

8

Record switch settings of primary and secondary LM processor cards.

9

Record switch settings of SIOM/PLDM cards.

10 Isolate power to remote I/O and record switch settings of SIOM.

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3.1.10 Remove Module
Use the following procedure to remove the Logic Manager System module.

Step Action

Remove power from the Logic Manager processor card file by placing

the power breakers in the off position.

1

Warning: Do not use the power supply module fuse as a means of

disconnecting power from the card file. Each card file must have its

own individual circuit breaker for this purpose.

Before removing a Logic Manager System module, connect your ESD

2

wrist strap to the cabinet ground bar, or if the equipment is panel

mounted, connect your ESD wrist strap to the panel ground.

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Cabling must first be disconnected from the front of the module to be removed. The connection method varies. Power supply module cable disconnection requires the removal of individual wires from its terminal strip. Control modules are connected to cables with friction fit connectors, requiring a small amount of pulling force to release the cable.

The illustration following this table namely:

1. Non-redundant Single Channel Serial I/O Multidrop Cable Configuration

2. Non-redundant Four Channel Serial I/O Multidrop Cable Configuration

3. Non-redundant Parallel I/O Cable Configuration

3

4. Redundant Serial I/O Cable Configuration

5. Redundant Parallel I/O Cable Configuration

show various typical system cable configurations for both redundant and non- redundant serial or parallel I/O. The I/O point modules in the I/O card file employ terminal block connectors which pivot away from the front of the module and thereby eliminate the need to disconnect each individual terminal block wire.

A) I/O modules may be removed from an I/O card file while power is applied to the card file IF:

i)

The I/O system is a serial I/O configuration.

ii)

A 621-9938R SIOM is used in each of the I/O car

files.

iii)

the I/O module has an “R” suffix in the model number

Modules are released and removed by two different methods. Five

modules, those behind a five module wide metal cover plate on the

Processor card file, are removed by simultaneously pulling on the

4

upper and lower extractor levers. The metal cover plate is first

removed by loosening the four thumbscrews that hold the plate in

place. All other modules are removed by loosening their thumbscrews

and pulling the module gently forward. Very little force is required.

When the module is free from its connector, carefully slide it out on

5

the card rails and into your hands. Immediately place the module in a

static safe pouch for transport.

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Nonredundant Single Channel Serial I/O Multidrop Cable Configuration

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ELMM WITH CONTROLEDGE PLC INSTALLATION Nonredundant Four Channel Serial I/O Multidrop Cable Configuration

Nonredundant Parallel I/O Cable Configuration

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3.1.11 Remove Card File
Use the following procedure to remove the card file.
Step Action 1 Remove power from the equipment. 2 Disconnect all cables attached to the card file modules.
Loosen, but do not remove the four screws holding the card file to its 3
support. Grasp the card file firmly and lift it about 1 cm (1/2 in.) to release the 4 file into your hands.

3.1.12 Remove Cabinet
See the chapter “ELMM with ControlEdge PLC Planning and Design”, and read the following additional guidelines to ensure you have made adequate preparations for installing the new ControlEdge PLC cabinet.

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· Perform a space assessment to ensure you have adequate space for the new cabinet.
· Use the tips provided for wiring changes provided in the engineering guidelines document to ensure power, grounding, IO cabling, and other safety precautions are followed before isolating power to the cabinet and moving it.
3.1.13 Install ELMM with ControlEdge PLC
This section provides information about cabling and connecting the ControlEdge PLC hardware. IO and Marshaling cabling information is not in the scope of this document. The ControlEdge PLC configuration you ordered is assembled and mounted in the cabinet by Honeywell. After you have selected a suitable location for your system equipment, use the following checklist to monitor the events that must occur prior to the actual delivery and installation of your system. To install:
1. Mount the rack in the enclosure.

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2. To insert new CPMs, perform the following procedure: a. Insert the power supplies in the slots in the rack. b. Insert the CPMs in the rack, adjacent to the power supplies. c. Insert the filler block cover in the middle slot.

· If no, assemble I/O racks, take the 8-slot I/O rack as an example. a. Insert the power supply. b. Insert the PSM between the two power supplies. c. If a EPM will be inserted, set the EPM address and network topology for the I/O rack using the rotary switch. d. Insert EPM as required.

3. Install I/O modules.
For each configured and labeled I/O module, ONLY break off the “key-tabs” in the pattern that matches that module ATTENTION type. For more information, see “Installing I/O modules” in the ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en).

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Assumptions and Cautions
Before you work on any electronic equipment, read and follow the safety guidelines to help protect the system from potential damage and ensure personal safety.
Only qualified personnel with working knowledge of ControlEdge PLC must perform this upgrade.
TIP
When disconnecting a cable, pull on its connector or on its strain-relief loop, not on the cable itself. As you pull connectors apart, keep them evenly aligned to avoid bending any connector pins. Ensure that both connectors are correctly oriented and aligned.

To guard against electrical shock, always turn off any electronic equipment before removing any covers or boards.
ELECTRICAL SHOCK

ESD HAZARD

Handle components and cards with care. Do not touch the components or contacts on a card. Hold a card by its edges or by its mounting bracket.

ControlEdge PLC Hardware Installation
See chapter “ControlEdge 900 Common Reference Information” in ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en).

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Overview of Tasks

Task
Replace LM cabinet with ControlEdge PLC cabinet.

Go to

Done?

“Overview” section in ELMM with ControlEdge PLC chapter of this document.

Install the assembly in the ControlEdge PLC cabinet.

ControlEdge RTU Getting Started (RTDOC-X283-en)

Mount the Cisco Level 2 FTE ControlEdge RTU Getting

switch on the backplane.

Started (RTDOC-X283-en)

Mount the PLC-CPM and PLC-EPM modules on the backplane.

Hardware Planning and Installation Guide (HWDOC-X430-en)

Mount the ControlEdge 900 Platform on the backplane.

Hardware Planning and Installation Guide (HWDOC-X430-en)

Mount the backplane on the carrier in the cabinet.

Hardware Planning and Installation Guide (HWDOC-X430-en)

IO cabinet cabling for ControlEdge 900 Platform or UIO.

Hardware Planning and Installation Guide (HWDOC-X430-en)

ControlEdge 900 Platform components cabling.

Hardware Planning and Installation Guide (HWDOC-X430-en)

Power and Grounding requirements.

Hardware Planning and Installation
Guide and ControlEdge PLC (HWDOC-X430-en) and ControlEdge RTU Getting Started (RTDOC-X283-en)

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Use the instructions provided in section “Hardware Configuration of PLCCPM” in ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en).

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3.2 Replace LM cabinets with PLC cabinet
This section provides information about replacing LM cabinet with ControlEdge PLC cabinet.
3.2.1 Pre-replacement checklist
The existing configuration and the vital information residing on LM must be preserved before shutdown, and suitably reapplied after the ControlEdge PLC installation. The following checklist assists you in this task.

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Step 1
2 3 4 5 6 7
8

Task Understand all the standard conventions of your plant and collect the relevant documents so that the newly added information is in synchronization with the old data. Collect the standard conventions for the following: · Ferrule nomenclature · Cable tags nomenclature · Tag naming conventions for I/O For more information about wiring, see the section “Wiring and Cabling” in ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).
Collect the control system specification document (write-up) of the plant to know the existing control configuration of the plant.
Collect the relevant drawings for the existing LM configuration.
Collect the existing I/O database details of the LM.
Collect the peer connection list and peer to peer design concepts of the LM.
Collect the list of all displays/graphics containing the LM points.
Verify the existing TPN release number. TPN/TPS Standalone System: The minimum supported TPN release is TPN R688.1 Experion-TPN/TPS Hybrid System: The minimum supported Experion release is Experion R510.1 and TPN release is TPN R688.1.
Extract the EB files of the LM identified for replacement. The EB files are required to obtain the point details, I/O module details, and node specific configuration details of the LM.

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9

Identify the mode of communication: RS232 or RS485.

10

Checkpoint the LM nodes identified to be involved in the migration

process.

For more information about checkpointing, see the Process Operations Manual SW11-601.

11

Extract the LM Printable Ladder (.prn) files for logics.

12

From the EB files, extract the I/O details and the node specific

configuration details of the LM.

13

Convert the existing I/O and the LM points into suitable

ControlEdge PLC points, ladder configuration.

14

Identify the LM modules that are excluded in the migration and

leave them untouched, until otherwise alternates are stated in

Honeywell references or guided by Honeywell personnel.

15

Ensure that the LM is ready for an offline migration.

16

Completely delete the LM database from the system to avoid

existence of ghost points.

17

Shutdown the LM and proceed with the migration.

3.2.2

Replacing LM processor
The plant must be shut down before performing the migration procedure. As the Wiring Kit retains the field wiring intact, the shutdown time for this migration is minimal.

Replacing the LM processor with the ControlEdge PLC processor

Perform the following steps to remove the LM processor and replace the ControlEdge PLC processor.
Ensure that the identified LM, which is to be replaced, is shutdown, turned off and disconnected from the power WARNING supply.

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Step Task Remove the LM Processor Rack

1

Remove the serial communication connection between the LM I/O

module and the LM processor module.

Tip: Preserve the Serial communication module with the rack installation as this module has all the address settings applicable to that particular rack.
The switches will be configured for particular applications and needs to be preserved.
For more information, refer to the Serial Link Module section of Logic Manager Service Manual, LM13-500.

2

Remove UCN Drop Cables.

3

If the LM is redundant, remove the LM Redundancy wiring from the

LMM and RCM modules, and the redundancy cable from the RCM

module.

For more information, refer to the Universal Control Network Planning, UN02-501.

4

Unscrew the mounting screws and remove the LM processor.

For more information about ControlEdge PLC Processor Rack installation, see section “Install ELMM with ControlEdge PLC” on page 40.

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3.2.3 Replacing LM I/O rack
Perform the following steps to remove the LM I/O rack. Note: The figures used in this procedure are for representational purpose only.

Step Task Removing the LM I/O rack

Before performing the following procedure, disconnect the power cord to the LM I/O rack Power Supply module from the ATTENTION power source. Ensure that the communication wiring between the LM processor and the LM I/O module is removed.

1

Identify the field cables to be removed.

Verify the field cable tags and ferrules to ensure that they match with the wiring diagrams.
CAUTION

2

Remove the LM I/O serial communication module from the LM I/O

rack.

3

Mark the I/O rack details (from where the module is removed) on

the module for reference.

4

Remove the power supply module, EDM, SLM/PDLM

5

Open the swing arm connectors or terminal block connectors of the

field cables sequentially from the first IO module.

6

Remove the I/O module.

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Step 7

Task
Mount the Weidmüller connector and reconnect the swing arm connectors.

8

Complete the replacement for all the I/O modules in that rack.

Mounting the ControlEdge PLC I/O Rack

1

Mount the ControlEdge I/O rack in the space released by the LM

processor racks one below the other.

2

Refer to the cable tags and the ferrules to identify the finger PCBs

to be inserted in the Wiring Kit.

Tip: If the cable tags are not available, identify the finger PCBs with the help of the I/O card details.

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Step 3

Task
Identify the custom cables to be connected to the finger PCBs. Tip: The Finger PCB and Custom cable mapping helps in identifying the following:
· The finger PCBs to be inserted in the Wiring Kit. · The custom cables to be connected to the finger PCBs.

One end of the custom cable (B1, B2) is connected to the finger PCB. The other end of the custom cable (C) is connected to the ControlEdge PLC I/O rack.

4

Insert the custom cable through the bottom of the Wiring Kit.

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Step 5
6

Task

Connect the lengthier wire of the Connectors to the upper end of the finger PCB and the shorter wire of the Connectors to the lower end of the finger PCB.

CAUTION

Avoid direct contact with the exposed pins of the finger PCBs or the Terminal Blocks, while connecting or removing the custom cables.

Once the cables are connected, close the bottom cover with the ESD cover, P/N 51306728-100 for Full Rack and P/N 51306729100 for Half Rack.

3.3 Provide strain-relief to FTE cables
You must provide proper strain-relief to the FTE cables that are connected to the Ethernet switches. Not providing adequate strain relief to the FTE cables can cause intermittent connections.
The FTE cables must be of an appropriate length. Ensure that there is sufficient cable length to provide the minimum required bend radii. However, excess cable length must be minimized such that it is easy to manage inside the FTA tray cable channel.
For more information, see Experion Network Best Practices.

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3.4 Cabling Considerations for PLC Components
3.4.1 Installation Declarations
This equipment shall be installed in accordance with the standard requirements such as National Electrical Code ATTENTION (NEC), ANSI/NFPA 70, or the Canadian Electrical Code (CEC), C22.1. It is supplied as “open equipment” that is intended to be mounted on a sub-panel within an enclosure. The suitability of the enclosure and installed system shall be acceptable to the local “authority having jurisdiction,” as defined in the NEC, or “authorized person” as defined in the CEC.

ESD HAZARD

Electrostatic discharge can damage integrated circuits or semiconductors if you touch connector pins or tracks on a printed wiring board.
· Touch a grounded object to discharge static potential
· Wear an approved wrist-strap grounding device · Do not touch the wire connector or connector pins · Do not touch circuit components · If available, use a static safe workstation · When not in use, keep the component in its static
shield box or bag.

Unless the location is known to be non-hazardous, do not:

WARNING

· Connect or disconnect cables · Install or remove components

· Install or remove isolators

While the control system is powered.

3.4.2 FTE and IOLINK Cabling
The following diagram shows an example of a redundant star topology.

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For information on I/O link cabling, see section “Wiring and cabling” in the ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283en).

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ELMM WITH CONTROLEDGE PLC INSTALLATION The following diagram shows an example of a redundant ring topology.

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3.4.3

Connecting I/O modules and field devices through I/O Termination Assemblies
See chapter “ControlEdge 900 platform” in the ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

3.4.4

Grounding and power considerations – IOTA boards
See chapters “ControlEdge 900 Common Reference Information” and “Wiring and Cabling Planning” in the ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en).

3.5 EUCN Installation Hardware
This section provides references to documentation available for installing the hardware and software for completing the EUCN installation.

3.5.1

Network Hardware Installation and Planning
For hardware installation procedures and cabling information, see the following documents.

For

See

information

about

Topology

Network Planning section of this document.

FTE network and planning

See chapters “Enhanced Universal Control Network” and “Planning an FTE network” in Universal Control Network Planning UN02501.

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For

See

information

about

Cabling information

See sections: EUCN Cable Construction and Installation, Selecting copper cables for the EUCN, Terminating copper cables, Grounding the copper cables, Selecting fiber cables for the EUCN, Routing fiber optic cables, Identifying network cables, Splicing and connecting fiber optic cables, and Testing EUCN cables of Universal Control Network Installation UN20500

EUCN Power- See “EUCN Power-On Test” section in Universal Control

On Test

Network Installation UN20500

Ethernet switch Fault Tolerant Ethernet Installation and Service Guide installation & (EPDOC-XX36-en) configuration

3.5.2

Redundant ELMM with ControlEdge PLC considerations
Primary ELMM must be configured with an odd number between 1-509. Secondary will be the following even number.

3.6 For information on redundancy operations, see “Verifying ELMM with ControlEdge PLC Hardware and Firmware versions
For an ELMM, the Hardware Version (H/W) and Firmware Version (F/W) fields on the LM Detailed Status Display do not display correct information, you can instead go to ControlEdge Builder to verify this information. To know the H/W and F/W information,
1. From the Start Page, select Connect to connect the target controller.
2. From the Home page, make sure that you have selected ELMM as the controller type under Controller and Programming.

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3. From the Home page, select View Diagnostics under Diagnostics. 4. Go to System > Platform.
The View Diagnostics page is displayed, verify the hardware and firmware versions.

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3.7 Setting Device Index on ControlEdge PLC CPM
The FTE Device Index uniquely identifies the controller on the FTE Network. The FTE Device Index is configured in two places. First, the CPM rotary switches are used to set the FTE device index of the UOC. Second, ControlEdge Builder is used to configure the same FTE Device Index that is set using the CPM rotary switches in the ELMM with ControlEdge PLC Platform Function Block.
The CPM rotary switches are used to set the FTE device index of the controller. In the following example, “204” is set as the device index for the node, 100X2 + 10X0 + 1X4 = 200 + 0 + 4 = 204.
Tip: Use a flat blade screwdriver and rotate the screw head to the desired number. The arrow on the switch should point to the number that needs to be set for the FTE address.

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3.8 Setting Address and Network Topology on ControlEdge PLC EPM
The EPM rotary switches are used to set the EPM address and network topology for the I/O rack as shown in the following image.
· Set the 10x and 1x switches to the two-digit address ranging from 01 to 99. The lower switch (10x) is used to set the tens digit and the upper switch (1x) sets the ones digit.
· Set the network topology using the 100x switch. 3 is for Ring network topology, 4 is for Star network topology and 5 is for DLR network topology.
Tip: Use a flat blade screwdriver and rotate the screw head to the desired number. The arrow on the switch should point to the number that needs to be set for the address.

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4 ELMM with ControlEdge PLC Configuration and Operations

4.1 Pre-configuration checklist

Step 1

Task Ensure LM checkpoint backup is taken on an emulated drive.

2

Complete configuration of I/Os.

3

Check cable connections.

Ensure that all the Migrated XML files, Modbus Mapping files, and

4

ControlEdge IO Configuration details are available to load into

ELMM ControlEdge PLC.

Ensure that the ControlEdge Builder station is available on the

same FTE network. For installing ControlEdge Builder, see the

5

ControlEdge Builder Software Installation User’s Guide (RTDOC-

X285-en).

4.2 Configuration Overview
After installing the hardware, you are now ready to power up the ELMM hardware and perform the configuration. This section provides information about providing Ethernet IP addresses, powering up ELMM, performing diagnostic checks, and configuring ELMM. The major tasks involved in configuring ControlEdge PLC are as follows.
Step Task 1 Startup Experion Server and BOOTP server.
2 Power on ENIM/ENB and ELMM.
3 Perform hardware diagnostics tests.
4 Load the redundant ELMM with LM personality and database.

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4.3 FTE configurations on PLC

4.3.1 BOOTP Server
The BOOTP is a low-level protocol that provides configuration to other nodes on a TCP/IP network with the Windows operating system. The BOOTP configuration files let you automatically assign IP addresses to the Ethernet module. You can also obtain subnet masks and gateway addresses from BOOTP. Ensure BOOTP Server service is running. See section “Checking status of BOOTP server service” in the Fault Tolerant Ethernet Bridge Implementation Guide (EPDOC- XX35-en) for details about starting the service in case it is not running.
The Ethernet module factory default setting is BOOTP enabled. Upon power up, the Ethernet module sends a message to the BOOTP server on the network with its physical (or MAC) address. The server compares the MAC address to those in its look-up table in the configuration file and sends a message back to the module with the appropriate IP address.
Base IP address
The base IP address consists of the following:
· The first number in the address represents the network number.
· The second number in the address represents the community number.
· The third number is user-defined.
· The last number represents the Device Index of the embedded node which is usually 0.
The IP address consists of the base IP address + device index (configured on the rotary switches of the node).
· The rotary switches are located on the CPM.

CAUTION

Changing the base IP address of BOOTP server and rebooting the ELMM with ControlEdge PLC results in a mismatch in the base IP address settings. This mismatch might result in a loss of view to the EUCN nodes.

· A valid Device Index has a range from 1-509.

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If a board obtains an IP address from a BOOTP server, then that IP address is retained in memory. The IP is maintained TIP even if the server is not present on subsequent reboots. If the default IP address in the BOOTP server is changed or if the Device Index is changed on the node, then the IP is overwritten on node reboot. To clear the IP information from memory, set the device index to 0.

4.3.2

Non-BOOTP Server
In the case of BOOTP server unavailability, you must configure the Base IP Address (BIP) and subnet mask (MSK). Set the Base IP Address (BIP) and Subnet Mask Address (MSK).

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Base IP Address configuration:

Base IP Address format

Description The first octet of the IP Address.

The second octet of the IP Address.

The third octet of the IP Address.
The fourth octet of the IP Address.
Note: The Node IP Address is the sum of the Base IP Address and FTE Device Index. This is calculated by the UEA during startup.
For example,
· If the FTE Device Index is 45 and the base IP address is 10.0.0.0, then the node would be assigned with 10.0.0.45 as the IP address.
Or
· If the FTE Device Index is greater than 255, in this case “346” and the Base IP address is 10.0.0.0, the third octet is assigned as “1” and the fourth octet will be FTE Device Index minus 255, then the node would be assigned with 10.0.1.91 as the IP address.
Subnet Mask configuration: The Subnet Mask address is provided by the Experion BOOTP server. If BOOTP? =N, and the default address 255.255.255.0 is incorrect, then the Subnet Mask Address must be configured.

4.3.3

Base IP Address configuration on ControlEdge Builder
ControlEdge Builder is used to configure the Base IP Address in the ELMM with ControlEdge PLC Platform Function Block.

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Step Action 1 Open ControlEdge Builder.

2 Select Open Project and browse to the project.

Under Controller and Programming, select Configure Ethernet Port 3
ETH 1.

Perform one of the following tasks depending on BOOTP Server availability/unavailability.

· Under FTE Setting, select Yes from the BOOTP Available dropdown list in the case of BOOTP Server availability.

4

OR

· Under FTE Setting, select No from the BOOTP Available dropdown list in the case of BOOTP Server unavailability and then select Use the following IP address option to configure the Base IP Address manually.

4.3.4

EUCN Protocol selection
In ControlEdge Builder’s Configure Ethernet Port ETH 1 section, under Protocol Binding, ensure that the EUCN check box is selected to startup the PLC module as an ELMM. Note that each time there is a change in this option, the module needs a reboot to pick up the changes in configuration.

4.3.5

Controller Type configuration for ELMM
Beginning with ControlEdge PLC RTUPLC_172.1-15.1, in ControlEdge Builder’s Configure Controller Type section, PLC_FTE should be selected as the PLC variant, this is required for the ELMM functionality to work.

4.3.6

Device Index configuration
Beginning with ControlEdge PLC RTUPLC_172.1-15.1, there is no option to configure the FTE Device Index in ControlEdge Builder. The FTE Device Index is derived from the CPM rotary switches setting. For authentication needs of ELMM, the Device Index configuration is available on the Native Window Box Specific Configuration page.

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NOTE

When BootP Availabe is set to Yes, any engineering operations for communication with the controller always recognizes the CPM rotary switches setting, the IP configuration in ControlEdge Builder is no longer effective for FTE ports (ETH1/ETH2).

4.3.7

EUCN Connection
This section describes the procedure for connecting ELMM with ControlEdge PLC, non-redundant or redundant, to the Enhanced Universal Control Network (EUCN).

Configure EUCN Node

With ELMM, DIP switches are no longer used to provide the node address. Instead, you can set the node address from the Station’s Engineering Main menu.
To specify a node address:

Step 1

Action On the Engineering Main menu, select Network Interface Module.

2

Select UCN Node Configuration.

Specify the FTE Device Index ($DEVIDX) setting. This must be the

3

same odd numbered address you entered on the ELMM’s CPM as

described in the previous section.

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Specify the following details to configure the UCN node: · Network Number · Node Number · UCN Node Type. Select LM · Node Assignment ­ Select ThisNIM · Device Index from rotary switch setting
4

·

5

Press Ctrl + (F12) on the key board to load the changes.

To modify a node address:

1

Reboot LMM.

Set the UCN node number using the same procedure as

2

Specifying a node address. It is recommended to retain

the same UCN node address..

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4.4 Power on ELMM with ControlEdge PLC
4.4.1 ELMM startup

NOTE

Both AC power supply and DC power supply can be used in ControlEdge PLC. Based on existing wiring, choose the type of power supply.

Step 1

Action
Connect 24 VDC supply or 120/240 VAC power supply to the controller.

Connect an Ethernet cable to the CPM port most appropriate for 2
your situation.

Connect the other end of the Ethernet cable to the PC installed ControlEdge Builder directly or through a switch.

3

4.4.2

Compiling and downloading a project
See sections “Compiling a project” and “Downloading a project to the controller” in the ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

Ensure successful compilation of a project before downloading the same.
ATTENTION

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ELMM points can be activated irrespective of the PLC address configuration on the project downloaded onto the ATTENTION controller, unlike in the case of a LM. However, write operations on a PV value onto these points fail if the Modbus mapping is not configured.

4.4.3 Downloading all xml files using Ladder Logic Migration Tool
Download all xml files for the translated LM logics, IOP configuration details, and MODBUS mapping details after startup using the LM Ladder Logic Migration Tool.
For more information, refer to the Ladder Logic Migration User’s Guide (XXDOC-X339-en-100).

4.4.4 Configuring date/time
Setting time source
The section introduces how to synchronize the controller time to the LCN time source.
For ELMM with ControlEdge PLC, even though ControlEdge PLC supports SNTP time source, the ELMM component within ControlEdge PLC requires time synchronization with the TPN/LCN network. Honeywell recommends that you always use the LCN time source for ELMM with ControlEdge PLC.
To set time source:

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

From the Home Page, under Miscellaneous, select Configure 2
Date/Time.

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On the Set Time Source page, uncheck the Enable checkbox.

3

RESULT: The ELMM time is now synchronized to the LCN time

source.

Select Set Time Zone tab and select UTC + 00:00 from the Time 4
Zone drop-down list.

Select Automatically Switch to Daylight Saving Time if it is 5
applicable.

4.4.5 Configuring hardware in ControlEdge Builder
Setting Controller name You can set a new name for a controller.
1. From the Home Page, under Controller and Communications, select Set Controller Name.
2. Enter the desired name for the controller, and select Save. Configuring the controller IP address
The first thing you will normally want to do is set the IP address for the controller. The following steps describe how to configure a fixed IP address starting with creating a new project. The following table lists the factory default network settings for nonredundant controller. If your controller has been previously configured, these settings may have been changed.
Port Default setting IP address is dynamically assigned from a DHCP server. If no DHCP server is found by the controller, an IPv4 link-local
ETH1 address will be assigned (169.254.x.x).
ETH2 configuration is a replica of ETH1 configuration since they ETH2
represent FTE A and FTE B respectively.

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The following table lists the factory default network settings for the redundant controller.
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Port Default setting IP address is dynamically assigned from a DHCP server. If no DHCP server is found by the controller, an IPv4 link-local address will be
ETH1 assigned (169.254.x.x). The secondary controller IP address is incremented by 1 from the primary controller IP address. The primary controller static IP address: 192.168.1.50
ETH2 The secondary controller static IP address: 192.168.1.51
To configure IP address: Step Action
From the Home page, make sure that you have selected PLC_FTE as 1
the controller type under Controller and Programming.
From the Home Page, select the arrow beside Configure Ethernet 2
Ports, and select ETH1. Under Network Setting, configure the IP address of the Ethernet 3 port for the controller. Under the Protocol Binding, select the protocol which you want to bind to the port. 4 Ensure that the EUCN check box is selected, this is required for the ELMM functionality to work.

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5

Select Save to complete the Ethernet port configuration.

Select Back to return to the Home Page.

6

If new IP settings are compiled and downloaded, the

controller will be disconnected from the configuring device.

TIP

Configuring controller redundancy To disable redundancy:

Step Action From the Home page, make sure that you have selected ELMM as
1 the controller type under Controller and Programming.

Under Controller and Communications, select Configure 2
Controller Redundancy.

3

Select Disable Redundancy to disable the redundancy function.

Select OK. Redundancy has been disabled. The IP address 4
configured for the secondary controller will be disabled.

To enable redundancy:

Step Action From the Home page, make sure that you have selected ELMM as
1 the controller type under Controller and Programming.

Under Controller and Communications, select Configure 2
Controller Redundancy.

Select Enable Controller Redundancy, and then select OK.

3

The configuration of I/O modules in the rack local to the controller

will be removed and a static IP address must be configured for the

secondary controller.

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Configure the IP address of the controllers.

· Select the BOOTP option as YES or NO depending on the

network topology. If the BOOTP option is set to YES, the

4

Obtain an IP Address Automatically option is enabled.

Configure the Primary Controller IP Address and

Secondary Controller IP Address manually. If the BOOTP

option is set to NO, then you must manually configure the IP

addresses.

Configuring an I/O module for ControlEdge PLC

Step Action From the Home Page, under Programming and I/O and select
1 Configure I/O.

2

Select Add I/O Module. The Add I/O Module dialog appears.

Select the Type, assign the Rack and Slot, and set the IOM Scan 3
Time for the Module.

4

Select OK to add the I/O module.

5

Select the corresponding I/O module, configure I/O channels.

4.4.6

ELMM with ControlEdge PLC states in boot mode
At the conclusion of POST, the ELMM determines whether or not there is a valid Application Image present in the controller and whether it should then transition to executing this Application image (Application mode) or to continue in the Boot mode.

· If the controller remains in the Boot mode, the controller then enters one of the states listed in Controller in Boot mode table and joins the FTE network on which it resides. See Display indications when controller is in boot mode table for a description of the faceplate indications when the controller is operating in the boot mode.

· If the controller transitions to the Application mode, the controller then joins the FTE network and enters one of the operating states described in ELMM in Application mode table.

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ELMM State Description

READY

The controller received a command to remain in the boot mode to allow upgrading ControlEdge PLC firmware. See section Firmware Upgrade on page 95.

FAIL

The controller detected a failure during startup.

Do not power off when upgrading firmware.
ATTENTION
Before flashing ELMM firmware into ELMM with ControlEdge PLC, it is required to:
· Log in as the Administrator to connect the target controller. For more information, see “Connecting a controller” in ControlEdge Builder User Guide (RTDOC-X283-en).
· Ensure that the latest ControlEdge Builder is installed on your computer. See the ControlEdge Builder Software Installation User’s Guide (RTDOC-X285-en) for details.
· Make sure the CPM version is same as or newer than the EPM version. In this case:
No specific upgrade sequence Downgrade EPM before CPM

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4.4.7 Upgrading firmware for a redundant controller
It is recommended to upgrade the firmware without opening a project.
ATTENTION

There are two scenarios for the firmware upgrade of an redundant controller. · On-process – The primary CPM is synced with the secondary CPM. · Off-process – The primary CPM is not synced with the secondary CPM. The migration from LM to ControlEdge PLC must be performed offprocess. Any future firmware upgrades will support on-process and offprocess upgrades. Prerequisites · Assume the primary CPM is at slot A and the secondary CPM is at slot B. · Both primary (slot A) and secondary (slot B) CPMs are powered on.

To upgrade the firmware On-process

ATTENTION

If you are upgrading from RTUPLC_160.2-03.14 to RTUPLC_172.1-15.1, it is mandatory to install HotFix 2 with “special image” before performing this upgrade operation.

Prerequisites
· Install ControlEdge builder RTUPLC_172.1-15.1 before performing the below upgrade procedure.

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Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

From the Start Page, select Connect to connect the target primary 2
CPM (slot A).

From the Home Page, select Upgrade Firmware under 3
Maintenance, and select the CPM you want to upgrade.

Click Upgrade. 4
The Upgrade firmware dialog appears.

From the Release Number list, select the target release module as R160.2 HotFix 2. The target firmware version RTUPLC_160.2-03.14 is displayed. 5
If you want to use a controller as an FTE node, you must select “Release number_FTE”.
TIP

Click Next. The target firmware name, state, and version are 6
displayed.

7

Click Next to transfer and upgrade the firmware.

After the boot and application firmware is upgraded, enter the 8
password to re-connect the controller.

Click Go Back to revert to the previous firmware version, or click 9
Proceed to complete the upgrade.

The primary CPM is synchronizing with the secondary CPM. Click OK to complete the firmware upgrade. 10 The secondary CPM (slot B) becomes the primary one and the original primary CPM (slot A) becomes the secondary one.

On the Native window, ensure that the ELMM shows OK/BACKUP

11

state and the secondary controller is fully synchronized with the

primary controller.

Repeat the steps from 1 to 10 to upgrade RTUPLC_160.2-

12

03.14(special image) to RTUPLC_172.1-15.1. by choosing an

appropriate release number from the Release target List in Step 5.

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Post-upgrade procedure

Step 1

Action Upgrade the Project to the latest RTUPLC_172.1-15.1 release.

Enable EUCN option under ETH1. A failure to enable this option, may cause the ELMM functionality to be disabled.

2

Ensure PLC-FTE is selected as the controller type 3

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To upgrade the firmware Off-process

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

From the Start Page, select Connect to connect the target primary 2
CPM (slot A).

From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under Maintenance, 5
and select the CPM you want to upgrade.

Select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, we provide the interactive mode to control when the controller stops.

6

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

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7

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 8
target firmware version is displayed.

Select Next. The target firmware name, state and version are 9
displayed.

10

Select Next to transfer and upgrade the firmware.

After the boot firmware is upgraded, enter the password to reconnect 11
the controller. The application firmware is transferred and upgraded.

After the application has been upgraded, enter the password to 12
reconnect the controller. The firmware upgrades.

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4.4.8

Upgrading EPM firmware
EPM firmware upgrade is ONLY allowed in Stop Locked, Stopped, or Remote operating modes.

You can rotate the mode switch on CPM to change operating modes, see “CPM mode switch” in ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en). If the mode switch is in REMOTE position, see “Setting operating modes” in ControlEdge PLC and ControlEdge RTU Getting Started (RTDOC-X283-en).

If the EPM is being upgraded, all I/O modules in the same rack will keep in failsafe state until the firmware upgrade is ATTENTION completed.

To upgrade EPM:

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

2

From the Start Page, select Connect to connect the target controller.

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From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under 5
Maintenance, The Upgrade Firmware dialog appears.

Select EPM tab, all available EPMs are displayed.

At least one I/O module, which is in the same rack with the target

6

EPM, must be added in the Configure I/O page, then the target EPM

will be displayed here. See “Configuring an I/O module” in Software

Chapter in ControlEdge PLC and ControlEdge RTU Getting Started

Guide (RTDOC-x283-en).

Select or multiselect the target EPMs and select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, interactive mode is provided to control when the controller stops.

7

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

· If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

8

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 9
target firmware version is displayed.

Select Next. The target firmware name, state and version are 10
displayed.

Select Next to transfer and upgrade the firmware.

11

After the upgrade is completed, a dialog appears. You can check

which EPM is upgraded successfully, which one is failed.

12

Select OK.

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4.4.9 Upgrading I/O module firmware
I/O module firmware upgrade is ONLY allowed in Stop Locked, Stopped, or Remote operating modes.
The target I/O module must be added in the Configure I/O page. See “Configuring I/O modules and channels” in ATTENTION ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

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To upgrade I/O module

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

2

From the Start Page, select Connect to connect the target controller.

From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under

5

Maintenance.

The Upgrade Firmware dialog appears.

6

Select the UIO 16 tab, all available I/O modules are displayed.

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Select or multiselect the target I/O modules and select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, we provide the interactive mode to control when the controller stops.

7

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

· If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

8

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 9
target firmware version is displayed.

Select Next, the target firmware name, state and version are 10
displayed.

Select Next to transfer and upgrade the firmware.

11

After the upgrade is completed, a dialog appears. You can check

which module is upgraded successfully, which one is failed.

12

Select OK.

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4.5 ELMM with ControlEdge PLC Configuration
Use the following procedure to load the redundant ELMM with LM personality and database. Step Action
Invoke the Engineering Main Menu display by pressing the 1

and keys on the keyboard.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS Start the process by selecting the NETWORK INTERFACE MODULE target on the Engineering Main Menu display. This invokes the NIM Build Type Select Menu display.
2
Select the UCN NODE CONFIGURATION target to invoke the UCN Node Configuration display.
3

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Reconstitute the LM by entering the UCN NETWORK NUMBER, NODE NUMBER, UCN NODE TYPE, and pressing the and keys.

4

Note: As a better engineering practice, remove all Secondary ELMMs

from the network and reconfigure it after Primary ELMMs are

running. For removing Secondary ELMMs, use UCN Node

configuration, change the BACKUP ELMM to NOT CONF and load by

pressing Ctrl + F12.

5

Ensure that the node type is LM and then press enter.

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Enter the FTE Device Index and press ENTER. NOTE:
· Use the FTE Device Index assigned to this ELMM in section “Appendix A: EUCN Configuration Data Checklist” on page 158. Ensure that there are no errors.
· The FTE Device Index entered must be the same as the FTE Device Index physically set in the rotary switches of the ELMM FTE Interface Module.
Note: Initially, the $DEVIDX parameter will be 0. After you change the value from 0 to a non-zero value, a warning message is received, “WARNING: CHANGING $DEVIDX WHILE IN A RUNNING STATE MAY CAUSE LOSS OF VIEW. $NMuuNnn EXISTS ­ SELECT OVERWRITE OPTION IF DESIRED”. Where “uu” is the UCN Network Number and “nn” is the Primary LM’s UCN Node Number. For the redundant ELMM, the Secondary ELMM FTE Device Index is automatically set to the Primary ELMM Device Index plus one. 6

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Press the and keys to load. 7
RESULT: The Primary ELMM transitions to IDLE state. From the UCN Status Display, checkpoint the NIM to save the FTE 8 Device Index information in the NIM checkpoint.
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Make sure that the PLC CPM hardware is connected to the power supply. The PLC CPM’s status must indicate IDLE on the UCN Status

display with ELMM on the Auxiliary status line.

9

After the LM is migrated to ControlEdge PLC, the

personality download procedure is obsolete and

ATTENTION hence the module starts up from the IDLE state

with no database.

For the redundant ELMM, repeat steps 4, 5 and 7 for the secondary ELMM to come to the BACKUP (yellow) state indicative of IDLE status.

10

Restore the LM checkpoint taken earlier. Select the Primary ELMM > LOAD/SAVE RESTORE > RESTORE DATA and then press ENTER 11 and choose DEFAULT SOURCE. NOTE: As the ELMM transitions to IDLE state directly, there is no need to download the TPN personality.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS Reconstitute ELMM’s UCN node-specific configuration and choose LMM CONNECTED CONTROLLER type as CEPLC and then press ENTER.
12
13 Reload the configuration by pressing Ctrl + F12. Select RUN STATES > STARTUP to perform a startup of the ELMM.
14 RESULT: The Primary ELMM transitions from IDLE to OK state.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS On a successful database sync, ensure that the Secondary ELMM transitions to the BACKUP (cyan) state indicative of OK/RUN state.
15

Checkpoint ENIM and ELMM, once onto the HM and once onto the 16
emulated drive. 17 All LM to ELMM upgrade activities are complete for this EUCN.

4.5.1

ELMM with ControlEdge PLC states in application mode
The following table describes the controller states of the ELMM after it transitions to the application mode after the LCN personality download. See Faceplate display information for a description of the faceplate indications when the controller is operating in the application mode.

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ELMM State Description

IDLE

The ELMM is configured as non-redundant or as redundant and has assumed the primary redundancy role. And… Starts up with no database onto which a valid database can be created/retained if restored from previous checkpoint file.

The ELMM is configured as non-redundant, or as redundant and has assumed the primary redundancy role,

OK

And…

Has retained a valid database from previous operations prior to startup.

BKUP

The ELMM is configured as redundant and has assumed the secondary redundancy role. The ELMM moves to the BACKUP state.

Primary Fail

Check whether both Primary & Secondary ControlEdge PLC’s are in Sync. If both are in Sync, then Select Primary ELMM from UCN status display and Startup the Controller to initiate resync.

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Do not power off when upgrading firmware.
ATTENTION
Before flashing ELMM firmware into ELMM with ControlEdge PLC, it is required to:
· Log in as the Administrator to connect the target controller. For more information, see “Connecting a controller” in ControlEdge Builder User Guide (RTDOC-X283-en).
· Ensure that the latest ControlEdge Builder is installed on your computer. See the ControlEdge Builder Software Installation User’s Guide (RTDOC-X285-en) for details.
· Make sure the CPM version is same as or newer than the EPM version. In this case:
No specific upgrade sequence Downgrade EPM before CPM

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4.6.1 Upgrading firmware for a redundant controller
It is recommended to upgrade the firmware without opening a project.
ATTENTION

There are two scenarios for the firmware upgrade of an redundant controller. · On-process – The primary CPM is synced with the secondary CPM. · Off-process – The primary CPM is not synced with the secondary CPM. The migration from LM to ControlEdge PLC must be performed offprocess. Any future firmware upgrades will support on-process and offprocess upgrades. Prerequisites · Assume the primary CPM is at slot A and the secondary CPM is at slot B. · Both primary (slot A) and secondary (slot B) CPMs are powered on.

To upgrade the firmware On-process

ATTENTION

If you are upgrading from RTUPLC_160.2-03.14 to RTUPLC_172.1-15.1, it is mandatory to install HotFix 2 with “special image” before performing this upgrade operation.

Prerequisites
· Install ControlEdge builder RTUPLC_172.1-15.1 before performing the below upgrade procedure.

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Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

From the Start Page, select Connect to connect the target primary 2
CPM (slot A).

From the Home Page, select Upgrade Firmware under 3
Maintenance, and select the CPM you want to upgrade.

Click Upgrade. 4
The Upgrade firmware dialog appears.

From the Release Number list, select the target release module as R160.2 HotFix 2. The target firmware version RTUPLC_160.2-03.14 is displayed. 5
If you want to use a controller as an FTE node, you must select “Release number_FTE”.
TIP

Click Next. The target firmware name, state, and version are 6
displayed.

7

Click Next to transfer and upgrade the firmware.

After the boot and application firmware is upgraded, enter the 8
password to re-connect the controller.

Click Go Back to revert to the previous firmware version, or click 9
Proceed to complete the upgrade.

The primary CPM is synchronizing with the secondary CPM. Click OK to complete the firmware upgrade. 10 The secondary CPM (slot B) becomes the primary one and the original primary CPM (slot A) becomes the secondary one.

On the Native window, ensure that the ELMM shows OK/BACKUP

11

state and the secondary controller is fully synchronized with the

primary controller.

Repeat the steps from 1 to 10 to upgrade RTUPLC_160.2-

12

03.14(special image) to RTUPLC_172.1-15.1. by choosing an

appropriate release number from the Release target List in Step 5.

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Post-upgrade procedure

Step 1

Action Upgrade the Project to the latest RTUPLC_172.1-15.1 release.

Enable EUCN option under ETH1. A failure to enable this option, may cause the ELMM functionality to be disabled.

2

Ensure PLC-FTE is selected as the controller type 3

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To upgrade the firmware Off-process

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

From the Start Page, select Connect to connect the target primary 2
CPM (slot A).

From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under Maintenance, 5
and select the CPM you want to upgrade.

Select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, we provide the interactive mode to control when the controller stops.

6

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

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7

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 8
target firmware version is displayed.

Select Next. The target firmware name, state and version are 9
displayed.

10

Select Next to transfer and upgrade the firmware.

After the boot firmware is upgraded, enter the password to reconnect 11
the controller. The application firmware is transferred and upgraded.

After the application has been upgraded, enter the password to 12
reconnect the controller. The firmware upgrades.

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4.6.2

Upgrading EPM firmware
EPM firmware upgrade is ONLY allowed in Stop Locked, Stopped, or Remote operating modes.

You can rotate the mode switch on CPM to change operating modes, see “CPM mode switch” in ControlEdge 900 Platform Hardware Planning and Installation Guide (HWDOC-X430-en). If the mode switch is in REMOTE position, see “Setting operating modes” in ControlEdge PLC and ControlEdge RTU Getting Started (RTDOC-X283-en).

If the EPM is being upgraded, all I/O modules in the same rack will keep in failsafe state until the firmware upgrade is ATTENTION completed.

To upgrade EPM:

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

2

From the Start Page, select Connect to connect the target controller.

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From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under 5
Maintenance, The Upgrade Firmware dialog appears.

Select EPM tab, all available EPMs are displayed.

At least one I/O module, which is in the same rack with the target

6

EPM, must be added in the Configure I/O page, then the target EPM

will be displayed here. See “Configuring an I/O module” in Software

Chapter in ControlEdge PLC and ControlEdge RTU Getting Started

Guide (RTDOC-x283-en).

Select or multiselect the target EPMs and select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, interactive mode is provided to control when the controller stops.

7

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

· If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

8

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 9
target firmware version is displayed.

Select Next. The target firmware name, state and version are 10
displayed.

Select Next to transfer and upgrade the firmware.

11

After the upgrade is completed, a dialog appears. You can check

which EPM is upgraded successfully, which one is failed.

12

Select OK.

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4.6.3 Upgrading I/O module firmware
I/O module firmware upgrade is ONLY allowed in Stop Locked, Stopped, or Remote operating modes.
The target I/O module must be added in the Configure I/O page. See “Configuring I/O modules and channels” in ATTENTION ControlEdge PLC and ControlEdge RTU Getting Started Guide (RTDOC-X283-en).

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To upgrade I/O module

Step 1

Action
Select Start > All Programs > Honeywell > ControlEdge Builder > ControlEdge Builder to launch ControlEdge Builder. The Start Page appears.

2

From the Start Page, select Connect to connect the target controller.

From the Home page, select Configure Controller Type under

3

Controller and Programming.

The Configure Controller Type dialog box is displayed.

4

Choose Yes and then select OK.

From the Home Page, select Upgrade Firmware under

5

Maintenance.

The Upgrade Firmware dialog appears.

6

Select the UIO 16 tab, all available I/O modules are displayed.

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Select or multiselect the target I/O modules and select Upgrade. The Upgrade firmware dialog appears.

The controller is running when you transfer the firmware to the controller and will be stopped when you upgrade the firmware. So, when the controller is running, we provide the interactive mode to control when the controller stops.

7

· If you select the Interactive mode, a dialog appears

confirming that the transfer is complete. Select Next to

upgrade the firmware, and the controller is stopped. You can

also select Cancel to quit the upgrade process.

· If you do not select the Interactive mode, the firmware will be upgraded directly after the transfer. The controller will be stopped without any prompt.

8

Select Proceed with Upgrade to continue.

From the Release Number list, select the target release module. The 9
target firmware version is displayed.

Select Next, the target firmware name, state and version are 10
displayed.

Select Next to transfer and upgrade the firmware.

11

After the upgrade is completed, a dialog appears. You can check

which module is upgraded successfully, which one is failed.

12

Select OK.

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4.7 ELMM with ControlEdge PLC Configuration
Use the following procedure to load the redundant ELMM with LM personality and database. Step Action
Invoke the Engineering Main Menu display by pressing the 1

and keys on the keyboard.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS Start the process by selecting the NETWORK INTERFACE MODULE target on the Engineering Main Menu display. This invokes the NIM Build Type Select Menu display.
2
Select the UCN NODE CONFIGURATION target to invoke the UCN Node Configuration display.
3

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Reconstitute the LM by entering the UCN NETWORK NUMBER, NODE NUMBER, UCN NODE TYPE, and pressing the and keys.

4

Note: As a better engineering practice, remove all Secondary ELMMs

from the network and reconfigure it after Primary ELMMs are

running. For removing Secondary ELMMs, use UCN Node

configuration, change the BACKUP ELMM to NOT CONF and load by

pressing Ctrl + F12.

5

Ensure that the node type is LM and then press enter.

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Enter the FTE Device Index and press ENTER. NOTE:
· Use the FTE Device Index assigned to this ELMM in section “Appendix A: EUCN Configuration Data Checklist” on page 160. Ensure that there are no errors.
· The FTE Device Index entered must be the same as the FTE Device Index physically set in the rotary switches of the ELMM FTE Interface Module.
Note: Initially, the $DEVIDX parameter will be 0. After you change the value from 0 to a non-zero value, a warning message is received, “WARNING: CHANGING $DEVIDX WHILE IN A RUNNING STATE MAY CAUSE LOSS OF VIEW. $NMuuNnn EXISTS ­ SELECT OVERWRITE OPTION IF DESIRED”. Where “uu” is the UCN Network Number and “nn” is the Primary LM’s UCN Node Number. For the redundant ELMM, the Secondary ELMM FTE Device Index is automatically set to the Primary ELMM Device Index plus one. 6

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Press the and keys to load. 7
RESULT: The Primary ELMM transitions to IDLE state. From the UCN Status Display, checkpoint the NIM to save the FTE 8 Device Index information in the NIM checkpoint.
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Make sure that the PLC CPM hardware is connected to the power supply. The PLC CPM’s status must indicate IDLE on the UCN Status

display with ELMM on the Auxiliary status line.

9

After the LM is migrated to ControlEdge PLC, the

personality download procedure is obsolete and

ATTENTION hence the module starts up from the IDLE state

with no database.

For the redundant ELMM, repeat steps 4, 5 and 7 for the secondary ELMM to come to the BACKUP (yellow) state indicative of IDLE status.

10

Restore the LM checkpoint taken earlier. Select the Primary ELMM > LOAD/SAVE RESTORE > RESTORE DATA and then press ENTER 11 and choose DEFAULT SOURCE. NOTE: As the ELMM transitions to IDLE state directly, there is no need to download the TPN personality.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS Reconstitute ELMM’s UCN node-specific configuration and choose LMM CONNECTED CONTROLLER type as CEPLC and then press ENTER.
12
13 Reload the configuration by pressing Ctrl + F12. Select RUN STATES > STARTUP to perform a startup of the ELMM.
14 RESULT: The Primary ELMM transitions from IDLE to OK state.

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ELMM WITH CONTROLEDGE PLC CONFIGURATION AND OPERATIONS On a successful database sync, ensure that the Secondary ELMM transitions to the BACKUP (cyan) state indicative of OK/RUN state.
15
Checkpoint ENIM and ELMM, once onto the HM and once onto the 16
emulated drive. 17 All LM to ELMM upgrade activities are complete for this EUCN.

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4.9 Displays

4.9.1

Enhanced Logic Manager with ControlEdge PLC Detailed Status Display
ControlEdge PLC detail status display is a modified version of the existing LMM Detail status display. All the information which is essential for PLC maintenance is retained on this display removing all unwanted parameters. The SCANTIME, REG, SCM and PRC LEDS for the PLC shall not be displayed on this display. The offline SIOM Starting address information shall be removed from this display. Option module information shall be removed since it does not apply to ControlEdge PLC.

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Targets: Swap Primary This target provides the operator with a mechanism for requesting a redundancy switchover. It is functionally equivalent to a target on the UCN Status display. It is visible when NODESTS is not equal to OFFNET for both chassis. An ENTER is exposed to the right of this target that completes the request. UCN nn – Displays UCN network number and acts as a target for calling up (returning to) UCN STATUS display. System Parameter: NTWKNUM Range: 1 ­ 20 NN – Identifies node number (1-64) and acts as a target to select the chassis for calling additional detailed status displays. Detail Status – Acts in conjunction with the NN targets for calling up additional detailed status displays. Node Status fields: NODE nn – Node number of the ELMM. System Parameter: NODENUM Range: 1 ­ 64 TYPE tt ­ UCN Node Type. System Parameter: NODETYP Range: NotConfg, LM (red.status) – Current redundancy status of the ELMM. System Parameter: PMMOPER Range: NON-REDUNDANT, PRIMARY, SECONDARY (node status) – Current node status of the ELMM. System Parameter: NODESTS Range: IDLE, OK, PARTFAIL

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4.9.2

Enhanced Logic Manager with ControlEdge PLC I/O System Status Display
ControlEdge PLC IO status display is a modified version of the existing LMM IO status display. All the information which is essential for PLC maintenance is retained on this display removing all unwanted parameters. LM Processor Type information will be removed from this display. All the SIOM related information will be removed from this display.

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4.9.3

Enhanced Logic Manager with ControlEdge PLC Hardware Status Display
ControlEdge PLC hardware status display is a modified version of the existing LMM hardware status display. All the information that is essential for PLC maintenance is retained on this display removing all unwanted parameters.

For an ELMM, the Force Count field always shows 0000′ and the Force Function and Data Change Function fields on the LM ATTENTION Hardware Status Display always showDISABLED’, you can ignore these values.

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4.9.4 Enhanced Logic Manager with ControlEdge PLC Revisions and Personality Display
This display is called up from the VERS/REVIS target of the Enhanced LM Detailed Status Displays.

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The targets along the left side and the textual status information along the bottom are standard for all ELMM Detailed Status Displays. The display presents identification information for the ELMM hardware, firmware, and Personality. Targets: ELMC Diagst, LM Status, VERS/REVIS, LM Config, UCN STATS, MAINT SUPPORT, SOFT FAILURE, UCN xxx ­ Fields: H/W – LMM Processor Board hardware version. F/W – LMM Processor Board firmware version. NAME – Personality name (always LMPI).
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VERS – Personality version.
REV – Personality revision.
DAY – Personality creation day.
MONTH – Personality creation month.
YEAR – Personality creation year.
For an ELMM, the Hardware Version (H/W) field on the Revisions and Personality Data Display does not display ATTENTION correct information, you can instead go to ControlEdge Builder to verify this information. To know the H/W and F/W information, perform the following procedure.
1. From the Start Page, click Connect to connect the target controller.
2. From the Home page, make sure that you have selected ELMM as the controller type under Controller and Programming.
3. From the Home page, select View Diagnostics under Diagnostics.
4. Go to System > Platform. The View Diagnostics page is displayed, verify the hardware and firmware versions.

4.9.5

Enhanced Logic Manager with ControlEdge PLC Configuration Display
This display is called up from the LM Config target of ELM Detailed Status Display.

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The targets along the left side and the textual status information along the bottom are standard for all Enhanced LM Detailed Status Displays. The display summarizes the ELMM’s Point Mix and the data access overrun statistics.
Targets:
ELMC Diagst, LM Status, VERS/REVIS, LM Config, UCN STATS, MAINT SUPPORT, SOFT FAILURE, UCN xxx ­ Fields:
Scanrate – ELMM Point Processor scan rate AR represents analog point scans, with the number following being 1 or 2 (once or twice per second). DT represents digital, timer, and logic point scans, with only the value of 2 available for ELM.
System parameter: SCANRATE
Range: AR1DT2, AR2DT2
Analog Inputs – Number of AI points available.
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System Parameter: NAISLOT Range: 0-127/254 Analog Outputs – Number of AO points available. System parameter: NAOSLOT Range: 0-482/965 Digital Inputs – Number of DI points available. System parameter: NDISLOT Range: 0-1866 Digital Outputs – Number of DO points available. System parameter: NDOSLOT Range: 0-4000 Digital Composites – Number of DC points available. System parameter: NDCSLOT Range: 0-304 Timers – Number of Timer points available. System parameter: NTIMER Range: 0-700 Logic Points – Number of Logic points available. System parameter: NLOGSLOT Range: 0-14 Flags – Number of Flag points available. System parameter: NFLAG Range: 0-1024 Base Flag address – Starting address (least significant) of the block of flags. System parameter: FLLSBA Range: -1 (not configured), 0-4095 Numerics – Number of Numeric points available. System parameter: NNUMERICS Range: 0-1024
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Base numeric address – Starting address (least significant) of the block of numerics.
System parameter: NNLSBA
Range: -1 (not configured), 4096 to 8191
Point Processor Overruns – Number of times ELMM was unable to complete a full scan of its points within the allotted 1/2 or 1 second. Such overruns are usually caused by a burst of activity (e.g., alarms or parameter requests) and should only be a cause for concern if they occur frequently. If this number accumulates steadily, it usually means the ELMM is receiving an excessive amount of parameter requests.
System parameter: CRPPXORN, LSPPXORN
UCN Access Overrun – Number of times ELMM was unable to collect UCN data in time to start its next scan. This involves Logic Point inputs connected to points on other UCN nodes. Such overruns are usually caused by a burst of activity (e.g., alarms or parameter requests) and should only be a cause for concern if they occur frequently.
Excessive loading at the ELMM or at one or more remote nodes could cause frequent overruns, a situation which should be corrected.
System parameter: CRUCNORN, LSUCNORN
LM Processor Overruns – Number of times ELMM was unable to collect fresh Logic Controller (ControlEdge PLC) data in time to start its next scan. Such overruns are usually caused by a burst of activity (e.g., alarms or parameter requests) and should only be a cause for concern if they occur frequently. Excessive logic controller (ControlEdge PLC) scan times (approaching ELMM scan time) could cause such overruns.

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4.9.6

Enhanced Logic Manager with ControlEdge PLC UCN Stats Display
This display is called up from the UCN STATS target of any ELM Detailed Status Display. The display may also be called up from the UCN STATS display, Page 2, by selecting the STATISTICS PAGE ONE target.

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The targets along the left side and the textual status information along the bottom are standard for all ELM Detailed Status Displays. The display, in conjunction with PAGE 2, summarizes the ELMM’s UCN Error statistics. Targets: ELMC Diagst, LM Status, VERS/REVIS, LM Config, UCN STATS, MAINT SUPPORT, SOFT FAILURE, UCN xxxx Page 2 is selected by touching the STATISTICS PAGE TWO target. This display is called up from the UCN STATUS target of any ELM Detailed Status Display, followed by the selection of the STATISTICS PAGE TWO target.
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The targets along the left side and the textual status information along the bottom are standard for all ELM Detailed Status Displays. The display, in conjunction with PAGE 1, summarizes the ELMM’s UCN error statistics.
Targets:
ELMC Diagst, LM Status, VERS/REVIS, LM Config, UCN STATS, MAINT SUPPORT, SOFT FAILURE, UCN xxx Descriptions of the ELM Local UCN Statistics Display’s statistics are found in following two tables respectively.
Local UCN Statistics Descriptions

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Statistic No Copy Buffers

Description
The number of times no buffers on the LCN side of PNI/EPNI for copying received messages (NIM only) were available. The count is normally zero. Increasing counts indicate extreme NIM congestion. The LLC increments the count. The situation can lead to a “No Receive Buffers” count.

Token Rotation Time

NIM only. Sampled, the averaged token rotation time in 0.1 millisecond units. This is not an absolute measurement, and only roughly correlates to the Concord Token Scope. A 2-node UCN with no traffic will be in the 0.1 millisecond range, while a moderatelyloaded 64-node UCN will be in the 4-6 millisecond range. OFFNET nodes and heavy traffic will increase the observed token rotation time.
The nominal token rotation time for the system should be recorded when there are no errors and the load is moderate. Deviations from the count noted in a smoothly operating system should be investigated. An abnormally slow token rotation time may be caused by a level of trunk noise not quite high enough to cause a cable swap.

No Successor Found

The ring collapsed, and token-passing was lost. The count is incremented once in most nodes for a ring collapse. It is preceded by an “Asked Who Follows” count in the node that had the token. The count is incremented by the TBC.

The number of times the successor node dropped out of the ring, temporarily or permanently (shutdown, failure, Asked Who Follows failover). It does not change in a system that is running normally. The count is incremented by the TBC.

The number of times a token pass to successor node was retried. The count is normally zero. This does not change in a smoothly operating system. The cause can Token Passes Failed show up as noise, checksum error, or frame fragment count in the successor node. The count is incremented by the TBC.

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Statistic Noise Bits
Checksum Error Repeater Error Partial Frame

Description
Noise periods or bursts are detected by the TBC. This may be caused by physical network problems. It can occur without the loss of any messages. A count of zero is expected, but low counts are acceptable.
A burst of noise, frame fragment counts over 25, three successive 300 millisecond periods of noise counts of 3, and/or partial frames of 2, will cause noise to be reported, the “Cable A/B Noise” count to be incremented, and the cable to be swapped. These low thresholds are empirically derived from introducing various types of trunk faults.
The number of times message corruption was detected by the TBC. The theoretical bit error rate for errors not detected by the modem and noted as noise or frame fragments is 1 x 10E-9. This works out to approximately three checksum errors per hour, per network. The observed rate is much less, and because messages are tokens, real messages are seldom lost. If frequent checksum errors occur, there may be a physical network or modem problem. If the predecessor to a node with checksum errors indicates a corresponding increase in the “Token Pass Failed” count, the problem is likely to be in the node with the checksum errors.
The number of times the TBC detected that the error bit in the message end delimiter was set, indicating that a repeater received a message with a bad checksum, then retransmitted it. Because the UCN does not use repeaters, this means corruption in the end delimiter of the message. A count of zero is expected, but occasional counts are acceptable.
The number of times message corruption was detected by the TBC. This may be caused by physical network problems. It can occur without loss of messages. See the “Noise” description.

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Statistic

Description

The number of times the received message exceeded

Received Frame Too the 8 Kbyte IEEE 802.4 limit. Note that UCN messages

Long

are limited to 1 Kbyte in length. A count of zero is

expected. The count is incremented by the TBC.

The number of times no buffers were available for the TBC to store received messages. Zero is the expected No Receive Buffers count, but an occasional count under continuous, very heavy demand is acceptable. The count is incremented by the TBC.

Receive Overrun

The number of times there was insufficient local processor DMA bandwidth for the TBC to copy a received message into memory. A count of zero is expected. The count is incremented by the LLC based on the transmit status.

Duplicate RWR

The number of times a duplicate Type 3 message was received. This could be caused by the TBC retrying a message because an ACK was lost. A count of zero is expected, but a small number is acceptable. A count here can sometimes be explained by an increase in one of the other error statistics. The count is incremented by the LLC based on the transmit status.

The number of times the Null RWR messages were used by other nodes to resynchronize with this node upon startup or after an error. A node that leaves and reenters Null RWR (Resynch) a running UCN will probably show and cause some counts. The count is incremented by the LLC based on the transmit status.

The number of times there was insufficient local processor DMA bandwidth for the TBC to transmit a Transmit Underrun message. A count of zero is expected. The count is incremented by the LLC based on the transmit status.

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Statistic

Description

The number of times there was a discrepancy between

the frame length and the sum of the data block

Transmit Frame Too lengths given to the TBC. A count of zero is expected.

Long

The count is incremented by the LLC based on the

transmit status.

A count of the operator, periodic, or fault-induced cable Total Cable Swaps
swaps. The periodic swap is every 15 minutes.

Cable A Silence

The number of times Cable A was found silent. A count of zero is expected. Normally, a silent cable is a broken or disconnected drop cable, or a bad tap. Certain types of trunk cable problems, such as a short in the middle of a trunk cable segment, can also cause silence to be reported, perhaps by multiple nodes.

Cable B Silence

The number of times Cable B was found silent. A count of zero is expected.

Cable A Noise

The number of times Cable A was found noisy. A count of zero is expected.

Cable B Noise

The number of times Cable B was found noisy. A count of zero is expected.

The number of times one or more nodes did not respond to RDR messages. One or more nodes can be OFFNET or can be temporarily overloaded. The count is normally zero, but will increase when access to an OFFNET node No Response Errors is attempted. The count is incremented by the LLC based on the transmit status. The count is not incremented if the TBC is successful on its automatic retry.

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Statistic
Unexpected Responses

Description
The number of times MAC control was not correct for an RWR response message (such as the wrong node number in a response). This indicates network contention or corruption within a node. A count of zero is expected. It also indicates the number of times SAPs were not as expected. The count is incremented by the LLC based on the transmit status and/or message header contents.

The number of times the LLC part of an RWR response was incorrect. This can indicate corruption in a node, or Errors In Responses network contention. A count of zero is expected. The count is incremented by the LLC based on the transmit status and/or message size, or header contents.

The number of times this node attempted to reconnect Auto- Reconnects
to the UCN after a serious UCN communication fault.

Local Messages

The number of messages between tasks in this node. The count is always incrementing in a NIM, zero in a LM.

Messages Sent

The number of messages sent from this node. The count does not include automatic TBC retries or driver retries.

Messages Received The number of messages received

References

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