Honeywell 900R12R-0200, 900R04-0200, 900CP1-0200, 900R08R-0200, 900SP1-0200 Getting Started
...
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
2
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
Contents
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
3
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
4
Contents
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
5
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
6
CHAPTER
ABOUT THIS GUIDE
1
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
RTU
ControlEdge
UOC
ControlEdge 900 controllers running the eCLR (IEC 61131-3) execution
environment with PLC software options configured with ControlEdge
Builder.
ControlEdge 2020 controllers running the eCLR (IEC 61131-3)
execution environment with RTU software options configured with
ControlEdge Builder.
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:
7
Chapter 1 - About this guide
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 with EPM installed
I/O rack
Expansion
I/O Module (IOM) external to the CPM that expand the I/O capacity
IOM
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
I/O rack with CPM installed (non-redundant)
rack
Mixed IOM Mixed input/output module, which supports DC current or voltage type
8
Terminology Description
signals, such as analog input, analog output, digital input, digital output
and pulse input.
Chapter 1 - About this guide
Onboard
I/O Module (IOM) 'onboard' with the CPM
IOM
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
Rack installed redundant CPM
CPM Rack
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
9
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.
n ControlEdge Builder Software Installation User’s Guide
n ControlEdge Builder Software Change Notice
n ControlEdge Builder User’s Guide
n ControlEdge 900 Platform Hardware Planning and Installation
Guide
n ControlEdge Builder Function and Function Block Configuration
Reference
n ControlEdge Builder Protocol Configuration Reference Guide
n ControlEdge PLC and ControlEdge RTU Network and Security
Planning Guide
n ControlEdge EtherNet/IP User's Guide
n ControlEdge_PLC_Interface_Reference
n DNP3 Interface Reference
n FDM User's Guide
10
CHAPTER
2
OVERVIEW
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.
11
Chapter 2 - Overview
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.
12
Figure 2-2: System architecture for ControlEdge RTU
Chapter 2 - Overview
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.
13
Chapter 2 - Overview
Item Go to...
1 See "Hardware" on page15 for more information.
2 See "Software" on page41 for more information.
3 See "Configuring Modbus " on page83 for more information.
4 See "Configuring OPC UA " on page94 for more information.
5 See "CDA Configuration" on page1 for more information.
6 See "FDM integration" on page115 for more information.
7 See "Security" on page119 for more information.
See the following table for the relevant configuration.
See "I/O network topologies" on page1 for more information.
See "Operating" on page67 for more information.
See "Modbus Slave Configuration" on page1 for more information.
8 See "Configuring Wireless I/O" on page111 for more information.
9 See "Configuring EtherNet/IP devices" on page92 for more
information.
14
CHAPTER
HARDWARE
3
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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Chapter 3 - Hardware
Item Model number Description
3 900R08R-0200 I/O Rack (8-slot) can include either a redundant power
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 900R08-0200.
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:
n Redundant CPM Rack
Rack installed redundant CPMs
n I/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
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
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Chapter 3 - Hardware
Item Description
1 Rack, available in 4-, 8- or 12-slot versions
2 Power Supply
Figure 3-3: I/O rack with redundant power supplies
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
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
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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.
20
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).
Item Description
4 Ethernet LED status indicators for communications functions.
Chapter 3 - Hardware
5
Rotary switch: used to set the EPM address and network topology for the I/O
rack.
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. A small slotted screwdriver works well; avoid pencils.
Set the network topology using the 100x switch. 3 is for Ring network topology
and 4 is for Star network topology.
Input/Output module
ControlEdge PLC supports the following I/O modules.
For more information, see "I/O module specification" in the
ControlEdge 900 Platform Hardware Planning and Installation Guide.
Model number I/O module
900U01-0100 Universal Input/Output Module (UIO)
900A01-0202 Universal Analog Input Module (UAI)
900A16-0103 High Level Analog Input Module (16 channels)
900B01-0301 Analog Output Module (4 channels)
900G03-0202 Digital Input Module (16 channels) - AC Voltage Type
900G32-0101 Digital Input Module (32 channels) - DC Voltage Type
900G01-0202 Digital Input Module - Contact Type (16 channels)
900H03-0202 Digital Output Module (8 channels) - AC Voltage Type
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Chapter 3 - Hardware
Model number I/O module
900H32-0102 Digital Output Module (32 channels) - DC Voltage
900H01-0202 Relay Output Module (8 channels)
900K01-0201 Pulse Input/Frequency Input Module (4 channels)
Type
Power supply
Both AC power supply (900P01-0301) and DC power supply (900P24-
0301) can be used in Redundant CPM rack, Local I/O rack and
Expansion I/O rack.
For more information, see "Power supply" in the ControlEdge 900
Platform Hardware Planning and Installation Guide.
Figure 3-4: AC Power Supply
22
Figure 3-5: DC Power Supply
As indicated in the figures, the power supplies include:
Chapter 3 - Hardware
Item Description
1 Voltage test points
2 AC/DC Input terminal block
3 Wiring label
4 Grounding lug (Reference; lug is not part of power supply; it is mounted to
bottom of rack.)
Power Status Module (PSM)
The PSM (900PSM-0200), shown in the following figure, sits between
redundant power supplies on the I/O rack. It is a status module for
both power supplies and indicates which are powered, PS-1 (left) or
PS-2 (right) or both (typical).
When the status indicator for either or both of the power supplies is
lit, it is reporting that the status of the associated power supply is
good and that the outputs are within specified limits. When the status
is off, either the power supply is off or the voltages are out of
tolerance.
23
Chapter 3 - Hardware
Figure 3-6: Power Status Module
Installing the assembly
This section introduces you to mount the assembly.
1. Mount the rack in the enclosure.
2. Check if your configuration needs a redundant controller.
l If yes, assemble the redundant CPM rack.
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.
24
l If no, assemble I/O racks, take the 8-slot I/O rack as an
Chapter 3 - Hardware
example.
a. Insert the power supply.
b. Insert the PSM between the two power supplies.
c. If a CPM will be inserted, set the mode switch for CPM
optionally.
d. If a EPM will be inserted, set the EPM address and network
topology for the I/O rack using the rotary switch.
e. Insert CPM or EPM as required.
3. Install I/O modules.
ATTENTION: For each configured and labeled I/O module,
ONLY break off the "key-tabs" in the pattern that matches
that module type. For more information, see "Installing I/O
modules" in the ControlEdge 900 Platform Hardware
Planning and Installation Guide.
Wiring and cabling
Terminal Block Wiring can be routed through the terminal block at
the top, at the bottom, or both. Wiring should be fixed in place using
wire ties at the slotted tabs that are molded in at top and bottom of
each terminal block. The terminal block is removable.
The optional Remote Termination Panel (RTP) provides an easy way to
connect the ControlEdge 900 Controller to the field wiring. The RTP
integrates some of the typical externally connected components,
reducing wiring and setup time. It also minimizes the need for
multiple wires under a single screw connection by expanding the
connectivity of the shared terminals of the I/O modules.
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Chapter 3 - Hardware
Routing and securing wires
Typically, field wiring is routed to connections at a terminal panel near
the racks, and then from the terminal panel to the terminal blocks on
the I/O modules.
Whatever method of routing is used, wiring must be mechanically
supported along its length, and must be protected from physical
damage and electromagnetic (noise) interference.
ATTENTION: All wires must be securely terminated, using
appropriate wiring practices.
Wire shield grounding
Aluminum grounding bars for I/O wiring are available as options.
When selected for use, they are fastened to the top and/or bottom of
each rack, as indicated in the following figure. To enable connection
of multiple ground wires with a single screw, the wires can be twisted
together and secured with a wire lug.
Figure 3-7: Wire-Shield Grounding
To facilitate module replacement, it is advisable in most cases to route
all wiring through either the top or the bottom of the terminal block.
This allows the terminal block to pivot up or down, allowing ready
access to the module, and is the preferred method for a limited
number of wires.
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Chapter 3 - Hardware
For more information about each I/O module wiring, see "Terminal
Block-to-Field (Signal) Wiring" in the ControlEdge 900 Platform
Hardware Planning and Installation Guide.
I/O network Topology
ControlEdge PLC can be configured as a redundant controller system
or non-redundant controller system. It includes provisions for
communication via Ethernet with host systems and the Ethernet ports
provide a layer of protection against cyberattacks. Honeywell
recommends use of Solarwinds and/or Honeywell Risk Manager to
detect unintended and excess network traffic.
ControlEdge PLC supports star and ring I/O topologies for I/O
communication.
Star Topology
The following diagram shows an example of the star topology. A
switch is required for this topology.
27
Chapter 3 - Hardware
Figure 3-8: Single star topology
28
Figure 3-9: Redundant Star topology
Chapter 3 - Hardware
CAUTION: ControlEdge PLC-I/O network is a private network, and
the switch used for the interconnection of CPM and EPM must
not be connected to any other LAN or WAN. Likewise, no devices
or communication traffic other than the ControlEdge PLC
components should be connected to the I/O network switch.
Failure to comply will cause communication failures on the I/O
network causing I/O modules to go in and out of their failsafe
settings.
29
Chapter 3 - Hardware
Ring Topology
The following diagram shows an example of the ring topology.
30
n CPM port 3 (ETH3) must be connected to CPM port 4 (ETH4) or
EPM port 2 (ETH2).
n CPM port 4 (ETH4) must be connected to CPM port 3 (ETH3) or
EPM port 1 (ETH1).
n EPM port 1 (ETH1) must be connected to EPM port 2 (ETH2) or
CPM port 4 (EHT4).
n EPM port 2 (ETH2) must be connected to EPM port 1 (ETH1) or
CPM port 3 (EHT3).
For more information, see “Planning for network topology” in the
ControlEdge 900 Controller Hardware Planning and Installation Guide.
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