Controlinc Network Master
Model M250 Version 5.1
Installation and Operations Manual
MAN-01-09-91-0726-EN Rev. 1
May 2020
Notes
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Installation and Operations Manual
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Table of Contents
Section 1: Introduction
1.1 Reference Documents ................................................................................... 1
1.2 System Configuration ................................................................................... 2
1.3 General System Specifications ....................................................................... 4
1.3.1 Environmental .................................................................................... 4
1.3.2 Electrical ............................................................................................ 4
1.3.3 LCD Touch Panel Specifications ...........................................................4
1.3.4 M250 PLC Port 2 Setup for Database Exchange Link (DxL) ................... 5
1.4 Parts List ....................................................................................................... 8
Section 2: Installation
2.1 Network Master Mounting ............................................................................ 9
2.1.1 Mounting of NEMA Enclosure ............................................................. 9
2.1.2 Mounting of Rack Mount Enclosure ..................................................11
2.2 Power Input ................................................................................................ 12
2.3 Field Network Wiring .................................................................................. 12
2.3.1 Network Grounding ......................................................................... 13
2.3.2 Network Termination ....................................................................... 14
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Section 3: Conguring the System
3.1 System Protection and Software Versions ................................................... 15
3.1.1 Password Protection ......................................................................... 15
3.1.2 CoProcessor Software Protection ..................................................... 15
3.1.3 Software Version Identification ........................................................15
3.2 Selecting Diagnostic/Programming Mode ................................................... 16
3.3 Chassis Identification and Hot Standby ........................................................ 16
3.4 Configuring Modbus Host Port Interface(s) ................................................. 16
3.4.1 Configuring Ethernet Ports ............................................................... 16
3.5 Configuring the Field Network .................................................................... 17
3.5.1 Configuring the Number of Slaves .................................................... 17
3.5.2 Configuring Field Network Baud Rate ............................................... 17
3.5.3 Configuring Network Master Receiver Time-Out ............................... 17
3.5.4 Configuring Report-By-Exception (RBE) ............................................ 17
3.6 Configuring Network Address Sequence ..................................................... 17
3.7 Configuring Device Types ............................................................................ 18
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Section 4: Modbus Register Maps
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4.1 Valve Status and Command Registers per Modbus Function Code ............... 19
4.2 Valve Status Bit Data for Each Valve ............................................................. 20
4.2.1 Multiple Valve Status Locations Using Function Code 02 ...................21
4.2.2 Multiple Valve Status Data Using Modbus Function Code 03 ............. 22
4.2.3 Multiple Valve Status Data Using Modbus Function Code 04 ............. 22
4.3 Reading Valve Position and Setpoint ............................................................ 23
4.4 Writing Discrete Commands to Valve Actuators .......................................... 23
4.5 Writing Analog Valve Position Setpoint (Function Codes 06 and 16) ............ 24
4.6 Reading Auxiliary Analog Inputs Using Function Code 03 ............................ 24
4.6.1 Reading Torque Analog Input Using Function Code 03 ...................... 24
4.7 Reading and Writing Auxiliary Analog Outputs ............................................ 24
4.8 Reading User Discrete Inputs ....................................................................... 25
4.9 Writing User Relay Outputs (MRTU Support) ............................................... 25
4.10 System Status Word .................................................................................... 26
4.11 Combined System Alarms ........................................................................... 27
4.12 Network Fault Location ............................................................................... 27
4.13 M250 Global Database and Modbus Holding Register Map .......................... 27
Section 5: Theory of Operation
5.1 Valve Actuator Network Connections .......................................................... 31
5.2 Power-up Initialization .................................................................................31
5.3 Hot Standby Fail-Over .................................................................................32
5.3.1 Modbus Host Link and Fail-over ........................................................ 33
5.4 Network Fault Detection ............................................................................. 33
5.5 Polling Process ............................................................................................ 33
5.6 Report-by-Exception ...................................................................................34
5.7 Priority Scan ................................................................................................ 34
5.8 Writing Discrete Commands to Valve Actuators .......................................... 34
5.9 Writing Position Setpoint ............................................................................ 35
5.10 Writing Analog Outputs .............................................................................. 35
5.11 Writing User Relay Outputs ......................................................................... 35
5.12 Writing ESD Command ............................................................................... 35
Section 6: Software Source Code
6.1 Host Database Configuration Aid ................................................................ 36
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Section 7: LCD Touch Panel Backup Terminal Operation
7.1 Home Screen ..............................................................................................37
7.1.1 Alarm Display ................................................................................... 38
7.1.2 Security Codes Screen ...................................................................... 38
7.1.3 ESD Screen ....................................................................................... 39
7.1.4 Switch Active Master to Standby Screen ........................................... 39
7.2 Valve Control and Status Display ................................................................. 40
7.2.1 Valve Control .................................................................................... 40
7.3 Navigation Buttons ..................................................................................... 41
7.4 Network Diagrams ...................................................................................... 42
7.5 Network Fault Location ............................................................................... 42
7.6 Alarm Display .............................................................................................. 43
Section 8: System Setup and Conguration Using LCD
Touch Panel
8.1 Main Menu Screen ....................................................................................... 44
8.2 Security Codes ............................................................................................ 45
8.3 Data Entry ................................................................................................... 45
8.4 Host Port Configuration .............................................................................. 46
8.5 System Setup .............................................................................................. 47
8.6 Scan List ...................................................................................................... 48
8.7 Device Type ................................................................................................. 49
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Section 9: Valve Network Topology
9.1 E>Net Ring Network on NEMA BOX or Rack Mount ...................................... 50
9.2 Redundant Parallel Bus Networks ................................................................ 51
Section 10: Multiple Masters to DCS
10.1 Master’s can be Distributed Throughout the Plant .......................................52
10.2 Using Ethernet Host Interface ..................................................................... 53
10.3 Using one RS485 and one Ethernet Modbus TCP/IP Host ............................. 54
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Section 1: Introduction
Section 1: Introduction
Emerson Controlinc Network Masters are the master of Emerson Controlinc valve actuator networks
with Modbus RTU protocol. The system provides network management, data concentration, and
protocol conversion, off-loading the host system of these tasks. This enhances overall system
performance and minimizes software development and system conguration tasks by the system
integrator. The Network Master serves as the master of a master/slave network. It manages the
network by keeping an orderly cycle of data transfers to and from the slave devices (valve actuators).
It handles error detection, alarming, and network recovery. The Network Master serves as a data
concentrator for the host by providing a common database for all slave devices. The host is required
to communicate with only one slave device (network master) for all data transfers to and from the
eld. Data can be transferred between the network master and host in large blocks at a much higher
communications rate than would be possible if the host communicated with each slave device
(valve actuator) on the eld network. The Network Master acquires data from the valve actuators by
polling or scanning each device in a sequence of slave address from a table called a scan list. Polling
is a process of the Network Master sending to each slave address, a command to return its status
information, including alarms, discrete and analog inputs and outputs. When control commands
(valve open, stop, close, position setpoint, etc.) are generated by a host system up-line of the
Network Master, it then sends the appropriate commands over the network to the addressed slave
device. A more detailed functional description of operation is provided in the Theory of Operation
section of this manual.
1.1 Reference Documents
In addition to this Controlinc Network Master Operations Manual, the following references are
required for proper installation, conguration, and operation of the Network Master. All referenced
documents are supplied with the system. Paragraph numbers, as listed below, are used for reference
to these documents in this manual.
1. Emerson Controlinc 320B Quick Start Guide
2. FACTS Engineering 205 Basic CoProcessor User's Manual
3. FACTS Extended BASIC Reference Manual
4. Direct Logic DL205 User Manual
5. Bettis XTE3000 Electric Actuator IOM
All manuals and software are provided in electronic format with the system on CD.
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1.2 System Conguration
Controlinc Network Master Model M250N contains redundant valve actuator network masters in a
single enclosure. M250N supports one Controlinc E>Net ring network with up to 250 valve actuators.
Options for support of redundant bus networks and redundant E>Net rings are also available. The
supplied system uses standard RS485 and Modbus RTU protocol for the valve actuator networks.
Ethernet TCP/IP encapsulated Modbus protocol connections are provided for redundant host
computer networks. The Ethernet links are IEEE 802.3 with RJ45 connectors for 10/100Base-TX.
Protocol is Ethernet v2 encapsulation TCP/IP Version 4.
Redundant systems consist of two identical chassis with identical software. One is the primary
master and the other a hot stand-by master. The two chassis may switch roles of primary and hot
stand-by at any time. Figure 1 shows the specic system conguration of the supplied system.
The network masters communicate with Controlinc valve actuators that control both block valves
(Open, Stop, Close) and modulating or positioner type valves. The system consists of two six-slot
chassis with each chassis having a central processor located in Slot 0, which provides a global
database for the CoProcessors installed the chassis. The central processor also performs such
functions as watchdog timers and system alarm generation for the CoProcessors. It also provides
interrupt control for fast data transfers between processor modules. The main processor in each
chassis supports a “Data Exchange Link” (DxL) to share all data between redundant databases. See
Figures 2 and 3 for internal communication link connections.
Each chassis consists of two Modbus Slave modules located in Slots 3 and 4. These slave modules
communicate with redundant Modbus host systems up line. The CoProcessor installed in Slot 1 is
the Controlinc Network Master to a ring eld network. Two ports of the Network Master module are
connected to Network Interface Module (NIM) Model M124I with redundant, isolated ports. Each
NIM has connections to the redundant Network Master modules of the redundant chassis. Any one of
the four ports may acquire data from and control all actuators in the eld in either direction around
the network. Multiple M250N systems may be networked from a single host or redundant hosts to
automate any size system from a few valves to thousands of valves covering a large network area.
Ten (10) independent processors ensure full redundancy of all functions in a single unit. All
components except display are redundant with double-redundant host links to redundant hosts
and automatic processor hot swapping. Host equipment is not required to implement any fail-over
logic. Full-time redundant Modbus host links are standard. Plug-in modular construction and DIN-rail
mounting of components ensure minimum MTR, minimizing down time. LCD touch panel provides
valve actuator monitor and control of all valves in case redundant host links fail. All valve status and
alarms may be displayed by the LCD touch panel for maintenance purposes. The LCD touch panel
is a valuable troubleshooting tool during system commissioning. A more detailed description of
operation is provided in the Theory of Operation section of this manual.
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Section 1: Introduction
Figure 1 DCS System Diagram
Ethernet Links
10/100 BaseT
RS232 Modbus RTU
Links at 115.2K baud
NEMA Enclosure
with LCD Touch Panel
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Installation and Operations Manual
1.3 General System Specications
1.3.1 Environmental
Storage temperature: –20 °C to 70 °C
Ambient operating temperature: 0 to 55 °C
Ambient humidity: 5 to 95% (non-condensing)
Vibration resistance: MIL STD 810C, Method 514.2
Shock resistance: MIL STD 810C, Method 516.2
1.3.2 Electrical
Standard input voltage: 117 V AC at 50/60 Hz (100-240 V AC)
Total current at nominal voltage: 3.5 A (includes LCD panel)
Maximum inrush current: 60 A
Total power consumption: 35 VA nominal (includes LCD)
Isolation resistance: >10 MΩ at 500 V DC
Dielectric withstand voltage: 1500 V AC at 1 min.
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1.3.3 LCD Touch Panel Specications
— Display type: 5.7 in. diagonal color TFT
— Enclosure: NEMA 4/4X (IP65)
— Input voltage: 12–24 V DC
— Power consumption: 16.0 W, 1.30 A at 12 V DC, 0.66 A at 24 V DC
— Operating temp: 0 to 50 °C
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Section 1: Introduction
1.3.4 M250 PLC Port 2 Setup for Database Exchange Link (DxL)
Primary Master Secondary Master
DirectNet DirectNet
Base Timeout x 1 Base Timeout x 1
RTS/CTS 0 mS, 0 mS RTS/CTS 0 mS, 0 mS
Station Address 2 Station Address 1
38400,1, Odd, Hex 38400, 1, Odd, Hex
PLC to PLC cable is RS232, 3-wire, rolled, with 15-pin D connectors
Primary Secondary
Pin/Wire Pin/Wire
2 Red 3 Red
3 Wht 2 Wht
7 Grn 7 Grn
8 Blk 8 Blk
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Figure 2 M250 NEMA TP Internal Wiring
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Section 1: Introduction
Figure 3
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1.4 Parts List
Figure 4 is a list of materials supplied within each Network Master enclosure. This may be used as a
spare parts list.
Figure 4
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Item Qty Model
1 1 EA9-T6CL-R 2000802501 Color graphics LCD touch panel
2 1 2938730 2001803004 Power Supply, 24 V DC, 3 A
3 1 NIM124I 84713 -C Network Interface Module, Iso. RS485
4 2 D2-06B-1 2001805050 Base, 6-slot with 110/220 V AC P/S
5 2 D2-250-1 2001805052 CPU, DL205-250
6 6 37586-1 Cable, CoProcessor to NIM, 6x6, 11”
7 8 F2-CP128 2001805051 CoProcessor, Overdrive
8 1 NIM-TCP 87065 Network Interface Module, Ethernet
9 1 37587-1 Cable, CPU to CPU DxL
10 3 BK/MDA-1 7019900428 Fuse, 1 A, 250 V, Time Lag, CRM MDA
11 2 37586-4 Cable, CoProcessor to LCD, 6x6, 15”
12 2 37586-3 Cable, CoProcessor to NIM, 6x6, 13”
13 2 37586-2 (NEMA) Cable, CoProcessor to LCD, 6x6, 46”
14 1 37587 (NEMA) Cable, CPU to CPU DxL
8
Emerson Part
Number
Description
Introduction
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Section 2: Installation
Section 2: Installation
2.1 Network Master Mounting
If the system is supplied from the factory in an NEMA enclosure, no internal wiring is required except
for connecting power and eld network wiring. The next three Sections (2.1, 2.2 and 2.3) discuss
mounting, power input and eld network wire connections to the NIM.
2.1.1 Mounting of NEMA Enclosure
The enclosure is rated for NAMA 4/12 and IP65/IP55. Dimensions of the enclosure are shown in
Figure 5. Mounting dimensions are shown in Figure 6. The enclosure may be bulkhead mounted
using the internal mounting holes. External mounting brackets may be used if desired.
When mounting using the internal mounting holes, caution must be used to ensure the holes are
sealed to maintain the NEMA/IP rating. The enclosure is supplied with ve 1/2" compression type
cable entry hubs. These may be tted with conduit type ttings if desired. If the system includes
backup LCD keypad terminal, some planning is required to allow for proper height above the oor to
view the display and properly operate the keypad.
Figure 5
Installation
(5) Cable entries are provided for:
(1) Power Cable
(2) Field RS-485 Network Cables
(2) Host RS-485 Network Cables
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NOTE
Allow 1 in. clearance on left side for ventilation and room for the door to swing open to left.
Figure 6 NEMA Box Mounting
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Section 2: Installation
2.1.2 Mounting of Rack Mount Enclosure
The enclosure is designed for standard EIA 19" DIN rail rack mounting. Dimensions of the enclosure
are shown in Figure 7. The enclosure conforms to EIA RS-310, IEC 297-1, and DIN 41 494, Part 1
standards. The rack in which the enclosure(s) are mounted must allow a minimum of 20" (508 mm)
depth, allowing space for cable connections. If the system includes backup LCD keypad terminals,
some planning is required to allow for proper height above the oor to view the display and operate
the keypad properly.
Figure 7
Enclosure Depth = 15.0" (381 mm)
Allow a total depth of 20" (508 mm)
for rear panel cable connections.
Figure 8 Rear Panel View
Valve Network Ports
RJ45 Ethernet Ports
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2.2 Power Input
The system operates from 120 V AC or 220 V AC, 50/60 Hz single-phase power with internal
three wire power terminals. Ensure that a good safety ground is provided to the electrical supply to
which the power input is connected. The system contains three main fuses (6.3x32 mm, 1 A) in the
DIN-rail mounted fuse blocks. Each chassis and the LCD touch panel are independently fused. Each
NIM is powered from redundant 24 V DC power supplies from the two chassis power supplies. The
LCD touch panel is powered from an independent 24 V DC power supply. All other modules within the
unit are powered over the base back plane from the associated main chassis power supply.
2.3 Field Network Wiring
The eld network is wired in a ring conguration from Port A around a loop to Port B of the network
master. Beginning at Port A, the network is wired to Port A of the rst actuator and then from Port B of
the rst actuator to Port A of the second actuator and so on until the network returns from Port B of the
last actuator to Port B of the network master. Networks may have parallel wired (bus wired) actuators
between series wired actuators. Always wire parallel actuators to Port A and remove termination and
bias. Do not connect more than 15 actuators in parallel between any two series connected actuators.
Networks are polarized with (+) and (-) symbols on all drawings. Proper operation requires that polarity
be observed at all connections. Connect the eld networks to the Port A and B connectors on the NIM in
the network master as shown in Figure 9. The networks must be connected to Port A and Port B of the
valve actuators as shown in the wiring diagram of the Controlinc 320B Quick Start manual. Controlinc
supports many different network topologies. This manual supports only a single ring E>Net network
topology that allows a combination of parallel (bus) and series E>Net connections on the same network.
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Section 2: Installation
Figure 9 Controlinc TEC2000 E > Net Ring Network Wiring (Typical)
2.3.1 Network Grounding
The shield or drain wire of the network must be earth grounded at only one point per network
segment. This single ground point may be at any location in the system where a good earth ground
can be obtained. This may be Port B of each actuator if desired. If the network shield is connected
to the internal ground or the chassis of the valve actuator, then the actuator housing must have
a good earth ground. The NIM connection is normally the building/vessel hull equipment ground
grid. A jumper may be installed between terminals 22 and 23 on the TBM of each actuator to carry
the ground throughout the loop. Do not connect the network cable shields to a power line ground
cable. Power lines can conduct lightning and other transients into the network. Do not connect both
ends of the network shield to earth ground at the network master. This can cause a ground loop,
making the transient protection system ineffective.
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