Endress+Hauser ControlCare SFC173 User manual

BA 035S/04/en/07.06
Software Version 2.02.xx
Nr. 56004887
Operating Instructions
ControlCare Field Controller
Commissioning and Configuration
8
ControlCare SFC162
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ControlCare SFC173
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ControlCare Field Controller: Commissioning and Configuration Table of Contents
Endress+Hauser 1
Table of Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Registered Trademarks . . . . . . . . . . . . . . . . . . . . . . 2
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Installation, commissioning and operation . . . . . . . . 3
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Conventions and icons . . . . . . . . . . . . . . . . . . . . . . 4
1.5 ControlCare documents . . . . . . . . . . . . . . . . . . . . . . 5
2 Getting Started . . . . . . . . . . . . . . . . . . 6
2.1 Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Installing Application Designer Suite . . . . . . . . . . . . 7
2.3 Installing the OPC Servers only . . . . . . . . . . . . . . . 10
2.4 Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1 Upgrade ControlCare Application Designer 11
2.5 Additional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1 Adobe Reader . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 OPC Data Spy . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Checking Your Installation . . . . . . . . . . . . . . . . . . . 13
2.6.1 License . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.2 Application versions . . . . . . . . . . . . . . . . . 13
2.7 Deinstalling ControlCare Application Designer
Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 FF Field Controller . . . . . . . . . . . . . . 15
3.1 Open ControlCare Application Designer . . . . . . . . 15
3.2 Create a FF project . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Determine the naming preferences . . . . . . . . . . . . 17
3.4 Add a bridge (SFC162) . . . . . . . . . . . . . . . . . . . . . 18
3.5 Add a fieldbus segment . . . . . . . . . . . . . . . . . . . . . 19
4 PROFIBUS Field Controller . . . . . . . . 20
4.1 Open ControlCare Application Designer . . . . . . . . 20
4.2 Create a PROFIBUS project . . . . . . . . . . . . . . . . . . 21
4.3 Add a gateway (SFC173) . . . . . . . . . . . . . . . . . . . . 22
4.4 Add a PROFIBUS segment . . . . . . . . . . . . . . . . . . . 23
5 Configuring the Field Controller . . . . 25
5.1 Customise the Controller I/O blocks . . . . . . . . . . . 25
5.1.1 Resource block . . . . . . . . . . . . . . . . . . . . . 26
5.1.2 Transducer block . . . . . . . . . . . . . . . . . . . . 26
5.2 Configure the I/O transducer blocks . . . . . . . . . . . 27
5.2.1 Hardware configuration block . . . . . . . . . . 27
5.2.2 Temperature transducer block . . . . . . . . . . 30
5.3 Add and configure the I/O function blocks . . . . . . . 32
5.3.1 CHANNEL parameter . . . . . . . . . . . . . . . . 32
5.3.2 Create input/output function blocks . . . . . 33
5.3.3 Analog Input block . . . . . . . . . . . . . . . . . . 34
5.3.4 Discrete Input block . . . . . . . . . . . . . . . . . . 36
5.3.5 Pulse Input block . . . . . . . . . . . . . . . . . . . . 37
5.3.6 Multiple Analog Input block . . . . . . . . . . . . 38
5.3.7 Multiple Discrete Input block . . . . . . . . . . . 39
5.3.8 Analog Output block . . . . . . . . . . . . . . . . . 40
5.3.9 Discrete Output block . . . . . . . . . . . . . . . . 42
5.3.10 Multiple Analog Output block . . . . . . . . . . 43
5.3.11 Multiple Discrete Output block . . . . . . . . . 44
5.4 Next steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Going On-line . . . . . . . . . . . . . . . . . . 46
6.1 Connecting the Field Controller to the subnet . . . . 46
6.1.1 Networks with two or more
Field Controllers . . . . . . . . . . . . . . . . . . . . 46
6.1.2 Network with DHCP Server . . . . . . . . . . . . 46
6.1.3 Networks without a DHCP Server . . . . . . . 47
7 Trouble-Shooting . . . . . . . . . . . . . . . 51
7.1 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2 Factory initialisation and reset . . . . . . . . . . . . . . . . 52
7.3 Field Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4 Application Designer . . . . . . . . . . . . . . . . . . . . . . . 54
7.5 Updating the firmware . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . 60

ControlCare Field Controller: Commissioning and Configuration
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Revision History
Product Version
The table below indicates the product versions of the main components of ControlCare Field-based
Control System. More details on the individual components can be seen in About ControlCare
Registered Trademarks
PROFIBUS®
Registered trademark of the PROFIBUS User Organisation, Karlsruhe Germany.
FOUNDATIONTM Fieldbus
Trademark of the Fieldbus Foundation, Austin, TX 78759, USA
HART®
Registered trademark of the HART Communication Foundation, Houston, USA
Microsoft®, Windows® , Windows 2000®,Windows XP®, Windows 2003 Server® and the
Microsoft logo are registered trademarks of the Microsoft Corporation.
Acrobat Reader®is a registered trade mark of the Adobe Systems Incorporated.
All other brand and product names are trademarks or registered trademarks of the companies and
organisations in question
Product
version
Manual Changes Remarks
2.00.xx BA035S/04/en/01.05 Original manual Split from previous manual BA021S/04/en of 07.02
2.01.xx BA035S/04/en/08.05 Setup Setup modified, Update added, OpenOCS added
Editorial Descriptions of function blocks descriptions improved
2.01.xx BA035S/04/en/03.06 Setup OpenPCS Service Pack 1: No effect on operation
2.02.xx BA035S/04/en/07.06 Setup Chapter 2: Setup changed to install all components
Editorial • Simulation for Local I/O added (Chapter 7.1)
• Pulse Input block description revised (Chap. 5.3.5)
Product Version Component Version
V2.02.xx ControlCare Application Designer Suite Version 2.02.xx
ControlCare PROFIBUS Configurator Version 2.9xx
ControlCare Field Control (OPC) Server Version 3.11.xx
ControlCare Device Libraries* Version 2.02.xx
Control Care Manualss Version 2.02.xx
*Version No. may increase independent of Product Version as
the latest devices are added to the library

ControlCare Field Controller: Commissioning and Configuration 1 Safety
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1Safety
1.1 Designated use
ControlCare is a field-based control system comprising hardware and software modules. It can be
used to visualize, monitor and control production processes. The hardware described in this manual
allows a modular FOUNDATION Fieldbus or PROFIBUS controller to be built. It comprises a
number of separate units that may include power supply modules, power conditioning modules,
fieldbus linking devices, controllers, interfaces, analog I/O and discrete I/O units. The approved
usage of the individual units used in the system can be taken from the corresponding parts of these
operating instructions.
1.2 Installation, commissioning and operation
ControlCare Field Controller modules have been designed to operate safely in accordance with
current technical safety and EU directives. Essential to their use is the ControlCare Application
Designer software, which allows control strategies to be created for both FOUNDATION Fieldbus
and PROFIBUS applications. Field devices, links, junction boxes, cables and other hardware
comprising the Fieldbus sytem must also be designed to operate safely in accordance with current
technical safety and EU directives.
If devices are installed incorrectly or used for applications for which they are not intended, or if the
controller is not configured correctly, it is possible that dangers may arise. For this reason, the system
must be installed, connected, configured, operated and maintained according to the instructions in
this and the associated manuals: personnel must be authorised and suitably qualified.
1.3 Operational safety
Location Field Controllers must be mounted in a permanent and weather-protected location in a safe area.
The environment shall be a metal cabinet or an installation frame with a well grounded mounting
plane. The environment shall be protected.
Hazardous areas The controller must be connected to networks operating in explosion hazardous areas via barriers
or other safety components. When installing components in explosion hazardous areas:
• Ensure that all installion and maintenance personnel are suitably qualified
• Check that all equipment has the appropriate safety certificates
• Observe the specifications in the device certificates as well as national and local regulations.
This topic is discussed in BA013S (FF Guidelines) and BA034S (PROFIBUS Guidelines).
EMC All modules are suitable for industrial use and conform with the following standard, see Appendix:
• EN 61326: 1997/A1: 1998
Interference emmision: Class A apparatus
Interference immunity: as per Annex A, industrial environment
Depending upon the environment in which the bus is operating, particular attention should be paid
to the grounding of the bus cables. This topic is discussed in BA013S (FF Guidelines) and BA034S
(PROFIBUS Guidelines).

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IP Address Field Controller is normally configured from a workstation connected into the control system
backbone. You will require a unique IP address to set it up.
Warning
The use of IP addresses is strictly controlled. Usually your system administrator will be authorised
to allocate unique addresses. Assigning an unauthorised address to a Field Controller may result in
conflicts within your system and the failure of the associated devices!
Since the system can be accessed and manipulated through the various Field Contoller tools, it is
advisable to control access both to the workstation and the folders in which the configuration is
stored. Always make a back-up of the project.
Technical improvement Endress+Hauser reserves the right to make technical improvements to its software and equipment
at any time and without prior notification. Where such improvements have no effect on the
operation of the equipment, they are not documentated. If the improvements effect operation, a
new version of the operating instructions is normally issued.
1.4 Conventions and icons
In order to highlight safety relevant or alternative operating procedures in the manual, the following
conventions have been used, each indicated by a corresponding icon in the margin.
Safety conventions Icon Meaning
A note highlights actions or procedures which, if not performed correctly, may indirectly affect operation
or may lead to an instrument response which is not planned
Caution!
Caution highlights actions or procedures which, if not performed correctly, may lead to personal injury or
incorrect functioning of the instrument
Warning!
A warning highlights actions or procedures which, if not performed correctly, will lead to personal injury,
a safety hazard or destruction of the instrument

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1.5 ControlCare documents
Table 1.1 indicates the documents, planned and realized, containing safety relevant information,
installation, commissioning and operating instructions for the equipment and software associated
with Field Controller.
All documentation available at the time of release is included on the ControlCare CD-ROM and is
installed in Start=>Programs=>Endress+Hauser=ControlCare=Manuals during set-up.
Tab. 1-1: ControlCare Documentation
Component Description Document type Designation Order No.
System ControlCare System Overview Operating manual BA016S/04/en 56004883
ControlCare System Design Operating manual BA039S/04/en Planned
ControlCare System Specifications Operating manual BA040S/04/en 56004888
Software Application Designer Overview Operating manual BA017S/04/en 71014301
Application Designer Drawing Tool Operating manual BA032S/04/en Planned
Application Designer: FF Tutorial Operating manual BA019S/04/en 70101151
Application Designer: PROFIBUS Tutorial Operating manual BA036S/04/en 70101152
Application Designer: MODBUS Tutorial Operating manual BA037S/04/en 70101153
Application Designer: IEC 61131 Tutorial Operating manual BA038S/04/en 70101386
Field Control(OPC)ServersOperating manualBA018S/04/en71031428
Field Controller Hardware Installation Guide Operating manual BA021S/04/en 56004885
Commissioning and Configuration Operating manual BA035S/04/en 56004887
Function Blocks Function Block Manual Operating manual BA022S/04/en 56004886
Set-Up Getting Started Operating manual BA020S/04/en 56004884
General FOUNDATION Fieldbus Guidelines Operating manual BA013S/04/en 70100707
PROFIBUS Guidelines Operating manual BA034S/04/en 56004242

2 Getting Started ControlCare Field Controller: Commissioning and Configuration
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2 Getting Started
ControlCare Application Designer Suite runs on the operating systems Windows 2000, Windows
XP and Windows Server 2003 with the service packs indicated in the System Requirements:
• You need to have administrator rights for the installation of the ControlCare Application
Designer Suite.
• Application Designer Suite operates with a license protection key. Any licence keys already
used on your computer should be unplugged before the software is installed.
• You will be warned, if the system requirements are not met.
2.1 Preliminaries
1 Place the ControlCare CD-ROM in your CD-ROM drive, the Setup menu appears just after the
CD has been inserted.
2 First check that your computer fulfils the minimum System Requirements as described
below
.
3 Before starting the installation it is advisable to carefully read the Release Notes.

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2.2 Installing Application Designer Suite
1 Click on ControlCare Field-based Control System to initiate the software installation
process.
2 The setup program starts the installation process:
– If an old ControlCare version is installed on your computer, you will be asked if you wish to
deinstall it
–PressYes to this and the following two confimation dialogs
– The setup program deinstalls the old ControlCare Application Designer Suite
– When the Uninstall Complete dialog appears, press Finish to close the procedure
3 If ControlCare was not installed previously or after deinstallation is complete the Welcome
dialog appears
– Continue the installation by clicking Next

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4TheLicence Agreement now appears
– Read the agreement, then check the button saying that you agree with it
–Print will cause a copy of the license agreement to be printed out
– Continue the installation by clicking Next
5TheComponents dialog appears
– Press Next to accept the default settings
6TheChoose Destination Location dialog appears
– Press Change and follow the instructions if you want to select a different destination.
– Press Next to accept the default destination and/or to continue installation.

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7TheStart Copying Files dialog appears
– Read the list the applications to be installed
– If you want to change anything, press Back until you reach the appropriate screen
– Continue the installation by pressing Install
8 ControlCare Application Designer Suite will now be installed
– You are informed of progress through the Setup Status dialog
–AnswerYes should you be prompted to delete a previous version of OpenPCS
9 The Installation Complete dialog appears after everything was installed
–PressFinish to complete the procedure and close the dialog
– Plug the hard key into the USB or parallel port of your computer

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2.3 Installing the OPC Servers only
The sequence is essentially the same as that described in Chapter 2.2.
1 Click on ControlCare Field-based Control System to initiate the software installation process.
2TheWelcome dialog appears, continue the installation by clicking Next
3TheLicence Agreement now appears.
– Read the agreement, then check the button saying that you agree with it
– Continue the installation by clicking Next
4TheComponents dialog appears
– Deselect both the Application Designer and OpenPCS boxes
– The remaining components are those needed for the OPC server
– Press Next to continue with the installation
5 Follow the wizard instructions to complete the installation, see Chapter 1.2, Steps 6 to 9.

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2.4 Upgrades
All previous versions of the ControlCare Application Designer Suite must be deleted before V2.02
can be installed (see Chapter 1.2, Step 2). For future releases it will be possible to upgrade from the
Setup menu.
2.4.1 Upgrade ControlCare Application Designer
1 Click on ControlCare Field-based Control System to initiate the software installation process.
2 If the setup program detects an earlier version of ControlCare Application Designer Suite on
your computer, the installation continues as decribed from Step 3 of Chapter 2.2.
3 If the setup program detects the same version of ControlCare Application Designer Suite on
your computer, it starts the installation process with the dialog below:
– Select Modify then click on Next
4IntheComponents dialog press Next to accept the default settings
– Alternatively select the components you wish to update and press Next.
5 When the Maintenance Complete dialog appears, press Finish to finish the procedure and
close the dialog.

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2.5 Additional Tools
2.5.1 Adobe Reader
All current manuals related to ControlCare hardware and software products and other auxiliary
information manuals are copied to your computer during installation. You require Adobe Reader
Version 5.0 or higher to read them. If not already on your computer, you can install the latest
version as described below.
1 Go to the main menu on the ControlCare CD-ROM and select Adobe Reader
2 Now choose the language version and follow the instructions in the Installation Wizard.
3 To open a manual from your computer select
Start=>Programs=>Endress+Hauser=>ControlCare=>Manuals=>English
From the Setup menu
–Getting Started opens a PDF version of the Getting Started manual
–Open Documentation opens the folder containing the manuals.
2.5.2 OPC Data Spy
OPC Data Spy is a simple OPC client tool that is installed with ControlCare Application Designer
Suite. It allows the values output by devices in a fieldbus network to viewed and monitored.
1OpenOPCDataSpy
– Start=>Programs =>Endress+Hauser=>ControlCare=>Tools=>OPC Data Spy
2 Instructions on use are to be found in the online help.

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2.6 Checking Your Installation
2.6.1 License
You can check your license to see the number of Tags and Function Blocks that are supported. This
information is also required should you want to request a Tags license upgrade.
1 Open Check Licence:
–Start=>Programs =>Endress+Hauser=>ControlCare=>Tools=>Check License
2 In the example, it can be seen that there are two licenses in the hard key (dongle):
– Field Control OPC Server supports an unlimited number of tags
– ControlCare Application Designer supports 256 Function Blocks.
2.6.2 Application versions
It is sometimes necessary to check all product related version information, for example, when you
are looking for product support or a product update.
1 Open About ControlCare:
–Start=>Programs =>Endress+Hauser=>ControlCare=>Tools=>About ControlCare
2 A dialog box now appears containing all version information for ControlCare software
components.
– It can be copied onto the clipboard by selecting the text within the box by scrolling the
mouse over it.
– Now press the sequence "Crtl+Insert" to copy it and "Shift+Insert" to paste it into another
text document.

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2.7 Deinstalling ControlCare Application Designer Suite
Once ControlCare Application Designer Suite has been installed, it can be deinstalled if required via
the Windows Control Panel.
1 Select Start=>Settings=>ControlPanel then click on Add or Remove Programs
2 Select ControlCare Field-based Control System and then Remove
3 You will be asked to confirm the removal of particular software components. Confirm that you
want to remove them with Yes
4 Windows proceeds with the de-installation
– Pressing “Cancel“ aborts the de-installation process.
Note!
• In the event that field devices were already integrated in ControlCare Application Designer, the
associated files (DDs & CFF) will not be deleted. Similarly if configuration files for projects have
been created, they will not be removed, The files can be found in the location they had before
ControlCare was deinstalled.

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3 FF Field Controller
The Field Controller is configured with the ControlCare Application Designer software. Before you
use this for the first time, check that the your hard key (dongle) is connected to your computer (This
is not necessary if you have a demo license or intend to use it as a demo version only).
3.1 Open ControlCare Application Designer
1 Start Application Designer:
Start=>Programs =>Endress+Hauser=>ControlCare Application Designer
– The welcome screen appears, followed by an empty protect window

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3.2 Create a FF project
1 The project starts from a blank application screen
– With the right mouse key select Project File=>New
1TheDocument Type box appears: Click the option Project
2TheNew Project dialog box opens:
1. Choose the folder where the project will be saved.
2. Type the name of the project in the File Name box.
3. Click Save.
If the new project is not to be created, click Cancel.
3 ControlCare Application Designer automatically creates a folder with the entered file name
within the selected folder.

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3.3 Determine the naming preferences
Before you start, you can set preferences for the way your project is created. Of particular interest
at this stage is the labelling of the function blocks.
1PressProject File => Preferences
–ThePreferences Dialog appears
Tag Policy Tag Policy determines how the blocks are labelled by default if no tag names are entered
1 Select the folder Block and the subfolder Tag Policy, then check the following buttons
–Device
–Update Block Tag
2PressOK to confirm your selection
– Application Designer will now automatically rename any blocks created in the control
strategy window as they are assigned to the devices by adding the device tag as prefix.
Tag Composition Tag Composition determines how the block identifiers are added to the block tag if no block name
is entered.
1 Select the subfolder Tab Composition:
– Enter a mnemonic separator: for this manual the setting was "-"
Default setting is "_" and mandatory if flexible function blocks are to be used
–CheckPrefix
2PressOK to confirm your selection
– Application Designer will now automatically compose the blocks according to your
selection, e.g. TagName-Block-n or TagName_Block_n.
Export Tag Export Tag causes tags to be automatically exported every time the project goes online
1 Select the subfolder Export Tag
–Check the Automatic button
2PressOK to confirm your selection

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3.4 Add a bridge (SFC162)
1 On saving, ControlCare Application Designer automatically creates a project, adding the HSE
fieldbus network and the HSE Host
– Click on + to expand the tree:
2 Now right-click on the HSE Network leaf and select New=>Bridge
3TheNew Bridge dialog box appears:
Select the SFC162 Field Controller and type in a device TAG
If you do not type in a tag, the default will be "Bridge n", where n is a consecutive number. At
this point, the Fieldbus Network does not have a direct correspondence to any of the existing
controllers.
4 Press OK to create the Bridge.
5 Repeat Steps 1 to 4 for as many bridges as you have in your network.