Honeywell EXPERION PKS, EPDOC-X512-en-516A User Manual

EXPERION PKS

RELEASE 516

UOC User Guide

EPDOC-X512-en-516A

August 2020

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 2020 - Honeywell International Sàrl

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Contents			3
Chapter 1 - About this guide			12
1.1	Revision history		12
1.2	Related documents		12
1.3	Terms and definitions		15
Chapter 2 - Overview of UOC features			19
2.1	Native Experion Integration		19
2.2	ControlEdge 900 Form Factor		19
2.3	FTE Uplink Connectivity		20
2.4	Ethernet I/O Connectivity		20
2.5	ControlEdge 900		21
2.6	Field Device Manager		22
2.7	EtherNet/IP Connectivity to I/O, Devices, and Controllers		22
2.8	CEE Control Processing		22
2.9	Control Builder Strategy Configuration		22
2.10		I/O Points and I/O Reference Blocks	23
2.11		Simulation	23
2.12		Control Redundancy	23
2.13		Peer-To-Peer Communication	24
2.14		Alarms and Events	25
2.15		Time Synchronization	25
2.16		Security	25
2.17		Licensing	25
2.18		vUOC	26
Chapter 3 - Networking			29
3.1	Uplink FTE Network		29
3.2	Downlink I/O Network Topology		30
	3.2.1 HSR Ring Topology with 900 I/O		31
	3.2.2 Redundant Star (PRP) Topology with 900 I/O		34
	3.2.3 DLR Ring Topology with EtherNet/IP and 900 I/O devices		35
	3.2.4 Non-Redundant Star to 900 I/O and EIP Devices		38
	3.2.5 EtherNet/IP in Experion		40

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Chapter 4 - Installation		43
4.1	Hardware Considerations	43
4.2	Firmware Considerations	43
	4.2.1 Converting PLC CPM to UOC CPM	44
	4.2.2 Upgrading UOC CPM to New Firmware Version	48
	4.2.3 Upgrading UOC EPM to new Firmware Version	48
	4.2.4 Upgrading UOC UIOM to new Firmware Version	50
	4.2.5 Firmware and Software Upgrade Considerations for vUOC	51
	4.2.6 Additional Maintenance Activities in Firmware Manager	51
Chapter 5 - Configuration		52
5.1	Configuration Studio	52
5.2	Define and add assets in your enterprise model	52
5.3	Control Building	52
5.4	Specifying a Time Server	52
5.5	FTE Device Index	52
5.6	Creating UOC Platform block	53
	5.6.1 Method 1: Using the File Menu	53
	5.6.2 Method 2: Using the Project Assignment Panel	53
5.7	UOC Platform Block	54
5.8	Secondary UOC Platform Block	69
5.9	CEE Function Block	70
5.10 Configure UOC for Retention Startup		80
	5.10.1 Introduction	80
	5.10.2 Configure RETENTIONTRIG block	80
	5.10.3 Loading Retention Trigger Block	97
5.11 Configure ControlNet for UOC		103
5.12 Configure ProfiNet for UOC		104
5.13 Configuring DLR for UOC		104
5.14 Convert a non-redundant UOC to a redundant controller		106
	5.14.1 Prerequisites:	106
	5.14.2 To convert a non-redundant UOC to a redundant controller	106
5.15 Convert a redundant UOC to a non-redundant controller		107
	5.15.1 Prerequisites	107
	5.15.2 To convert a redundant UOC to a non-redundant controller	107

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	5.16 Licensing Model		107
		5.16.1 I/O Analog/Digital point(s) license	107
		5.16.2 Composite Device Point(s) License	108
		5.16.3 License Matrix	108
Chapter 6 - Load Configuration			110
6.1		About load operations	110
		6.1.1 Loaded versus project database versions	110
		6.1.2 Load initiation and load dialog box	110
		6.1.3 Load action with Compare Parameters function	111
		6.1.4 Load options for server history and server displays configuration	111
6.2		Initial load order guidelines	112
		6.2.1 Component deletion considerations	112
6.3		Load components from Project	113
		6.3.1 Loading UOC	113
		6.3.2 Loading CEE	115
		6.3.3 Loading I/OMs and CMs	117
6.4		Load With Contents command	117
6.5		Reloading components from project	117
6.6		Upload to the Monitoring database	118
Chapter 7 - ControlEdge 900 I/O Device Connectivity			119
7.1		CE900 IO in UOC	119
		7.1.1 Model numbers	120
		7.1.2 ControlEdge 900 IO Version Compatibility Matrix	120
7.2		UOC Configuration	121
7.3		Controller Rack	123
		7.3.1 Rules	123
		7.3.2 Creating Controller Rack	123
		7.3.3 Method 1: Using the CE900_I/O library	123
		7.3.4 Controller Rack Configuration	125
		7.3.5 I/OM Status Summary	125
7.4		I/O Rack (EPM)	126
		7.4.1 Rules	126
		7.4.2 Creating I/O Rack	127
		7.4.3 Hardware Information	127
		7.4.4 Soft Failures and Alarms	127
7.5		I/O Module	128
		- 5 -

7.5.1 Rules	128
7.5.2 I/O Module Creation	128
7.6 Channel	130
7.6.1 Rules and Behaviors	130
7.6.2 Channel Type Configuration	130
7.6.3 Channel Configuration and Status	133
7.6.4 Soft Failures and Alarms	135
7.7 I/O Module Configuration	139
7.7.1 Maintenance	139
7.7.2 Module Configuration/Monitoring Tabs	140
7.7.3 Common CE900 Module Configuration/Monitoring Tabs	141
7.7.4 CE900 UIO DI Channel NAMUR Configuration/Monitoring Tabs	145
7.7.5 CE900 UAI Module Configuration/Monitoring Tabs	146
7.7.6 CE900 DI32-24VDC Module Configuration/Monitoring Tabs	149
7.7.7 CE900 DO32-24VDC Module Configuration/Monitoring Tabs	151
7.7.8 CE900 DI16-VAC Module Configuration/Monitoring Tabs	153
7.7.9 CE900 DO08-VAC Module Configuration/Monitoring Tabs	155
7.7.10 CE900 DI16-DRYCT Module Configuration/Monitoring Tabs	156
7.7.11 CE900 DO08-RELAY Module Configuration/Monitoring Tabs	158
7.7.12 CE900 AO04 Module Configuration/Monitoring Tabs	160
7.7.13 CE900 AI16-100MS Module Configuration/Monitoring Tabs	162
7.7.14 CE900 AO08 Module Configuration/Monitoring Tabs	164
7.7.15 CE900 DI16-VACDC Module Configuration/Monitoring Tabs	166
7.7.16 UIO Namur Support	168
Chapter 8 - EtherNet/IP Device Connectivity	170
8.1 EtherNet/IP Device Configuration in UOC	170
8.1.1 Slot 0 Diagnostic Information	171
8.1.2 Slot 0 Configuration	172
8.1.3 Configuring the EtherNet/IP GenAdapter Block	173
8.1.4 Configuring the IP address of an EtherNet/IP device	179
8.1.5 Configuring I/O module blocks	179
8.1.6 Assigning EtherNet/IP devices to the CEE	181
8.1.7 Configuring I/O Ref blocks in CMs to access data from EtherNet/IP devices	181
8.2 Configuration Parameters for arrayed custom parameters	182
8.3 Configuration Parameters for scalar (non-arrayed) custom
parameters	186
8.4 Scaling support for Generic Device	187

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	8.4.1 Scaling Configuration Tab	187
	8.4.2 Configuration	188
	8.4.3 To view and modify the scaling parameters in EtherNet/IP generic device
	instances	188
	8.5 UOC and ControlLogix integration	189
Chapter 9 - UOC Node Redundancy Operation		191
	9.1 Redundancy configuration restrictions	191
	9.1.1 FTE Device Index	191
	9.2 Partner controller compatibility	191
	9.2.1 Redundancy compatibility result - RDNCMPT	192
	9.3 UOC 1-slot I/O rack	194
	9.4 Redundancy synchronization	194
	9.4.1 Synchronization states - RDNSYNCSTATE	194
	9.4.2 Enable Synchronization - ENBLSYNCCMD	195
	9.4.3 Disable Synchronization - DSBLSYNCCMD	195
	9.4.4 Auto-Synchronization State - RDNAUTOSYNC	195
	9.4.5 Inhibit Sync Reason - RDNINHIBITSYNC	196
	9.4.6 Initial Sync Progress - RDNSYNCPROG	198
	9.4.7 Maximum Initial Synchronization Time - RDNISTIMEMAX	198
	9.4.8 Last Synchronization Time - SYNCTIMEBEG	198
	9.4.9 Last Lost of Sync Time - SYNCTIMEEND	198
	9.4.10 Redundancy Traffic Rate	198
	9.4.11 Conditions that result in loss of sync	199
	9.4.12 Conditions that do not result in loss of sync	199
	9.5 Switchover and secondary readiness	199
	9.5.1 Become Primary command - BECMPRICMD	200
	9.5.2 Initiate Switchover - SWITCHCMD	200
	9.5.3 Max Switchover Time - RDNSOTIMEMAX	200
	9.5.4 Conditions that result in switchover	200
	9.5.5 Conditions that do not result in a switchover	201
	9.5.6 Network switchover considerations	202
	9.6 Redundancy history	202
Chapter 10 - Operation		203
	10.1 UOC States And Transitions	203
	10.2 UOC Front Panel Indications	206
	10.2.1 Ethernet Port LEDs	206
	10.2.2 Behaviors of Status and Redundancy Role LEDs	206
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10.2.3 Status LED		207
10.2.4 Redundancy Role LED		211
10.3	UOC Startup	212
10.3.1 Actions During Boot		212
10.3.2 Restart After Power Loss		214
10.3.3 vUOC States and Startup Behaviors		214
10.4	Using Station displays	214
10.4.1 Identifying UOC		215
10.4.2 UOC Controller Point Detail Display (Redundant)		215
10.4.3 UOC Controller Point Detail displays (NonRedundant)		219
10.4.4 vUOC Controller Point Detail displays		223
10.4.5 UOC-CPM (Local I/O) Racks		226
10.4.6 UOC-EPM Racks		227
10.4.7 UIO Racks		228
Chapter 11 - Troubleshooting		230
11.1	What to do when faults occur	230
11.2	Initial checks	230
11.3	Checking Control Builder error code reference	230
11.3.1 Checking faceplate LEDs		230
11.3.2 Using Firmware Manager to capture diagnostic data		231
11.3.3 Viewing release information log		231
11.3.4 Checking server point build log		231
11.3.5 Checking server point build error log		232
11.3.6 Checking error log		232
11.4	Fixing common problems	232
11.4.1 Loss of power		232
11.4.2 Power-On Self Test (POST) does not complete		232
11.4.3 Module does not complete startup		233
11.4.4 One or both FTE LEDs are OFF		234
11.4.5 FTE receive fault diagnostic		234
11.4.6 Controller does not synchronize with backup		236
11.4.7 Fatal ECC error		236
11.4.8 Isolated (lonely) Node		237
11.4.9 Duplicate Device Index detection		238
11.5	UOC Controller soft failures	239
11.6	Additional status and fault messages	245
11.6.1 Redundancy-related notifications		245
	- 8 -

11.6.2 OPM-related notifications - RDNOPMSTATUS parameter		245
11.7	Online diagnostics	245
11.8	Fault classifications	246
11.8.1 Hard/Severe Failures		248
11.8.2 UOC Redundancy Communication Issues if CPM is not securely connected
to the rack		249
11.8.3 Soft Failures		249
11.8.4 Installation-Startup Failures		250
11.8.5 Hardware Watchdog Timer Expired		250
11.8.6 Communications Failure		250
11.9	Communications and system time faults during startup	250
11.9.1 Non-redundant UOC Controller		251
11.9.2 Redundant Primary UOC Controller		252
11.9.3 Secondary UOC Controller		254
11.10 Gathering information for reporting problems to
Honeywell		257
11.11 Guidelines for requesting support		257
Chapter 12 - Control Execution Environment		258
12.1	Functional Highlights	259
Chapter 13 - vUOC		260
13.1	Introduction	260
13.1.1 vUOC controllers with Private Path and Downlink I/O adapters		260
13.1.2 Flat Network Downlink I/O Topology		261
13.1.3 VLAN Tagged Network Downlink I/O Topology		262
13.1.4 Network Downlink I/O Topology		263
13.2	Guidelines for integration of virtual controllers	264
13.3	Creating Network Connections	265
13.3.1 Creating a Standard vSwitch		266
13.4	Defining Port Groups	272
13.4.1 Adding a Port Group to a Standard vSwitch		272
13.5	Physical network support for VLAN topologies	276
13.5.1 First level Switch configurations		276
13.5.2 Downstream Switch configurations		278
13.5.3 I/O Device Port configurations		280
13.5.4 Control Edge 900 IO and Switch Configurations		281
13.6	Download	282

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13.7	vUOC Deployment	282
13.7.1 Reconfigure Network Assignments		289
13.8	vUOC Provisioning (first-time start up only)	290
13.9	vUOC Configuration and Usage	293
13.10 vUOC and Virtualization Host Maintenance		293
13.11 vUOC and Virtualization Host Availability		296
13.11.1 Turning on Fault Tolerance protection for vUOC		296
13.11.2 Disabling Fault Tolerance protection for vUOC		298
Chapter 14 - Performance and Capacity Considerations		300
14.1	Key Specifications	300
14.2	Managing Processing Load	302
14.2.1 Relevant Parameters		302
14.2.2 Overall Load Limits		303
14.2.3 Cycle Overruns		304
14.2.4 CPU Free		304
14.2.5 Redundancy Throughput		305
Chapter 15 - Security Guidelines for UOC		306
15.1	General	306
15.2	Organizational Security	306
15.3	Physical Security	306
15.4	Communication Hardening	307
15.5	Securing Connection to Uplink Network	307
15.6	Securing Connection to Downlink Network	307
15.7	Maintenance, Configuration and Operation	308
15.8	Third Party Configuration Files	308
15.9	Third Party Firmware Files	308
15.10 Private Redundancy Network Path		308
15.11 Patch Management		309
15.12 Backup/Recovery Capability		309
Chapter 16 - Configuring a Secure Connection for Experion Integration		310
16.1	Secure Communications	310
16.1.1 Secure Communication System Planning		312
16.1.2 Configure and Setup Steps		312
16.1.3 Advanced Technical Information		313
	- 10 -

16.1.4 Certificate Management		313
16.1.5 Secure Communications using IPSec		313
16.1.6 Secure Commuincations Using TLS		314
16.1.7 Secure Boot		314
16.2	Obtaining and Installing the software	314
16.3	Overview of an IPSec deployment	315
16.4	Set Enrollment Information	316
16.5	Creating the Certificate Authority	316
16.6	Creating a certificate for Engineering Station and Console	320
16.6.1 Creating a certificate		321
16.6.2 Importing certificate and private key on target machine		322
16.7	Configure ControlEdge UOC for use with IPSec	329
16.7.1 Installing Certificate Manager Configuration Console		329
16.7.2 Setup certificates and IPSec policy in UOC		338
16.8	Configuring IPSec to secure traffic to the UOC	347
16.8.1 Configure and Activate Security Policies		347
16.8.2 Enable IPSec policy on PCs		347
16.8.3 Disable IPSec policy on Engineering Station/Console		351
16.8.4 Enable IPSec policy rules in the UOC		351
16.8.5 Disable IPSec policy rules in the UOC		353
16.9	Backup and Restore of CA	355
16.9.1 Backup		355
16.9.2 Restore		361
16.10 Renewal and revocation of certificates		365
16.10.1 CA Root certificate		365
16.10.2 Renewing the CA Root certificate		366
16.10.3 PC certificates		367
16.10.4 Revocation		367
16.10.5 UOC certificates		370
16.10.6 Revocation		370
16.11 Troubleshooting		370
16.11.1 How to reset UOC for IPSec configuration?		370
16.11.2 How to reset IPSec configuration on Windows?		371
16.11.3 Diagnosing IPSec with Network Analysis Software		371
16.11.4 If CMCC upload a large number of policies, the read data from the
transport connection can not be received		371

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CHAPTER

1 ABOUT THIS GUIDE

1.1Revision history

Revision	Date	Description
	August 2020
A		Initial release of the document.

1.2Related documents

The following list identifies publications that may contain information relevant to the information in this document. You can find these documents on https://www.honeywellprocess.com/en- US/support/pages/all-documentation.aspx.

- 12 -

Chapter 1 - About this guide

Document	Description
Firmware	This document describes the tool used for loading
Manager User	firmware to hardware modules of the UOC system and for
Guide_EPDOC-	uploading diagnostics information from them.
X470.pdf
Hardware	This document describes hardware components and
Planning and	related installation practices for the ControlEdge 900
Installation	family of controller hardware.
Guide_HWDOC-
X430-en-H.pdf
Virtualization	This guide provides high-level guidance on how to
Planning and	implement a virtualized Experion environment.
Implementation
Guide_EPDOC-
X147-en-A.pdf

EtherNet_IP_ Users_Guide_ EPDOC-X399- en-511A.pdf

Fault_Tolerant_

Ethernet_

Overview_and_

Implementation_

Guide_EPDOC-

XX37-en-511.pdf

Fault_Tolerant_ Ethernet_ Installation_and_ Service_Guide_ EPDOC-XX36- en-511A.pdf

This document provides an overview of the use of EtherNet/IP™ communications with level 1 Experion control systems and offers practical guidance to perform a successful integration of EtherNet/IP with Experion.

This guide contains basic installation instructions and configuration requirements for an FTE network and its components. Detailed network planning and requirements information is not included as this type of information is site-specific.

This document provides instructions for installing and servicing the Fault Tolerant Ethernet Mux driver.

Network_and_ Security_ Planning_Guide_ EPDOC-XX75- en-511B.pdf

Switch_

Configuration_

Tool_Users_

Guide_EPDOC-

X246-en-

This document contains networking and security-related information applicable to Experion. It provides information about the recommendations to assist you in planning, setting up, and maintaining a secure environment for your system.

This guide describes the user interface of the Switch Configuration Tool and provides an overview for configuring switches using the tool. It describes the tasks to create new switch configuration, open an existing switch configuration, generate text files from the switch

- 13 -

	Chapter 1 - About this guide
Document	Description
511A.pdf	configuration, and load the new switch configurations to
	the switches. It also briefly describes creating and saving
	projects using the tool.
Control Builder	This guide provides detailed information on the
Components	functionality of Control Builder and the function block
Theory_EPDOC-	libraries it is used to configure. It does not cover
XX16-en-	ControlEdge hardware modules such as the Control
511A.pdf	Processor Module (CPM) or Input / Output Modules
	(I/OMs).
Control Building	The procedures in this guide are intended to give you the
User’s Guide_	ability to perform basic tasks within the Control Builder
EPDOC_XX19_	application such as configuring hardware devices,
en-511A.pdf	continuous control strategies, and sequential control
	strategies. Only representative forms are shown to
	illustrate a procedure/concept.
Control Builder	This guide provides information about parameters
Parameter	associated with configuration forms of function blocks in
Reference	Control Builder.
Guides_EPDOC-
XX18-en-
511A.pdf

Control_Builder_ Components_ Reference_ EPDOC-XX15- en-511.pdf

This document provides a brief technical reference of function blocks configured through Control Builder.

Engineering Data Builder (EDB) User’s Guide- EPDOC-X417- en-511A.pdf

The Engineering Data Builder (EDB) add-in is a productivity enhancement tool integrated with the Control Builder.

EDB add-in deploys customized, reusable, and extensible spreadsheets, allowing project engineers to save time in updating configuration.

Virtualization	This guide gets you started with the Honeywell Premium
with the	Platform for Experion Virtualization Solutions.
Premium
Platform
EPDOC-X455-
en-B.pdf

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Chapter 1 - About this guide

1.3Terms and definitions

Term	Definition
AI	Analog Input
AO	Analog Output
CA	Certificate Authority
CBR	Class Based Recipe
CDA	Control Data Access
	It is the Experion system communication infrastructure and data
	access interface schema that provides application integration
	with Experion system objects.
CEE	Control Execution Environment
CIP	Common Industrial Protocol
	An industrial communication protocol now maintained as a
	standard by the Open Device Venders Association (ODVA).
Cleartext	Data that is stored or transmitted unencrypted
CM	Control Module
CMCC	Certificate Manager Configuration Console
Consolidate	A single connection used to group multiple I/O modules, instead
Connections	of one connection per I/O module.
	Also referred to as Assembly connections, Rack connections,
	Gateway connections.
ControlEdge	A family of controller hardware which can be assembled to create PLC or UOC
900	systems.
CPM	Control Processor Module (also commonly referred to as
	controller)
DI	Digital Input
DLR	DLR is a link layer protocol for establishing a form of ring
	redundancy on an Ethernet network.
DO	Digital Output
Downlink	Shorthand term use to refer to one of two possible types of I/O
	and device network that a UOC controller connects to.
EDB	Engineering Data Builder
EDS	Electronic Data Sheets

- 15 -

Chapter 1 - About this guide

Term Definition

Files which define the communication properties of devices capable of connecting to EtherNet/IP networks.

EtherNet/IP EtherNet/IP™

EPM	Expansion Processor Module
	Ethernet communications module connecting distributed racks
	of ControlEdge 900 I/O modules to the CPM.
ETAP	EtherNet/IP™ Tap
	A type of switch that allows a device incapable of supporting the
	DLR redundancy protocol to form a non-redundant connection
	into a DLR ring.
Expansion	I/O rack with EPM installed
I/O rack
FDM	Field Device Manager
FTE	Fault Tolerant Ethernet
GTAC	Global Technical Assistance Center
HART	Highway Addressable Remote Transducer
HMI	Human Machine Interface
HPS	Honeywell Process Solutions
HSR	HSR (High Availability Seamless Redundancy) is a link layer
	protocol for establishing a form of ring redundancy on an
	Ethernet network. HSR is referred to as “Ring-HSR” in the UOC
	platform block configuration form.
HW	Hardware
IIS	Internet Information Services
IKE	Internet Key Exchange
I/O	Input/Output
IP	Internet Protocol
IPSec	Internet Protocol Security
LEAP	Lean Engineering of Automation Projects
Local I/O	I/O rack with Control Processor Module installed (non-
rack	redundant)
NIC	Network Interface Controller
NTP	Network Time Protocol

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Chapter 1 - About this guide

Term	Definition
NVS	Non-Volatile Storage
ODVA	Open Device Venders Association
OTP	One Time Password
OWD	Open Wire Detected
PC	Personal computer
PCCC	Programmable Controller Communications and Commands
PCDI	Peer Control Data Interface
PLC	Programmable Logic Controller
Peer Server	Data sourcing service provided by the Experion Process Server
Responder	node which allows controllers like the UOC to access any data
	presented by the Server’s data points via peer communication
	over the supervisory network.
PRP	Parallel Redundancy Protocol is a link layer protocol for
	establishing a form of dual-path redundancy on an Ethernet
	network. PRP is also referred to as “Star-PRP”.
PSM	Power Status Module
PSU	Power Supply Unit
PTP	Precision Time Protocol PTP
	IEEE-1588
	It is a standardized internet networking protocol used for
	synchronizing computer clock times in a distributed network of
	computers. PTP provides higher precision than NTP. The UOC
	supports time synchronization by either NTP or PTP on its uplink,
	FTE network.
P&ID	A diagram representing the Process and Instrumentation Design
Diagram	of a plant or plant unit.
PWA	Printed Wiring Assembly
RCM	Recipe Control Module
Redundancy	A network switch that allows another device to connect into a
Box	ring topology even if the device itself cannot natively handle the
	ring redundancy protocol.
Redundant	ControlEdge 900 rack capable of hosting a redundant pair of
Controller	CPMs.
Rack
Redundancy	Module used with a CPM within a 1 I/O Slot Rack to implement

- 17 -

Chapter 1 - About this guide

Term	Definition
Module	Dual Rack Redundancy.
(RM)
SCM	Sequence Control Module
SD Card	Secure Digital Card
SW	Software
TCP	Transport Control Protocol
TLS	Transport Layer Security
UI/O	Universal Input/Output Module
UCM	Unit Control Module
	It is a container that represents a piece of or logical grouping of
	physical equipment. A Recipe may be configured to acquire a
	UCM before its procedure can be executed. A UCM can also be
	used as an auxiliary resource.
UOC	Unit Operations Controller
	This is a term used to refer to the CPM when used as a controller
	in the Experion PKS Distributed Control System.
Uplink	Shorthand term used to refer to the supervisory Ethernet
	network that the UOC controller connects to within an Experion
	system.
UPS	Uninterruptable Power Supply
Users	Human Actors
User Goals	What users are hoping to achieve at a high level and why. Independent of
	system implementation. Should be able to be linked to stakeholder business
	goals and SRS use cases.
User Scenarios	Specific examples that elaborate on user goals in a context. Told in the form of
	stories. Independent of system implementation.
vUOC	Virtual Unit Operations Controller

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CHAPTER

2 OVERVIEW OF UOC FEATURES

The Unit Operations Controller (UOC) is a high value, low cost, rack-based process controller that can be applied to any process control application in any industry. Its form factor, cost profile and licensing model make it especially well-suited to industries that prefer to limit the scope of a single controller to a single process unit, and to industries that require powerful batch enablers.

The UOC is paired with a virtualized controller called the virtual Unit Operations Controller (vUOC).The vUOC provides a set of functions parallel to those of the UOC except that they are deployed within a server hosted virtual machine.

Summary descriptions of UOC and vUOC features are presented within this section. Additional details may be found elsewhere within this document and within the overall Experion document set.

2.1Native Experion Integration

UOC integrates natively into the Experion DCS in a fashion parallel to that of existing controllers such as the C300 and C200E. It uses the same CEE (Control Execution Environment) control solver as those controllers. Experion Fault Tolerant Ethernet provides redundant, level 2 communications to the UOC. Engineering Station, Direct Station and Flex Station nodes all provide view of UOC parameter and alarm data via Experion native Control Data Access (CDA) protocol. Communication, monitoring, displays, trending, historizing, advanced applications, batch applications, configuration and field device management all work with the UOC controller in a fashion equivalent to that of existing CEE controllers.

2.2ControlEdge 900 Form Factor

UOC control algorithms and I/O communications processing run in a family of rack-resident modules called ControlEdge 900. ControlEdge can be used to deploy high density control and I/O installations meeting all environment and agency certification requirements with no restriction as to cabinet type.

In addition to the UOC, components of the ControlEdge HW family can be used to deploy the ControlEdge PLC, without the need to deal with a completely different component family.

The main components of UOC HW are listed here.

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Chapter 2 - Overview of UOC features

Component	Description
CPM	Control Processor Module
	Referred to as UOC-CPM.
	Host processor of control and communications supporting
	redundant and non-redundant configurations. Provides two
	uplink Ethernet ports for connectivity to FTE. Provides two
	downlink Ethernet ports for connectivity to an I/O and device
	network.
EPM	Expansion Processor Module
	Ethernet communications module connecting distributed racks
	of ControlEdge 900 I/O modules to the CPM.
UI/OM	Universal Input / Output Module
	16 channel I/O module with universal channels which can be
	configured as AO, DI or DO. Channels configured as AO support
	HART protocol.
I/O Racks	Five possible non-redundant racks which hold an EPM or a non-
	redundant CPM together with 1, 4, 8 or 12 I/O Modules. Three of
	the racks accommodate non-redundant power supplies. The 8
	and 12 slot racks are available with redundant power supplies
	and a power status module.
Redundant	Redundant controller racking supporting two power supplies and
CPM Rack	two CPM slots.
Power	AC or DC power supply modules and power status module.
System

Detailed information on the installation, planning and general characteristics of ControlEdge 900 HW components can be found in ControlEdge 900 Platform Hardware Planning and Installation Guide_HWDOC-X430.pdf.

2.3FTE Uplink Connectivity

UOC connects to a redundant FTE supervisory network via its uplink Ethernet ports (port #1& port #2). UOC hosts a full featured firewall allowing it to securely connect directly to level 2, FTEqualified, third party switches. UOC deployments do not require connectivity to FTE through a separate firewall.

Beginning with Experion R510.2, the vUOC connects to a redundant FTE supervisory network via its uplink Ethernet ports (virtual switches). A software-based firewall is included allowing a secured connection directly to Level 2, FTEqualified, third party switches.

2.4Ethernet I/O Connectivity

UOC connects to an I/O and device network via its two downlink Ethernet ports (port #3 & 4).

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Chapter 2 - Overview of UOC features

Multiple application-dependent typologies are supported with two configurable options:

•When only ControlEdge 900 I/O racks are connected, a native ring redundancy based on the High Availability Seamless Redundancy (HSR) protocol may be used, a star redundancy based the Parallel Redundancy Protocol (PRP) may be used or a non-redundant star may be used.

•When ControlEdge 900 I/O racks are used together with 3rd party EtherNet/IP devices, a ring redundancy based on Device Level Ring (DLR) may be used or a non-redundant star may be used.

2.5ControlEdge 900

ControlEdge PLC supports various input/output modules. The following I/O modules are included:

Module Type	Model Number
UI/O module	900U01-0100
UAI module	900A01-0102
DI 24VDC module	900G32-0001
DO 24VDC module	900H32-0102
DI High Voltage AC	900G03-0102
DO High Voltage AC	900H03-0102
AI16-100MS (High Level Analog Input, 16 Channels)	900A16-0103
AO04-500MS (Analog Output, 4 Channels)	900B01-0101
AO08-500MS (Analog Output, 8 Channels)	900B08-0202
DI16-DRYCT (DI - 16ch Dry Contact Type)	900G01-0102
DI16-VACDC (DI - 120/240 VAC, 125 VDC (16ch-Iso))	900G04-0001
DO08-RELAY (Digital Output Relays, 8 Channels)	900H01-0102

Additional I/O modules will be made available in future releases of the Experion PKS.

NOTE : For Module AI16-100MS, the Model Number should be 900A16-0103 and the firmware version should be 1.39 for the 100 ms scan rate support.

For below IO modules, there can be Model number mismatch between the IO module hardware and the IO module reports.

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Chapter 2 - Overview of UOC features

	Module Description	Model	Module Number report by the IO
		Number	Module
	Analog Output, 0 to 20mA, (4	900B01-	900B01-0101
	channel)	0301
	Digital Input, Contact type, (16	900G01-	900G01-0102
	channel)	0202
	Digital Output, Relays (8	900H01-	900H01-0102
	channel)	0202

2.6Field Device Manager

UOC supports integration with Experion Field Device Manager (FDM) for management of smart field instruments. The FDM can view and manipulate the digital HART variables of field instruments through the analog channels of UOC’s UI/OM.

The ability of UOC itself to access digital HART variables via a Field Device Server hosted on the Engineering Station will be introduced in a future release.

2.7EtherNet/IP Connectivity to I/O, Devices, and Controllers

UOC supports control through third party I/O and devices connected by the EtherNet/IP protocol on its Ethernet downlink.

A set of EtherNet/IP devices come preinstalled and ready for instantiation within Experion Control Builder. This includes Rockwell Allen Bradley’s ArmorPoint I/O, ArmorBlock I/O, PowerFlex Drive and E3 Relay.

Support for other EtherNet/IP I/O and EtherNet/IP device types can be integrated by projects personnel without dependence on a new Experion release through the use of Experion Control Builder’s Parameter Definition Editor (PDE).

Also supported are User Defined Type (UDT) blocks which enable UOC to communicate over its downlink via EtherNet/IP with Rockwell Allen Bradley’s ControlLogix.

2.8CEE Control Processing

UOC hosts the well-proven Control Execution Engine (CEE) strategy solver used in existing Experion controllers. CMs (Control Modules) are fully supported for continuous control strategies. SCMs (Sequential Control Modules), UCMs (Unit Control Modules), RCMs (Recipe Control Modules) and CBRs (Class Based Recipes) are fully supported for batch control strategies.

2.9Control Builder Strategy Configuration

Like all CEE controllers, UOC’s control strategies are configured using Experion Control Builder.

Control Builder offers a rich set of tools for the creation of strategies to control continuous, discrete and batch processes. Strategies may be created as individual instances or as replicable templates. Bulk creation of UOC control strategies is supported through Experion’s Engineering Data Builder (EDB) add-on to Control Builder. EDB allows application engineers to create large configurations using an efficient, spreadsheet-driven workflow.

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Chapter 2 - Overview of UOC features

2.10I/O Points and I/O Reference Blocks

UOC supports binding of I/O to control through a mechanism that allows the configuration of one to be independent of the other. UOC I/O points may be introduced into the system independent of UOC control strategies. UOC control strategies may be configured and tested independent of their corresponding I/O.

This independence is achieved through two kinds of function blocks supported by Control Builder and by CEE.

• I/O Points

oI/O Points are Experion tagged blocks representing the device connected to the UOC through an input or output channel of an I/O module.

oThey are typically tagged with the same name (up to 40 characters) that labels the device in a P&ID diagram.

o They serve as a connection target that binds a control strategy to an I/O channel.

oThey allow the binding to be made by name, without constraining the strategy to work with the particular channel of a particular I/O Module.

oThey allow the configuration of the I/O Module to be separated from the configuration of the control strategy.

o They can be created before or after the corresponding control strategy.

oIn addition to I/O channels, they can be used to represent key parameter data which do not correspond to actual I/O channels.

• I/O Reference Blocks

oI/O Reference Blocks are basic blocks instantiated in Control Modules to make an I/O signal available for connection to algorithm blocks.

oThey are bound to I/O Points though named references independent of particular channels in particular I/O Modules.

oThey support a simulation mode that allows for strategy checkout to be done in the absence of I/O Modules.

oThey complement I/O Points by serving as the reference end of the connection to the I/O Point.

oIn addition to referencing I/O channels, they can be used to reference key parameter data which do not correspond to actual I/O channels.

UOC’s I/O Points and I/O Reference Blocks provide key enablers of the Lean Execution of Automation Projects (LEAP) methodology supported by Experion.

2.11Simulation

UOC may be used for both control and strategy-check-out simulation without the need to deploy a special purpose simulation application. Simulation behaviors of strategies are controlled through the SIMMODE parameter of I/O Reference blocks within the Control Module under test.

2.12Control Redundancy

UOC optionally supports redundant control operation. Single Rack Redundancy is provided through a single rack scheme where the partner CPMs are placed in the same rack along with power supplies. The power supplies in a single rack scheme do not provide REDUNDANT power: The left power supply provides power to the CPM mounted in the left slot. Likewise, the right power

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Chapter 2 - Overview of UOC features

supply provides power to the CPM mounted in the right slot.

Switchover from the active primary to the backup controller may be commanded manually. If a fault occurs, the failed primary is detected automatically by virtue of comprehensive diagnostics, leading to automatic switchover. Switchover occurs within 500 milliseconds in order to ensure a seamless transition, preserving all configuration data and live data, and with no disturbance to outputs.

Dual Rack Redundancy is provided through 2 separate 1 I/O slot racks each with a power supply and a Redundancy Module . Refer to the ControlEdge 900 Platform Hardware Planning and Installation Guide_HWDOC-X430.pdf for additional information.

2.13Peer-To-Peer Communication

UOC supports multiple forms of peer-to-peer communication across its uplink FTE connection.

• Control Data Access (CDA)

UOC uses Experion native CDA protocol for communication with peer partners as well as level 2 server and station nodes. Parameter reads are supported under a cyclic publication paradigm. Parameter writes are supported under an acyclic store paradigm.

Within CMs and SCMs, the configuration of peer references is transparent to the application engineer. They are specified by configuring fully qualified parameter names such as “TT101.DATAACQ.PV” in expressions, inputs pins or selected output pins, without concern as to whether the parameter is in the same UOC or in a different controller.

UOC’s CDA peer connections may also be used to reference data from SCADA points by virtue of Experion Peer Server Responder capability.

The Experion node types with which UOC supports CDA peer-to-peer communication are listed in the following table. This set will be expanded in future releases.

Responding Node		UOC		vUOC		C200E	C200
Initiating Node
					C300
UOC
		ü		ü	ü	ü	ü
vUOC
		ü		ü	ü	ü	ü
C300
		ü		ü	ü	ü	ü
ACE
		ü		ü	ü	ü	ü
C200E
		ü		ü	ü	ü	ü
C200		Note1		Note1
					ü	ü	ü

NOTE 1: The C200 controller can respond to CDA peer communications from a UOC or vUOC but cannot initiate them.

• Exchange Blocks

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Chapter 2 - Overview of UOC features

UOC supports a library of blocks which enable communication with third party PLCs and devices via protocols which were originated by Rockwell Allen Bradley and now support transport over Ethernet. Blocks within the EXCHANGE library allow initiation of and response to read and write requests for flags, numeric and string arrays. EXCHANGE blocks support two protocols: the Common Industrial ProtocolTM (CIP) and Programmable Controller Communication Commands (PCCC).

• PCDI Blocks

UOC supports a library of blocks called Peer Control Data Interface (PCDI) which enable communication with third party PLCs and devices via the Modbus TCP/IP protocol. Blocks within the PCDI library allow initiation of read and write requests through a device proxy block to flag, numeric and string arrays in a Modbus-capable peer controller.

2.14Alarms and Events

UOC supports a comprehensive set of alarm and event reporting capabilities that integrate seamlessly with Experion enablers for the display and historization of alarms and events. Supported notification types include high, low and rate of change process alarms, state change process alarms, state change system events, diagnostic events and batch events.

2.15Time Synchronization

UOC maintains an internal clock which is synchronized with external wall clock time. Synchronization can be maintained over the uplink network using either the Network Time Protocol (NTP) or the Precision Time Protocol (PTP). All alarms and events reported by UOC are issued with synchronized time stamps.

2.16Security

UOC has built in enablers to provide for the secure and robust operation of its control and I/O configurations. This includes an uplink firewall that limits message types to those appropriate to the mission of the FTE network. It includes a downlink firewall that limits message types to those appropriate to the missions of 900 I/O and EtherNet/IP communication. UOC also supports mechanisms of signed firmware and secure boot which insure only Honeywell authorized firmware to be executed within the device.

2.17Licensing

UOC systems are delivered under a licensing model which allows HW and SW components to be deployed in the manner that most naturally fits the process control problem to be solved. Indirect cost penalties for good design practices are avoided. The bulk of the cost associated with deploying a UOC system is proportional to the count of Analog and Digital I/O points put into service. There is little additional cost if a good design dictates the deployment of small, per unit controllers. Similarly, there is little additional cost if the design dictates the deployment of small, modularized control strategies.

For more information on Licensing refer to LicensingModel section.

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Chapter 2 - Overview of UOC features

2.18vUOC

As noted above, the virtual UOC provides a set of functions nearly equivalent to those provided by the ControlEdge 900 based UOC. It is well suited to supervisory batch applications, lab applications and control strategy checkout before strategies are deployed to a ControlEdge UOC

Differences between the two are driven by the nature of their hosting platforms and, to a certain extent, by particular strengths that their respective deployments provide. Key differences are highlighted by the following table.

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				Chapter 2 - Overview of UOC features
Attribute	UOC		vUOC		Comment
Host	•	Runs on the	•	Runs as a
Platform		purpose-		virtual
		built,		machine on
		industry		general
		hardened,		purpose PC
		ControlEdge		servers
		CPM
Base Period	•	50 ms	•	50 ms or	A second vUOC variant
				500 ms	supports a slower base
					cycle in addition to the
					50 ms base cycle
					parallel to the UOC.
					The slower variant
					allows the vUOC to be
					applied as a very large
					batch supervisor
					managing UOCs or
					C200Es serving as
					equipment controllers.

User	•	32 MB	•	32 MB in
Memory				the 50 ms
Capacity				variant
			•	128 MB in
				the 500 ms
				variant
Control	•	Transparent	•	Not
Redundancy		redundancy		currently
		support		supported
		based on
		proprietary
		enablers

The 500 ms variant of the vUOC supports a user memory database 4 X that of the UOC as an additional enabler of large supervisory batch configurations.

The vUOC has no native redundancy enablers, but as an alternative, it can optionally be deployed in virtual platforms that provide high availability solutions.

Support In	• Runs on	• Can run	One of the key
VEP	purpose-	within HPS’	deployments of the
	built HW and	Virtual	vUOC is as a simulator
	cannot run	Engineering	within VEP to support
	within HPS’	Platform	early application
	Virtual		development.
	Engineering
	Platform

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Chapter 2 - Overview of UOC features

Users familiar with the Experion portfolio of controllers and simulators may be tempted to interpret the vUOC in terms of things they are already familiar with. There are indeed similarities that can be noted. But there are also significant differences which prevent vUOC from being equated with previous offerings. This point is highlighted by the following table.

Attribute	UOC	vUOC	C300	SIM-	ACE	SIM-
				C300		ACE
Hosting on Server	No	Yes	No	Yes	Yes	Yes
Direct I/O Connectivity	Yes	Yes	Yes	No	No	No
Deployment as Controller	Yes	Yes	Yes	No	Yes	No
Deployment as Simulator	Yes	Yes	No	Yes	No	Yes
Simultaneous Control and	Yes	Yes	No	No	No	No
Simulation

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CHAPTER

3 NETWORKING

3.1Uplink FTE Network

UOC and vUOC are deployed within Experion systems by connecting their uplink Ethernet ports to a Level 2 FTE network. Of the two parallel tree networks that comprise an Level 2 FTE installation, the ETH1 port connects to the A or Yellow tree while ETH2 connects to the B or Green tree.

FTE connectivity is summarized in the following diagram which shows a non-redundant UOC rack and a virtual machine server for a vUOC in the context of the following Experion nodes.

•Experion Process Server

•Experion Direct Station (ES-C)

•Experion Flex Station (ES-F)

•ACE

•Terminal Server

•Domain Controller

Figure 3.1 UOC Network Connectivity (Uplink FTE Network)

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Chapter 3 - Networking

UOC utilizes an existing FTE network, native to Experion PKS. It has a dual connection to Level 2 Yellow and Green FTE switches. No third party firewalls are required.

The number of levels of FTE switches above the UOC may be one, as shown in the diagram above, two or three.

vUOC’s deployment within an FTE network follows Experion guidance for virtual machines. For further information, see the vUOC section in this document.

Like existing CEE controllers, UOC requires the presence of a Process Server to function within an Experion system.

When connecting to FTE, the UOC CPM gets its IP address from the Experion BOOTP service running on the Engineering Station node. Its IP address is constructed by combining the CPM’s FTE Device Index with the subnet base address configured through Control Builder and known to the BOOTP server. Rotary switches of the UOC CPM are located on the module and are used to set the FTE Device Index. They must be set before the module is inserted into its slot.

ATTENTION

Ensure that the Device Index is set before you place a module in a rack.

Note that, in the special circumstance that a PLC CPM received from the factory is being converted to a UOC CPM, considerations on IP addressing are different initially. For further information on converting a PLC CPM to a UOC, see the ConvertingPLCCPMto UOCCPM section.

Care must be taken in the assignment of FTE device indices to a UOC’s rotary switches. In a redundant controller rack, the left hand UOC must be assigned an odd numbered device index while the right hand UOC must be assigned an odd + 1 device index. The odd + 1 position is reserved and must not be used for other than redundant partner. Non-redundant UOCs must always be assigned odd numbered device indices. For more information on how to set the FTE device index see the FTE Device Index section.

The L2 FTE switches to which UOC connects are managed switches which must be configured using the FTE Switch Configuration Tool. Any ports to which UOCs connect must be configured as “Other Auto” using this tool. For further information on the FTE Switch Configuration Tool, see the

Switch Configuration Tool Users Guide_EPDOC-X246-EN-511A.pdf.

Except for specific considerations noted within this document, all FTE installation and maintenance practices for the UOC and vUOC must be done in a fashion consistent with Experion and FTE guidelines. For further information, see Fault Tolerant Ethernet Overview and Implementation Guide EPDOC-XX37-en-511A.pdf, Fault Tolerant Ethernet Installation and Service Guide EPDOC-XX36-en-511A.pdf, and Network and Security Planning Guide EPDOC-XX75-en- 511A.pdf.

3.2Downlink I/O Network Topology

UOC supports direct connectivity to an I/O network through its downlink Ethernet ports, ETH3 and ETH4.

The table below provides a description of various downlink topologies supported.

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