Honeywell ControlEdge 900R04-0200 User manual

ControlEdge PLC and ControlEdge RTU
Getting Started
RTDOC-X287-en-152A
April 2019
Release 152
ControlEdge PLC
ControlEdge RTU

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 2019 - Honeywell International Sàrl
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CONTENTS
Contents 3
Chapter 1 - About this guide 7
Chapter 2 - Overview 11
Chapter 3 - Hardware 15
ControlEdge 900 platform 15
Hardware components 16
Installing the assembly 24
Wiring and cabling 25
I/O network Topology 27
Power on 31
ControlEdge 2020 platform 31
Hardware components 32
Installing the assembly 37
Wiring and cabling 37
I/O network topology 39
Power on 39
Chapter 4 - Software 41
Installing ControlEdge Builder 41
Launching ControlEdge Builder 41
Checking firmware versions 42
Creating a project 42
Configuring hardware 44
Setting controller name 44
Configuring the controller IP address 44
Configuring controller start up 45
Contents

Configuring controller redundancy 46
Configuring an I/O module 47
Configuring serial modules 49
Configuring a controller simulator 52
Programming with IEC 61131-3 58
Adding a library 58
Creating a data type 58
Creating a variable 61
Creating a Programming Organization Unit 62
Associating a program to a task 64
Compiling a project 65
Chapter 5 - Operating 67
Connecting a controller 67
Downloading a project to the controller 68
Configuring date/time 69
Setting time source 69
Setting time zone 70
Upgrading firmware 70
Upgrading firmware for a non-redundant controller 71
Upgrading firmware for a redundant controller 72
Upgrading EPM firmware 75
Upgrading ControlEdge 900 I/O module firmware 76
Upgrading serial module firmware 77
Upgrading ControlEdge 2020 Expansion I/O firmware 78
Upgrading the FDAP and field device firmware via Wireless 79
Upgrading the field device firmware 79
Upgrading the FDAP firmware 81
Uploading a project 82
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Contents

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Chapter 6 - Communication 83
Configuring Modbus 83
Configuring a Modbus Slave 83
Configuring a Modbus TCP Master 84
Configuring a Modbus Serial Master 86
Configuring EtherNet/IP devices 92
Configuring OPC UA 94
Configuring an OPC UA Server 94
Configuring an OPC UA Client 97
Communicating with Experion via OPC UA 99
Configuring an OPC UA server 99
Publishing to Experion 100
Configuring DNP3 Slave 100
Communicating with Experion via DNP3 102
Configuring a DNP3 slave 102
Publishing to Experion 102
Configuring HART 103
Configuring a HART-IP Server 103
Configuring a HART Function Block 104
Configuring CDA 106
Installing ControlEdge integration service 107
Configuring a CDA Responder 108
Publishing to Experion 110
Configuring Wireless I/O 111
Configuring User Defined protocol 113
Chapter 7 - Application 115
FDM integration 115
Getting started with FDM 115
Contents

Updating the FDM license 115
Configuring FDM for ControlEdge PLC/RTU network 116
Building networks 118
Chapter 8 - Security 119
Logon feature 119
Setting operating modes 119
Built-in Firewall 122
Configuring IPsec 122
Notices 124
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Contents

CHAPTER
1ABOUT THIS GUIDE
Revision history
Revision Date Description
A April 2019 Initial release of this document
Intended audience
This documentation allows the following audience to quickly startup
ControlEdge PLC and ControlEdge RTU system: Users who plan,
install, configure, or operate ControlEdge PLC and ControlEdge RTU
running the eCLR (IEC 61131-3) execution environment.
Prerequisite skills
Knowledge of SCADA systems and experience of working in a
Microsoft Windows environment are required.
Introduction to ControlEdge Technology
Item Description
ControlEdge
PLC
ControlEdge 900 controllers running the eCLR (IEC 61131-3) execution
environment with PLC software options configured with ControlEdge
Builder.
ControlEdge
RTU
ControlEdge 2020 controllers running the eCLR (IEC 61131-3)
execution environment with RTU software options configured with
ControlEdge Builder.
ControlEdge
UOC
ControlEdge 900 controllers running the Honeywell control execution
environment (CEE) configured with Experion Control Builder.
Special terms
The following table describes some commonly used industry-wide
and Honeywell-specific terminology:
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Terminology Description
ACE Application Control Environment
Adapter A communication device which connects to the EtherNet/IP network to
serve data from a set of devices or modules underneath it. Adapter
typically supports I/O connectivity from Scanners via implicit
EtherNet/IP connections.
Assembly A set of data passed between a Originator and a Target after an implicit
I/O connection has been established on an EtherNet/IP network.
CDA Control Data Access
ControlEdge
Builder
A integrated configuration tool to design, configure, program and
maintain ControlEdge controllers.
CPM Control Processor Module
DTM Device Type Manager
EDS Electronic Data Sheet. A text file which specifies all the properties of an
EtherNet/IP device necessary for a Scanner module to communicate
with it. EDS files my be used in the first step of creating an I/O module
or device type for interfacing to an EtherNet/IP device.
EPM Expansion Processor Module
Expansion
I/O rack
I/O rack with EPM installed
Expansion
IOM
I/O Module (IOM) external to the CPM that expand the I/O capacity
FDAP Field Device Access Point
FDM Field Device Manager
FTE Fault Tolerant Ethernet
HMI Human Machine Interface
IOTA Input Output Termination Assembly
Left End
Plate
Left end plate is used only in multi-row 2020 I/O systems. It starts a new
row of IOMs and provides connections for 24Vdc supply to the row
along with I/O Network connections.
Local I/O
rack
I/O rack with CPM installed (non-redundant)
Mixed IOM Mixed input/output module, which supports DC current or voltage type
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Chapter 1 - About this guide

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Terminology Description
signals, such as analog input, analog output, digital input, digital output
and pulse input.
Onboard
IOM
I/O Module (IOM) 'onboard' with the CPM
OPC UA An industrial machine-to-machine (M2M) communication protocol is
developed by the OPC Foundation, which provides a path forward from
the original OPC communications model (namely the Microsoft
Windows only process exchange COM/DCOM) to a cross-platform
service-oriented architecture (SOA) for process control, while enhancing
security and providing an information model.
Originator Originator is the controller that initiate any data exchange with
EtherNet/IP devices on the EtherNet/IP network.
PSM Power Status Module
PSU Power Supply Unit
Redundant
CPM Rack
Rack installed redundant CPM
Right End
Plate
A right end plate is required at the end of each row of expansion I/O
modules, including the row connected to a controller. It allows
additional rows to be added or terminates the I/O network.
RIUP Removal and Insertion Under Power
RPI Requested Packet Interval. The repetitive interval by which assemblies
are periodically transported over EtherNet/IP I/O connections between
Producer and Consumer.
RTU Remote Terminal Unit
SCADA Supervisory Control and Data Acquisition
Scanner A device which connects to the EtherNet/IP network to act as a client of
other EtherNet/IP connected devices. ControlEdge 900 Controller acts
as EtherNet/IP Scanner. It connects to and exchanges data with
Adapters of Modular IO stations, directly connected devices and
Rockwell AB ControLogix controllers.
SIM-300 Simulation for C300
SIM-ACE Simulation for ACE
Target Target is the EtherNet/IP device that address any data requests
Chapter 1 - About this guide

Terminology Description
generated by the controller.
UIO Universal Input/Output Module
Related documents
The following list identifies publications that may contain information
relevant to the information in this document.
nControlEdge Builder Software Installation User’s Guide
nControlEdge Builder Software Change Notice
nControlEdge Builder User’s Guide
nControlEdge 900 Platform Hardware Planning and Installation
Guide
nControlEdge Builder Function and Function Block Configuration
Reference
nControlEdge Builder Protocol Configuration Reference Guide
nControlEdge PLC and ControlEdge RTU Network and Security
Planning Guide
nControlEdge EtherNet/IP User's Guide
nControlEdge_PLC_Interface_Reference
nDNP3 Interface Reference
nFDM User's Guide
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Chapter 1 - About this guide

CHAPTER
2OVERVIEW
This document introduces an example for a redundant ControlEdge
900 controller connected with 4-slot, 8-slot and 12-slot expansion I/O
racks, and a redundant ControlEdge 2020 controller, to get you
quickly set up the hardware, connect and configure the controller
from ControlEdge Builder.
This document does not provide any detailed instructions. Please
refer to other related documents, and online helps embedded in
ControlEdge Builder for more information.
Make sure all the hardware modules used in the system are installed
with the right firmware version and the engineering station has the
latest ControlEdge Builder. You can find the firmware and software
updates on http://honeywellprocess.com with valid credentials.
See the following example of system architectures for ControlEdge
PLC and ControlEdge RTU.
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Figure 2-1: System architecture for ControlEdge PLC
ControlEdge PLC system has two network levels, while level 1 network
is used for internal I/O communication between CPM and related
IOMs, and level 2 is aimed for the communication with the third party
devices, HMI, SCADA or Engineering Workstation.
On the level 1 network, CPMs and EPMs connect to a switch, this
network is the most critical network in the system as a failure or loss
of service on this network can result in loss of control. On the level 2
network, the Engineering Workstation, third party devices, HMI, and
SCADA connect to the switch at this level. A failure of this level
network may result in a loss of view of the process if HMI or SCADA is
employed. The two network levels must be isolated with each other.
ETH1/ETH2 ports are required to be protected using a firewall device
configured to prevent uncontrolled messages into the controller.
Built-in firewall is supported on CPM of ControlEdge PLC.
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Chapter 2 - Overview

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Figure 2-2: System architecture for ControlEdge RTU
ControlEdge 2020 system has two networks, I/O network is used for
internal I/O communication between CPM and Expansion IOMs,
control network is aimed for the communication with the third party
devices, HMI, SCADA or Engineering Workstation.
I/O network is the most critical network in the system as a failure or
loss of service on this network can result in loss of control.
At control network, Engineering Workstation, third party devices, HMI,
and SCADA connect to the switches. A failure of this level network may
result in a loss of view for operator of the process if HMI or SCADA is
employed.
The two networks must be isolated from each other.
Chapter 2 - Overview

See the following table for the relevant configuration.
Item Go to...
1 See "Hardware" on page15 for more information.
See "I/O network topologies" on page1 for more information.
2 See "Software" on page41 for more information.
See "Operating" on page67 for more information.
3 See "Configuring Modbus " on page83 for more information.
See "Modbus Slave Configuration" on page1 for more information.
4 See "Configuring OPC UA " on page94 for more information.
5 See "CDA Configuration" on page1 for more information.
6 See "FDM integration" on page115 for more information.
7 See "Security" on page119 for more information.
8 See "Configuring Wireless I/O" on page111 for more information.
9 See "Configuring EtherNet/IP devices" on page92 for more
information.
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Chapter 2 - Overview

CHAPTER
3HARDWARE
ControlEdge 900 platform
The Honeywell ControlEdge 900 family comprises a set of hardware
and software enabling users and OEMs to assemble a system that fits
a broad range of requirements. Any configuration can be readily
modified or expanded as requirements dictate.
ControlEdge PLC can be deployed standalone or with a SCADA
system such as Experion.
Item Model number Description
1 900RR0-0200 Redundant CPM Rack
2 900R04-0200 I/O Rack (4-slot)
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Item Model number Description
3 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.
4 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.
Hardware components
This section provides a description of the major components that can
be included in a ControlEdge 900 Controller physical configuration
and indicates how the components can be combined. Some of the
components are required in all configuration. Others are optional and
can be used to provide additional functions, or to "size" the system, or
to modify or expand the system to meet changing requirements.
Rack
There are two types of racks:
nRedundant CPM Rack
Rack installed redundant CPMs
nI/O Rack, containing 4, 8 or 12 slots
I/O racks can include a topology with; either a non-redundant
power supply or with redundant power supplies, accommodate a
CPM or an EPM, and additional input/output modules. The I/O
rack inserted with an EPM enables I/O modules to be located
close to the field devices and remote from the CPM.
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Chapter 3 - Hardware

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Slot number from left to right is 1~n, and n stands for the quantity of
the slots.
Figure 3-1: Redundant CPM Rack Components
Item Description
1 Redundant CPM rack
2 Redundant Switchover Module Slot Filler
3 Primary/Secondary CPMs
4 Two Power Supplies
Figure 3-2: I/O rack with non-redundant power supply
Chapter 3 - Hardware

Figure 3-3: I/O rack with redundant power supplies
Item Description
1 Rack, available in 4-, 8- or 12-slot versions
2 Power Supply
Redundant power supply is optional and only available in 8- or 12-slot racks.
You can only install one power supply in either of the two slots.
3 CPM or EPM with Security Cover
4 Grounding bars (for I/O wiring; optional; required for safety applications)
5 Input/Output modules
6 I/O Terminal Blocks
7 Power Status Module (PSM) (required if using redundant power supply)
Control Processor Module (CPM)
CPM (900CP1-0200) contains most of the electronics required to
perform the function of a process controller. A redundant CPM rack
contains two CPMs. Either CPM can be primary.
The CPM is shown in the following figure.
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Chapter 3 - Hardware

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Item Description
1 Status LED indicator for the CPM.
2 Role LED indicator for the CPM.
3 SD card slot: supports 32GB Class 6 / Class 10 industry standard, not hot-
swappable, maximum weight 3g (0.0066 lb, 0.1058 oz)
An SD card can be inserted and used to reset the controller to factory settings, or
save datalog or DNP3 event.
CAUTION: Do not insert or remove the SD card when the CPM is powered
unless the area is known to be non-hazardous.
4 Mode switch.
There are four mode switch positions on CPM: STOP, RUN, and two REMOTE
positions. Two REMOTE positions are identical.
Rotate the four positions in clockwise or counter-clockwise. When the mode
switch is in REMOTE position, the operating modes can be configured in the
Configuration tool. For more information for the operating modes, see “Selecting
operating modes” in ControlEdge Builder User’s Guide.
ATTENTION: For redundant controller system, the position of mode
switch in primary CPM determines the system operating mode. If the
Chapter 3 - Hardware

Item Description
mode switches on the primary and secondary CPMs are in different
positions, the system will drop sync.
5 First (ETH1) and second Ethernet (ETH2) Host ports to PC applications and/or
other CPMs, or other devices.
6 Third (ETH3) and fourth (ETH4) ports connect to the Ethernet ports of EPM,
switch (for star topology), or CPM (for the interconnection between redundant
CPM in Ring topology).
7 Ethernet LED status indicators for communications functions.
Expansion Processor Module (EPM)
EPM (900SP1-0200) is installed in the expansion I/O rack and
provides the link between the CPM and remote I/O modules.
The EPM is shown in the following figure.
Item Description
1 Status LED indicator for EPM functions.
2 Role LED indicator for EPM functions.
3 Ethernet 10/100 Base-T Ports; connect to the ports on other EPMs, CPM, or a
switch that connects to the CPM (for star topology).
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Chapter 3 - Hardware