Whitepaper

Connectivity Options between Honeywell and DeltaV Systems

February 2009Page 1

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Connectivity Options between Honeywell and DeltaV Systems

This paper describes the methods of implementation and the benefits of preparing an existing Honeywell legacy
system to connect with a DeltaV system.

Emerson Process Management 19962009. All rights reserved.

Page 1

For Emerson Process Management trademarks and service marks, go to http://www.emersonprocess.com/home/news/resources/marks.pdf

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are
not to be construed as warrantees or guarantees, express or implied, regarding the products or services described herein or their use or applicability.
All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the design or
specification of such products at any time without notice.

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Connectivity Options between Honeywell and DeltaV Systems
February 2009Page 2

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Contents
Introduction ----------------------------------------------------------------------------------------------------------------------------------4
Connecting -----------------------------------------------------------------------------------------------------------------------------------4
OPC For Data Exchange -----------------------------------------------------------------------------------------------------------------5
Serial Interface ------------------------------------------------------------------------------------------------------------------------------6
DeltaV Connect Solution for Honeywell Systems --------------------------------------------------------------------------7
FlexConnect Solutions Save Device Wiring, Minimize Down Time --------------------------------------------------------9
FOUNDATION Fieldbus for LEPIU ------------------------------------------------------------------------------------------------------ 12
Profibus DP for TDC 2000 and TDC 3000 Discretes -------------------------------------------------------------------------- 12
Transition Services ---------------------------------------------------------------------------------------------------------------------- 13
Conclusion --------------------------------------------------------------------------------------------------------------------------------- 16

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List of Figures
Figure 1DeltaV to TDC 2000 Connectivity Options ............................................................................................... 4
Figure 2DeltaV to TDC 3000 Connectivity Options ............................................................................................... 5
Figure 3OPC Connectivity between DeltaV and Honeywell Systems ................................................................... 6
Figure 4DeltaV Connect Solution for Honeywell Systems directly connects to the LCN ...................................... 8
Figure 5DeltaV FlexConnect Solutions for Honeywell TDC 2000 and TDC 3000............................................... 10
Figure 6LEPIU Replacement Solution with Rosemount 848T to DeltaV H1 Card .............................................. 12
Figure 7DeltaV Profibus DP to TDC 2000 Discrete I/O ....................................................................................... 13
Figure 8DeltaV Profibus DP to TDC 3000 Discrete I/O ....................................................................................... 13
Figure 9US-style Faceplate and Detail Displays on DeltaV Graphics................................................................. 14
Figure 10GUS-style DeltaV faceplates ................................................................................................................ 14
Figure 11DeltaV User-configurable Operator Keyboard ..................................................................................... 15
Figure 12DeltaV Consoles with Operator Keyboard............................................................................................ 15

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Introduction
Honeywell TDC 2000 and TDC 3000 systems have provided excellent control for many years. However, the aging
components of these systems are mostly obsolete and often unavailable to many users. Maintenance programs
(such as SE&SP) are costly without necessarily satisfying your needs and these costs may outweigh benefits of
keeping the legacy system. Struggling with basic system maintenance puts you in a weak position when
negotiating for system expansions or process optimization using advanced control applications both of which
require additional equipment and the advanced controls require interface development, as well. Bringing the
legacy system up to current software revision is expensive and usually requires hardware upgrades. Yet, coming
current does not necessarily provide compelling new capabilities that help you advance beyond your competitors.
Emerson offers excellent migration services and products to facilitate low risk, low maintenance system
improvements that help you derive greater benefits from your existing TDC system and plan for a full transition to
the DeltaV system and PlantWeb at your own pace. Emerson personnel understand the TDC systems and work
with clients to determine the best options for your site, from total system replacements (in phased approaches) to
standalone DeltaV systems for new plant areas. These standalone DeltaV systems can integrate with other plant
systems more easily than can any other control system. This paper describes how to connect the DeltaV system
with TDC systems and the benefits of each connectivity option.

Connecting
Not shown below is the revolutionary DeltaV Connect Solution for Honeywell Systems. This unique solution
makes DeltaV Operator Stations the Human Machine Interface (HMI) for the Honeywell TDC controllers and I/O,
and more information about this solution can be found here.
For basic interconnectivity, Honeywell and DeltaV systems can share data by several methods. Figure 1 shows
TDC 2000 connectivity options:

Figure 1DeltaV to TDC 2000 Connectivity Options

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Figure 2 shows connectivity options for DeltaV systems with TDC 3000:

Figure 2DeltaV to TDC 3000 Connectivity Options

As shown above, Object Linking and Embedding (OLE) for Process Control (OPC) allows for data exchange
between a DeltaV system and a Honeywell system. Various serial interfaces also allow for data exchange
between the two systems. FlexConnect solutions provide hardware boards and/or cables that preserve device
wiring up through the Honeywell I/O terminations. The next few sections explore benefits of each method.

OPC for Data Exchange

OPC simplifies the task of sharing data between systems with different operating systems and data types. An
OPC server gets data from a source, such as a control system, puts the data into a standard format, and makes it
available to be read by an OPC-compliant client. Normally, OPC servers provide data to clients only; however, the
DeltaV OPC Mirror enables data sharing between OPC Servers.
The DeltaV OPC Mirror then can serve data from various sources up to an OPC client. For instance, one OPC
client can see data from TDC 3000 and DeltaV systems in one common format.

Benefits

OPC Mirror can link to all plant subsystems with OPC servers, in addition to the Honeywell control
system.
Data historian or information management software can access multiple process control systems through
one common interface protocol, OPC.
You can select applications by functionality, rather than by conformance to a proprietary communication
protocol.
Allows operation of a limited number of Honeywell points from a DeltaV workstation and control a limited
number of DeltaV points from a Honeywell console. Your Team Emerson Account Manager can show
you a video showing this interoperability.
You get seamless integration with Microsoft and other OLE compliant applications.
You realize reduced integration costsapplications already speak the same language; so developers
spend no time creating interfaces.

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Architecture
Figure 3 shows an example of OPC interface architecture and the software required.

Figure 3OPC Connectivity between DeltaV and Honeywell Systems

Serial Interface
Serial interfaces have been in use for many years. Typically, serial interfaces use a Modbus protocol and drivers
must be written for the applications on both ends of the serial link. Special hardware for the serial type I/O is also
required.
Serial links between Honeywell TPS and DeltaV enable operator actions performed at one system to result in
control actions in the other system. Honeywell TPS has three types of serial interfaces, first via the PLC gateway
(also EPLCG), secondly, using IOP/FTA serial ports within the APM/HPM and third, connecting via the TDC 2000
DHP (Data Hiway Port). For all of these, the DeltaV requirement is simply a serial I/O card with serial
communications terminations and the appropriate (Modbus) protocol.

Benefits
Serial connectivity is a reliable and well known data exchange method that allows monitoring and operation of
Honeywell control data from a DeltaV workstation. Serial interface implementation allows data to be brought
directly into a DeltaV controller. Thus, the points become DeltaV tags.

Performance
Per Honeywell technical specifications, an I/O subsystem, such as IOP/FTA for the APM/HPM has two serial
ports per IOP. Each serial port can support <= 10 writes per second and <= 2048 Boolean, 32 integer, 64 real, or
weighted combinations of these reads per second. Each Honeywell PLCG has two serial ports with a capacity of
3000 points per gateway. Data acquisition performance depends primarily on the PLC response to requests by
the gateway. Point scan rate is 500 points per second, and may be up to 1000 points per second when digital

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points dominate the point type mix. Maximum capacity for each PLCG by point type is shown in Table 1 (next
page).

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Table 1. Maximum Capacity for PLCG Serial Interface

Capacity
3000
1920
1280
1440
960
576
50
600
500

Point Type
digital inputs
digital outputs
digital composites (one in, one out)
analog inputs
analog outputs
analog composites (one in, one out)
critical alarms
events
point contact cutouts

Output requests from other control network nodes go into a stack for first in, first out processing. Rates vary with
the frequency of requests from all nodes on the control network that are interrogating the PLCG. While adequate
for monitoring, this data exchange rate may be insufficient for control across links between the two systems.

DeltaV Connect Solution for Honeywell Systems

DeltaV Connect Solution for Honeywell Systems is a low risk, low maintenance option to preserve customer
controllers for a period of time, while replacing the HMI immediately with a state-of-the-art DeltaV system, using
familiar looking graphics, faceplates and detail displays. This solution enables you to continue using the TDC
control and I/O for uninterrupted processing. Adding DeltaV interface stations to the Local Control Network
establishes the ability to communicate between the systems. The DeltaV system network is then expanded to
include DeltaV Operate HMI stations at a minimum. You can also add a historian and workstations that perform
advanced controls such as model predictive and neural applications.

Benefits

Links to the Honeywell Local Control Network (LCN) and therefore has direct access to all the points &
alarms communicating on that network
NOT an OPC solution, it is a unique/exclusive interface connecting directly on the LCN
Interface does not appear as an LCN node, but communicates as one
NO Honeywell system configuration required
NO shutdown of LCN nodes required
Does NOT require updating older versions (e.g., R5xx) to latest release
Reduces # of nodes on LCN, as Universal Stations are removed
Connect & manage multiple LCNs data & alarms within the DeltaV system
Interface redundancy provides diagnostics for monitoring health status of standby station and minimizes
the impact of hardware failure on plant operations
Operate Honeywell control points from a DeltaV workstation
Seamless integration
Honeywell Universal Station (US)-style instrument faceplates provided, easing the learning curve for
personnel
Standard configuration tools and methodsno interface programming required

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Architecture
The DeltaV Connect Solution for Honeywell Systems architecture is shown in Figure 4:

Figure 4DeltaV Connect Solution for Honeywell Systems directly connects to the LCN

Performance

Actually reduces traffic on the LCN (compared to an equivalent US/GUS); it does NOT increase it.
Alarm annunciation is equivalent to a Honeywell station.
Small server supports up to 2,000 tags; large server supports up to 6,000 tags redundant or up to 10,000
tags in simplex mode.
Multiple redundant servers may be attached for larger LCNs.

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FlexConnect Solutions Save Device Wiring, Minimize Down Time

As the Honeywell controllers and I/O are replaced, if the associated field devices are not being replaced, the
DeltaV controllers can connect directly to the Honeywell systems I/O terminations. This is done using
FlexConnect solutions, a special set of cables, interface panels and pass through cards that transform Honeywell
field wiring terminations into DeltaV terminations.

Benefits
The most compelling of FlexConnect benefits is the dramatic reduction in downtime which can be 75% or
moreversus rewiring. Another benefit is lower wiring costs; they drop by 50% when using FlexConnect versus
rewiring. Table 2a shows wiring costs for a conventional switchover, based on 640 I/O channels.
Table 2a. Cost impact of A 640-channel system switchover, conventional method
Activities

Impact

Disconnect old terminations

Remove old terminations
Install new terminal blocks
Re-terminate wires
Wire from new terminal blocks to DeltaV system
Document

5 minutes/channel

Total time required per channel

Total installation time for 640 channels

8 minutes/channel
10 minutes/channel
20 minutes/channel
43 minutes/channel
458 hours

Labor costs @$50/hour

$22,900

Downtime (not including documentation time)

20 days

Table 2b shows wiring costs using FlexConnect solutions. Compare the downtime with that listed in Table 2a:
Table 2b. Cost impact of A 640-channel system switchover using the FlexConnect solution
Activities

Impact

Install FlexConnect panels

2 minutes/channel

Install inter-connect cables

4 minutes/channel

Document

4 minutes/channel
Total time required per channel
Total installation time for 640 channels
Labor costs ($50/hour)

Downtime (not including documentation time)

21 minutes/channel
224 hours
$11,200
5 days

During planning the installation and startup of the DeltaV system with an existing Honeywell system, the
FlexConnect solution makes a phased implementation entirely feasible. Phased startups let you plan and execute
switchover of your most critical plant areas first, while keeping other areas running.

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Architecture
FlexConnect adds cables and/or panels between Honeywell I/O and a DeltaV controller. Some solutions include
special terminal strips designed for quick assembly and installation. The exact structure varies with the type of
system and the type of I/O. The DeltaV FlexConnect solutions for TDC 2000 and TDC 3000 are shown in
Figure 5:

Figure 5DeltaV FlexConnect Solutions for Honeywell TDC 2000 and TDC 3000

Process Interface Unit (PIU) capacities are listed in Table 3. Table 4 lists TDC 2000 I/O types supported with
FlexConnect solutions:
Table 3. TDC 2000 PIU I/O options with FlexConnect capability

Channels
4
8
16

HLPIU I/O Type

AO, PI
AI, DO, Relay DO
DI

Table 4. TDC 2000 Basic, Extended, Multifunction and Advanced Multifunction controller I/O terminations
with FlexConnect capability

I/O Type

Termination

Analog Termination Panels

Discrete Termination Panel
Point Card Terminal Panels
AMC Discrete Input Panel
AMC Discrete Output Panel
AMC Analog Input Panel
AMC Analog Output Panel
AMC Relay Output Panel

TCB00, 20, 21, 30

TPM02
TCB50, 60
J-RTP00
J-RTP00
J-RTP10
J-RTP20, 30
J-RTP80

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One method uses the removable termination strips on the field termination assembly (FTA). Compression
terminations can be physically removed from the Honeywell I/O card and inserted onto the FlexConnect
panel. Another method uses the IOP cable connection, keeping the FTA in place.
The screw terminal type I/O can be seated on the FlexConnect board, in place of the compression
terminations. With this type of connection, the raw field signal is brought directly into the DeltaV controller,
which allows HART pass through. The AMS Suite Device Manager capability in the DeltaV workstation
is then accessible to these devices for monitoring and diagnostics. Table 5 shows the TDC 3000 Field
Termination Assemblies for which FlexConnect solutions have been developed:
Table 5. TDC 3000 Field Termination Assemblies (FTA) with FlexConnect solutions.
FTA Model

Termination Type

Circuits

Size

MU-TAIH02

COMPRESSION

16

MU-TAIH03

COMPRESSION

16

MU-TAIH12

COMPRESSION

16

MU-TAIH13

COMPRESSION

16

MU-TAOX02

COMPRESSION

MU-TAOX03

COMPRESSION

MU-TAOX12

COMPRESSION

MU-TAOY22

COMPRESSION

16

MU-TAOY23

COMPRESSION

16

MU-TDID12

COMPRESSION

32

MU-TDIA12

COMPRESSION

32

MU-TDIY22

COMPRESSION

32

MU-TDIY62

NONREMOVABLE SCREW

32

MU-TPIX12

COMPRESSION

MU-TDOD11

COMPRESSION

16

MU-TDOD12

COMPRESSION

16

MU-TDOD13

COMPRESSION

16

MU-TDOD21

COMPRESSION

16

MU-TDOD22

COMPRESSION

16

MU-TDOD23

COMPRESSION

16

MU-TDOA11

COMPRESSION

16

MU-TDOA12

COMPRESSION

16

MU-TDOA13

COMPRESSION

16

MU-TDOR12

COMPRESSION

16

MU-TDOR22

COMPRESSION

16

MU-TDON12

COMPRESSION

16

MU-TDON52

NONREMOVABLE SCREW

16

MU-TDOY23

COMPRESSION

16

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February 2009Page 13

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FOUNDATION Fieldbus for LEPIU

For the TDC 2000 Low Energy Process Interface Unit (LEPIU) remote multiplexer I/O, a simple and elegant
transition solution is to use the FOUNDATION fieldbus device Rosemount 848T. Each MUX has a capacity for up to
16 inputs and up to 16 remote MUX boxes per LEPIU.

Benefits
This solution allows you to re-use existing shielded twisted pair wire as the FOUNDATION fieldbus home run cable
to a DeltaV H1 card.

Architecture
Figure 6 shows an example of the architecture for the multiplexer replacement with the Rosemount 848T:

Figure 6LEPIU Replacement Solution with Rosemount 848T to DeltaV H1 Card

An even newer solution is to replace the MUX box completely, and rewire directly to new wireless 848Ts.

Profibus DP for TDC 2000 and TDC 3000 Discretes

The TDC 2000 TCB50 and TCB60 and the TDC 3000 FTA discrete I/O can directly connect to Profibus DP
modules from either Microsmith or Phoenix Contact. The DeltaV Profibus card connects directly to the Microsmith
or Phoenix Contact module, providing a complete path for this I/O to the DeltaV system.

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Architecture
Figure 7 shows the architecture for TCB50 and TCB60 discretes to connect to a DeltaV Profibus DP card, using a
Phoenix Contact module. Figure 8 shows the architecture for FTA discretes to connect to a DeltaV Profibus DP
card using Microsmith modules:

Figure 7DeltaV Profibus DP to TDC 2000 Discrete I/O

Figure 8DeltaV Profibus DP to TDC 3000 Discrete I/O

Benefits
This solution allows you to bring large quantities of discretes through single cable connections into the DeltaV
system. You use standard DeltaV engineering tools for the Profibus DP I/O configuration.

Transition Services
Transferring the required I/O and regulatory configuration from a Honeywell system to a DeltaV system requires
careful oversight by engineers who understand both systems. Emerson has migration teams that:

Are focused exclusively on conversion services

Are experts who understand configuration in both DeltaV and TDC systems
Are familiar with common errors in conversions
Oversee use of tools
Provide new or enhanced design services

Control Database Conversion

Engineering database transfers are accomplished most efficiently by using a set of conversion tools. Automated
tools reduce manual errors and provide expedient entry of required I/O assignments. These are used to the
extent possible, based on the system. For instance, you get a TDC 2000 control database via a printer port
capture; to get the TDC3000 control database, you export Exception Build files. Either database is then converted
to a spreadsheet or Access database and then imported into the DeltaV Bulk Edit Tool.

DeltaV Connect Solution Database Conversion

Fully automated conversion services are included with the DeltaV Connect solution. This gives you an initial
configuration on which you can expand your DeltaV network.

Display Conversion
TDC displays can be recreated for the original look and feel on the DeltaV Operate workstations. This speeds the
learning curve for your operators, but doesnt allow for newer graphic technologies, nor accommodates more

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recent customer or industry graphic standards. TDC 2000 EOS displays are converted manually, as are TDC
3000 GUS displays. However, TDC 3000 US display conversion utilities take these displays directly into the
format required for the DeltaV system.
With any DeltaV project, US style faceplates can be implemented, again to help operators acclimate to the new
DeltaV system. Figure 9 shows sample US style faceplate and detail displays on a DeltaV Operate station. These
faceplates and detail displays are automatically used for DeltaV Connect Solution for Honeywell Systems.

Figure 9US-style Faceplate and Detail Displays on DeltaV Graphics

Figure 10 shows GUS style faceplates on the

DeltaV system, with standard DeltaV buttons for
fast one-click access to detail, process graphic,
trend, engineering, history or alarm summary
displays.

Figure 10GUS-style DeltaV faceplates

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A user-configurable keyboard allows you to customize display navigation to suit your process needs and
operational philosophy. A sample operator keyboard is shown in Figure 11; you can reproduce the familiar USlook keyboard if desired. Figure 12 shows how this keyboard might be installed with your consoles:

Figure 11DeltaV User-configurable Operator Keyboard

Figure 12DeltaV Consoles with Operator Keyboard

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With a new DeltaV system, you have several options that can help ease the adjustment and minimize errors in
the early learning phases. One of the first considerations is the type of people who will manage and execute the
transition. Emerson offers a mature suite of services to help make all control system transitions successful.
Emerson engineers and project managers are experienced with Honeywell to DeltaV upgrades. They have
implemented successful hot cutovers, as well as performed site checkout and system startups during tight
turnaround periods. For details about how customers have benefited from Emerson expertise when upgrading
from their Honeywell systems, visit DeltaV Solutions for Honeywell Systems and to learn more about Emerson
service capabilities, visit Emerson Process Solutions.
Other considerations are training your personnel and providing tools that facilitate quick adoption of the new
technologies. As your project progresses, with DeltaV database configuration and graphics complete, you will
have the tools needed for training operators on the new system. DeltaV Simulate Pro can provide realistic field
responses to operators without connecting to real I/O. In a safe and virtually risk-free environment, operators can
practice running the familiar process from the new DeltaV system. For all system sizes Operator Training
solutions are available to suit the specific needs of your site and personnel. Emerson also offers custom courses
either at your site or in their training centers. For more information about these powerful training systems, please
visit DeltaV Operator Training Solutions.
Reference sites are available for all of the solutions described in this white paper.

Conclusion
Successfully implementing Honeywell systems to DeltaV systems connectivity enables you to:

Make a low-risk transition to new technologies, at your own pace

Significantly lower the costs of maintaining your control systems
Save existing wiring and avoid costly re-wiring
Reuse existing control strategies and I/O assignments through conversion services using automated
conversion tools
Train operators and verify configuration in a risk-free, offline environment
Replicate familiar operations displays on the new system consoles
Easily expand the control system and integrate your process control data with various plant systems
Optimize your processes, using embedded advanced controls

DeltaV connectivity brings great possibilities to the legacy Honeywell DCS user. Coupled with the expertise of
Emerson personnel, the DeltaV system enables you to maximize process potential while minimizing transition
costs.