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System Manual
6510020204 Rev 01
September, 2006
Confidentiality Statement
This manual is a product of Honeywell. It is intended for use only by Honeywell and customer personnel in
connection with Honeywell products. It is strictly prohibited to copy this manual or any part thereof or to
transfer this manual or any part thereof to any non-Honeywell person or entity, except customer personnel for
use in connection with Honeywell products. Persons employed by a third-party service company shall not have
access to this manual.
Notice
All information and specifications contained in this manual have been carefully researched and prepared
according to the best efforts of Honeywell, and are believed to be true and correct as of the time of this printing.
However, due to continued efforts in product improvement, we reserve the right to make changes at any time
without notice.
To view or order additional or revised copies of this publication, visit Honeywell's Process Solutions Center at
http://az18nt1019/index.html under Literature Technical Literature
Trademarks
All trademarks and registered trademarks are the properties of their respective holders.
Copyright
2006 Honeywell
500 Brooksbank Ave, North Vancouver, BC, Canada V7J 3S4.
All rights reserved. No part of this publication may be reproduced or translated, stored in a database or retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of Honeywell.
Printed in Canada
Contents
Introduction........................................................................................................................................... 1-1
Audience ............................................................................................................................................ 1-1
About This Manual........................................................................................................................... 1-1
Related Reading ................................................................................................................................ 1-2
Conventions ....................................................................................................................................... 1-2
Honeywell, Vancouver Operations Part Numbers...................................................................... 1-4
1. System Overview ............................................................................................................................ 1-1
1.1. Supervisory Control System Communications Interface................................................. 1-1
1.2. The LON Server Software ..................................................................................................... 1-2
1.3. The i.LON 100......................................................................................................................... 1-2
1.3.1.
i.LON Status Lights.................................................................................................... 1-3
1.4. The CDWeb Processor........................................................................................................... 1-4
1.5. HC900 Hybrid Controller ..................................................................................................... 1-5
1.5.1.
Controller Mode Switch ............................................................................................ 1-6
1.5.2.
Status LED................................................................................................................... 1-6
2. Installation Requirements ............................................................................................................. 2-1
2.1. CDWeb Manager Environmental Specification................................................................. 2-1
2.2. CDWeb Manager Electrical Specification........................................................................... 2-1
2.2.1.
Mill Power Requirements ......................................................................................... 2-1
2.2.2.
Voltage, Current and Frequency Ratings ............................................................... 2-2
2.2.3.
Installation of Distribution Circuits......................................................................... 2-2
2.3. CDWeb Manager Installation............................................................................................... 2-2
2.3.1.
Enclosure Installation ................................................................................................ 2-2
2.3.2.
Cable Installation........................................................................................................ 2-3
3. Utilities.............................................................................................................................................. 3-1
P/N 6510020204 Rev 01
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Contents
3.1.
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CDWeb Manager
Contents
9/21/06
iii
Contents
C.2.
Modbus..............................................................................................................................C-8
C.2.1.
Modbus Communication Specification ..................................................................C-8
C.2.1.1. Introduction ..........................................................................................................C-8
C.2.2.
CDWeb Manager Registers ......................................................................................C-9
C.2.2.1. Number of Actuators Register .........................................................................C-10
C.2.2.2. System Status Registers.....................................................................................C-10
C.2.2.3. Actuator Type Register .....................................................................................C-11
C.2.2.4. Host Set point Registers ....................................................................................C-11
C.2.2.5. Actuator Position Registers ..............................................................................C-11
C.2.2.6. Actuator Status Registers..................................................................................C-11
C.2.2.7. Zone Enable/Disable Registers .......................................................................C-11
C.2.2.8. Zone Reset Registers..........................................................................................C-12
C.3.
OPC Communications...................................................................................................C-12
C.3.1.
Introduction ..............................................................................................................C-12
C.3.2.
OPC Client Setup .....................................................................................................C-12
C.3.3.
OPC Tagnames.........................................................................................................C-13
List of Figures
Figure 1-1 i.LON 100 ............................................................................................................................ 1-3
Figure 1-2 Honeywell HC900 Hybrid Controller (configuration may vary) ............................... 1-5
Figure 4-1 Diagnostic Messages Menu .............................................................................................. 4-2
Figure 4-2 Diagnostic Messages Window ......................................................................................... 4-2
List of Tables
Table B-1 Aqualizer System Status Words........................................................................................B-2
Table B-2 Aqualizer Actuator Alarm Word Mapping.....................................................................B-3
Table B-3 AutoSlice CDW/ProCoat CDW System Status Words .................................................B-4
Table B-4 AutoSlice CDW/ProCoat CDW Actuator Alarm Word Mapping ..............................B-5
Table B-5 Calcoil CW System Status Words .....................................................................................B-6
Table B-6 Calcoil CW Actuator Alarm Word Mapping ..................................................................B-7
Table B-7 IDP System Status Words ..................................................................................................B-8
Table B-8 IDP Actuator Alarm Word Mapping ...............................................................................B-9
Table B-9 ProFlow II System Status Words.....................................................................................B-10
Table B-10 ProFlow II Actuator Alarm Word Mapping................................................................B-11
Table B-11 AutoSlice/ProCoat System Status Words ...................................................................B-12
iv
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CDWeb Manager
Contents
9/21/06
Introduction
Audience
This manual is intended for use by engineers or process engineers and
assumes that the reader has some knowledge of the operation of a paper
machine and a basic understanding of mechanical, electrical and computer
software concepts.
1-1
Introduction
Related Reading
The following documents contain related reading material.
Honeywell P/N
46000001
51-52-25-107
51-51-25-110
6510020134
Other Equipment
Manufacturer
Conventions
The following conventions are used in this manual:
NOTE:
Boldface
Special Type
Italics
Boldface
lowercase
Type
Press
1-2
9/21/06
[ENTER]
or [RETURN]
[CTRL]
Conventions
[ENTER] is the key you press to enter characters or commands into the
Click
Double-click
Drag X
Press X
Connected keys indicate that you must press the keys simultaneously;
for example,
[CTRL]-C.
Click means to position the mouse pointer on an item, then quickly
depress and release the mouse button. This action highlights or
selects, the item clicked.
Double-click means to position the mouse pointer on an item, then
click the item twice in rapid succession. This action selects the item
double-clicked.
Drag X means to move the mouse pointer to X, then press the mouse
button and hold it down, while keeping the button down, move the
mouse pointer.
Press X means to move the mouse pointer to the X button, then press
the mouse button and hold it down.
The information icon appears beside a note box containing
information that is important.
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1-3
Introduction
1-4
9/21/06
1. System Overview
1-1
System Overview
1-2
9/21/06
Power/Wink LED
Illuminates when the i.LON has power and blinks when i.LON
applications are not running.
Service LED
Blinks when the i.LON application is unconfigured (normal for
operation in a CDWeb Manager). On steady when the i.LON 100 is
in Security Access Mode.
Meter LEDs
Indicates a pulse was detected on the corresponding meter input (1
or 2).
Input LEDs
Illuminate when an ON value is detected on the Input1 and Input2
digital inputs.
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1-3
System Overview
Output LEDs
Illuminate when the corresponding outputs relay is closed.
LAN Link
Illuminates when an Ethernet connection is present.
LAN ACT
Illuminates with Ethernet activity.
LAN 100
Illuminates when the Ethernet connection is communicating at 100
Mbps.
LON Connect
Illuminates when an OpenLDV session is open.
LON BIU/RX
Illuminates when LON data is being received.
LON PKD/TX
Illuminates when LON data is being transmitted.
Further details on the i.LON 100 can be read in the i.LON 100 Internet
Server Users Manual.
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1-5
System Overview
1-6
9/21/06
2. Installation Requirements
NEMA 4, IP 66
0 to 50C*
-20 to 75C
30 to 90% @ 40C Relative Humidity(noncondensing)
20 to 90% Relative Humidity(noncondensing)
*without CDWeb Processor. Systems with CDWeb processor have a maximum operating
temperature of 40C.
2-1
Installation Requirements
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9/21/06
2-3
3. Utilities
3.1. Introduction
The CDWeb Manager is shipped factory configured to operate with the
specified Supervisory Control System. During system installation and
maintenance, it may be necessary to change some of the configuration and
tuning values used by the system, or to replace components of the CDWeb
system. Various utilities are required to assist with these changes.
6510020204 Rev 01
3-1
Utilities
3-2
CDWeb Explorer
Ports: Ethernet
9/21/06
3-3
Utilities
[CDWeb]
The CDWeb section is used to define the number of beams, the number of
controllers, and a name for the system that will be displayed.
[CDWeb]
Display Label=Example Web
Number of Beams=1
Number of Controllers=35
[CDWeb Manager]
The CDWeb Manager section holds the definitions for number of CDWeb
processors and the number of routers attached to the system.
[CDWeb Manager]
Number of Processors=1
Number of Routers=1
[Processor x]
There is a processor section for each processor connected to a specific
CDWeb system (normally only 1 processor is connected). This section
contains the display label, the CDWeb processor name, the network
address of the CDWeb processor, the type of Processor, and which beams
are controlled by this processor.
[Processor 1]
Display Label=
Name=
Address=++
Processor Type=(LDV,FC,QNX,Da Vinci)
Beam 1 = (non zero value)
Tool = (Always = 1)
Interface index = (0X, where X is the index
of the iLON on the performance CD system)
3-4
9/21/06
CDWeb Explorer
++
[Beam x]
There is one Beam section for each beam included in a system. This
section defines the beam Display label, the type of actuator, the actuator
version, and a listing of the actuators on a specific beam.
[Beam 1]
Display Label=Beam
Actuator Type=CalcoilCW
Actuator Version=112
Controller 1=1
...
Controller 35=1
The controllers attached to the beam are defined in the same way as the
beams attached to a processor, that is, any non-zero value will define the
controller to be attached to the beam.
[Router x]
There will be one Router section for each router in the CDWeb system.
This section defines the name of the router, its configuration setting, and
which actuators are connected to it.
[Router 1]
Name=Router_b1_s1
Configuration=configured
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3-5
Utilities
Visible = 0
(first router in each
beam is not visible, subsequent routers
visible = 1)
Controller 1=1
...
Controller 35=1
[Controller 1]
For multi zone controllers there is a section for each controller to indicate
which physical zone is controlled by which zone on the controller. The
NeuronID of the controller will also be stored in this section once the zone
has been confirmed.
NeuronID=00 04 23 20 77 00
ZoneA=1
ZoneB=2
ZoneC=3
ZoneD=4
3-6
9/21/06
CDWeb Explorer
From the link configuration window, you can select various options to
communicate through CDWeb Explorer.
3-7
Utilities
3.2.2.1.
3.2.2.2.
3-8
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CDWeb Explorer
NOTE:
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3-9
4. Common Tasks
6510020204 Rev 01
4-1
Common Tasks
4-2
9/21/06
9/21/06
4-3
Common Tasks
4. Select the configuration message from the right pane showing the
variables for that actuator. After double-clicking on it, a network
variable properties box appears with the variable contents.
4-4
9/21/06
on the tool
9/21/06
4-5
Common Tasks
4. Select the tuning message from the right pane showing the
variables for that actuator. After double-clicking on it, a network
variable properties box appears with the variable contents.
on the tool
9/21/06
7. Press the edit mode button again to send the values to the actuator.
8. If the values need to be copied to other actuators, select Copy to All
or Copy to
6. From the Target dialog box, select the data you want to save. The
highlighted node option refers to the current actuator that you
have highlighted. The visible nodes option refers to all nodes that
are currently shown in the network variable viewer. The group
nodes option refers to all of the actuators in the beam.
9/21/06
4-7
Common Tasks
button in Step 5.
9/21/06
3. Right click the zone that requires new application software, and
choose Download Application. Choose the .nxe to download.
NOTE:
DO NOT change any settings other than the TCP/IP parameters. Many
options and features can be changed and activated in the i.LON
configuration page, however, these are not used by the CDWEB
Manager and changing them could hamper performance.
To change the TCP/IP parameters of the i.LON 100:
1. Ensure a direct Ethernet connection exists between the i.LON 100
and the maintenance PC.
9/21/06
4-9
Common Tasks
b.
c.
4-10
9/21/06
5. Press the red Login button at the bottom left of the page. A login
prompt appears.
6. Enter User Name ilon and Password ilon.
7. From the menu at the top of the page select Setup, then select
TCP/IP. Change the TCP parameters as required.
8. Save your changes.
9. If this procedure was used to change the IP address of an i.LON
from the one previously used for the actuator set, refer to section
4.12.5 on page 4-40 for instructions on changing the address that
the server, or CDWeb Processor, uses to communicate to the i.LON.
10. If this is a replacement i.LON that has not been used with a CDWeb
system before, a subnet/node address on the LON must be
assigned using CDWeb Explorer. To do this, start CDWeb Explorer
and load the .web file for the system.
11. Select CDWeb Processor from the tree structure and highlight it by
clicking on it.
12. Right-click on the CDWeb Processor and select the Install function
from the context menu. Follow the on-screen prompts. A service
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9/21/06
4-11
Common Tasks
4-12
9/21/06
5. If the IP address of the HC900 does not appear in the list click on
Add, otherwise proceed to step 7.
P/N 6510020204 Rev 01
9/21/06
4-13
Common Tasks
7. Highlight the address of the HC900 in the list and click on Loop
Back to test communications.
4-14
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9/21/06
4-15
Common Tasks
9. Set the desired IP address and press Next. Confirm that the address
was changed. You may need to change your IP address and subnet
mask to be on the same domain as the new TCP/IP configuration.
4-16
9/21/06
10. Set the controller back to run mode, by selecting Set Controller
Mode from the Utility menu.
9/21/06
4-17
Common Tasks
New.
6. The Upload File dialog appears. Select Network for the Port and
select the IP address for the HC900. Click Start.
4-18
9/21/06
8. Once the configuration has been uploaded from the HC900 the
temporary configuration used to add the IP address may be
deleted.
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4-19
Common Tasks
4.10.
4-20
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9/21/06
4-21
Common Tasks
4.11.
4.11.1.
Introduction
Installation of the LON Server software involves a few basic steps:
4-22
9/21/06
4.11.2.
4.11.3.
9/21/06
4-23
Common Tasks
7. Leave all other settings at the default and click Apply, then OK.
4-24
9/21/06
10. Highlight CDWeb and click Add, to add a new i.LON router to the
system.
11. Enter the name of the interface to be added. Generally the gauge ID
of the CD actuator system should be used here.
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4-25
Common Tasks
4-26
9/21/06
4.11.4.
9/21/06
4-27
Common Tasks
NOTE:
CDWebRTDR.exe
CDWebNet.exe
CDWeb.ini
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4.11.5.
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4-29
Common Tasks
4-30
9/21/06
2. Set up a viomap:
9/21/06
4-31
Common Tasks
4-32
9/21/06
9/21/06
4-33
Common Tasks
4.12.
4.12.1.
3. Click Options>>.
4-34
9/21/06
4. On the General tab fill in the User Name (CDWeb) and password
(cdweb).
5. On the Local Resources tab select the Disk Drives box under Local
Resources.
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4-35
Common Tasks
6. Click Connect.
7. Click OK to the Remote Desktop Security Warning
4-36
9/21/06
4.12.2.
4.12.3.
9/21/06
4-37
Common Tasks
4.12.4.
HC900 Address
Use this procedure to change the address that the CDWeb processor uses
to locate the HC900. For instructions on changing the actual IP address of
the HC900 see Section 4.8.
1. Establish a Remote Desktop connection.
2. Open C:\Honeywell\Database\Build\Modbus Links.txt
3. Edit the HostName line to the correct IP address of the ODX server.
4-38
9/21/06
9/21/06
4-39
Common Tasks
4.12.5.
i.LON Address
Use this procedure to change the address that the CDWeb Processor, or
DaVinci server, uses to communicate to the i.LON. To change the actual
IP address of the i.LON see Section 4.5.
1. Establish a Remote Desktop connection to the CDWeb Processor.
If the CDWeb Processor is not present and you are working on
the DaVinci server, skip this step.
2. From the Windows Control Panel, choose LonWorks Interfaces.
4-40
9/21/06
9/21/06
4-41
Common Tasks
4-42
9/21/06
5. Glossary
Actuator
CD
Cross Direction
Used to refer to those properties of a process measurement or
control device that are determined by its position along a line that
runs across the paper machine. The Cross Direction is transverse to
the MD (Machine Direction) that relates to a position along the
length of the paper machine.
Da Vinci
QCS
RAE
RTDR
Setpoint (SP)
VIO
Virtual Input/Output
6510020204 Rev 01
5-1
A.2. CDWeb.ini
When CDWebNet.exe first starts, it searches for the CDWeb.ini file in the
%MXRTDB%\CDWeb directory, where MXRTDB is a system
environment variable normally set during the RAE installation process.
The CDWeb.ini file internally references the other configuration files by
name, with paths included. If the other files are located in the same
directory as CDWeb.ini, then no path information is required.
The structure of the file conforms to conventional Windows INI file
format.
6510020204 Rev 01
A-1
The CDWeb.ini file consists of one or more INI sections. Each section name
is enclosed in square brackets and corresponds to one LON interface.
Each INI file section has the following parameters defined:
A-2
9/21/06
CDWeb.ini
Example:
Number of actuators = 65
9/21/06
A-3
A.2.9. Flushable
Defines if the actuator supports flushing sequences. Can be defined as 0
(default, non-flushable), or 1 (flushable).
Example:
Flushable = 0
A.2.10.
Database
Defines the name, and optionally the location, of the LON network
configuration file.
Example:
Database = export.csv
A-4
9/21/06
A.2.11.
CDWeb.ini
Node name
Defines the name of the host node (i.LON) in the database file. It is used
for extraction of the host node address and the bound network variables.
Example:
Node name = cdweb_proc_1; standard name for
the host node
A.2.12.
Beam id
Defines the ID number of the CD actuator system within the database file.
One database file can contain configuration for several CD actuator
systems.
Example:
Beam id = 1
A.2.13.
A.2.14.
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A-5
A.2.15.
A-6
:NODE:
:SUBNET_NODE:
:NODE_NV:
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A.3.1. :NODE:
The :NODE: record starts the definition of each LON network node. This
record contains a node name as its second value, and the optional
INSTALLED value as its sixth value.
Example:
:NODE:,cdweb_proc_1, , , ,INSTALLED,
A.3.2. :SUBNET_NODE:
The :SUBNET_NODE: record defines the network address of the node.
The second value is the name that was defined for the node. The fourth
value represents the subnet, while the sixth value represents the node.
Example:
:SUBNET_NODE:,zone_001_b1, ,2, ,1,
A.3.3. :NODE_NV:
Most nodes will have several :NODE_NV: records associated with them.
These records define the LON network variables for the node. These
records contain the node name as the second value, the network variable
(NV) name as the third value, and a NV selector value as the sixth. Service
type (acknowledged, or unacknowledged) is define in the seventh value,
and NV direction (input or output) is defined in the eighth value. The 14th
value is the NV priority level, and the 21st value is the message length. All
other values are unused.
Examples:
:NODE_NV:,zone_001_b1,nvi_ActSetpnt, ,
,16383,ACKD,INPUT, , , , , ,FALSE, , , , , ,
,2 , ,
:NODE_NV:,zone_001_b1,nvo_ActStatus, ,
,1,UNACKD,OUTPUT, , , , , ,FALSE, , , , , ,
,14 , ,
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A-7
9/21/06
The bit formula for each of the 16 actuator status bits is used by the QCS.
Raw actuator status information generally contain 32 to 48 specific alarms
that are then mapped to the 16 status bits defined in the QCS.
Default source A0,A1,,A48 represent raw actuator status bits associated
with each control zone.
Source AF represents Actuator Failure (lost communications)
Source BT represents bumpless transfer required flag.
Source MA, MM, and MD represent actuator mode (Auto, Manual,
Disabled).
The formula for each target bit is:
[Target Bit] =
([~][Source]|[~][Source]||[~][Source]) &
([~][Source]|| [~][Source])
Example:
ActAlarm[3] = (A3|A5|A6)&(~MM)
Defines actuator alarm bit 3 as the logical OR of raw actuator status alarm
bits 3, 5, and 6 when the actuator is not in manual mode.
The target bit can be ActAlarm[0] through ActAlarm[15], with
ActAlarm[15] normally defined as being equal to the AF flag.
Undefined bits are defaulted to zero.
The formulas may occupy several consecutive lines, with the interrupted
line ending with the underscore _ character. Line interruption is not
permitted to break a name, or separate the inversion tilde character ~
from its identifier.
9/21/06
A-9
This appendix outlines the system alarms and actuator alarms that may
appear on operator displays.
6510020204 Rev 01
B-1
NOTE:
B.3.1. Aqualizer
Table B-1 Aqualizer System Status Words
Bit
Position
1
2
3
4
5
Roll Rotation
Sheet Break
not used
not used
Beam Advanced
6
7
8
9
10
11
12
13
14
15
16
B-2
Minor System
Status Word
not used
not used
PLC link down
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm Description
Alarm
Bit
Disabled
Hardware Failure
Over Temperature
Temperature Sensor
Failure
Actuator Not Moving
Not Used
Not Used
Invalid Calibration
Not Used
Open Limit
Close Limit
Not Used
Invalid Configuration
Invalid Tuning
Bumpless Transfer
Required
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
[a1] Disabled
[a2] Hardware failure
[a7] Over temperature
[a6] Temperature sensor failure
4
5
6
7
8
9
10
11
12
13
14
15
9/21/06
B-3
B-4
Minor System
Status Word
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm Description
Alarm
Bit
Disabled
Active Protection Zone
Moving Too Slow
Wrong Direction
Invalid Calibration
Locked by Previous
Locked by Next
Open Limit
Close Limit
Bend Limit
Invalid Configuration
Invalid Tuning
Not used
Not used
Bumpless transfer required
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
9/21/06
B-5
B.3.3. Calcoil CW
Table B-5 Calcoil CW System Status Words
Bit
Position
1
2
3
4
Roll Rotation
Sheet Break
Stack Loaded
Emergency Stop
Beam In Position
AC Power On
7
8
9
10
not used
Beam Air Pressure
Low Water Flow*
High Water
Temperature*
Beam Fan Fault**
not used
not used
not used
not used
not used
11
12
13
14
15
16
Minor System
Status Word
Interlock Bypass
Door Switch Bypass
Water Filter Clogged*
High Water
Temperature
Warning*
Low Water Level
Warning*
Low Water
Temperature
Warning*
Beam Fan Warning**
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
PLC Link down
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
* indicated alarms are used only with Calcoil CW-HT systems that include
the Calcoil cooling unit.
** indicated alarms are used only for Calcoil CW systems with offmachine power module cabinets.
B-6
9/21/06
Alarm Description
Alarm
Bit
Disabled
Hardware Interlock
Module Shutdown
Phase Loss
Heat Sink Over
Temperature
Work Coil Over
Temperature
Power Limited (Check
workcoil gap)
Not Used
Not Used
Not Used
Not Used
Setpoint Override
Invalid Command
Invalid Configuration
Bumpless Transfer
Required
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
4
7
8
9
10
11
12
13
14
15
9/21/06
B-7
B-8
Minor System
Status Word
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
not used
not used
PLC Link down
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm Description
Alarm
Bit
Disabled
Hardware Failure
Over Temperature
Large Leak
Slow Leak
Exhaust Pressure out of
range
Supply Pressure out of
range
Not used
Not used
Open Limit
Close Limit
Not used
Invalid Configuration
Invalid Tuning
Feedback disabled
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
4
5
In disabled mode
Pressure sensor failure
Over temperature
Large leak
Small leak
Incorrect exhaust pressure
7
8
9
10
11
12
13
14
15
9/21/06
Open limit
Close limit
Invalid configuration
Invalid tuning
Feedback disabled
Based on actuator communications
timeout
B-9
B.3.5. ProFlow II
Table B-9 ProFlow II System Status Words
Bit
Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
B-10
Minor System
Status Word
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm Description
Alarm
Bit
Disabled
not used
not used
not used
not used
Actuator not moving
Actuator moving too slow
Feedback error
Invalid setup
Open Limit
Close Limit
not used
not used
not used
Bumpless transfer required
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
9/21/06
B-11
B.3.6. AutoSlice/ProCoat
NOTE:
These alarms refer to the legacy 75mm AutoSlice and 60mm ProCoat
actuators with AC synchronous motors. They are not applicable to the
AutoSlice CDW and ProCoat CDW actuators.
Table B-11 AutoSlice/ProCoat System Status Words
Bit
Position
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
B-12
Minor System
Status Word
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm
Bit
Disabled
Hardware Failure
Sensor Under Voltage
0
1
2
4
5
6
7
8
9
10
11
12
13
14
15
Disabled
Runaway Relay, Output driver, A/D failure
Sensor undervoltage, Active Protection
Zone Violation
Sensor overvoltage, Active Protection
Zone Violation
Moving too slow
Moving wrong direction
Runaway
Invalid calibration
Locked by previous, Locked by next
Open limit
Close limit
Bend limit
Invalid configuration
Invalid tuning
9/21/06
B-13
B.3.7. ProFlow
NOTE:
Bit
Position
B-14
Minor System
Status Word
Flush Active
not used
not used
not used
not used
not used
not used
not used
3
4
5
6
7
8
9
10
11
12
13
14
15
16
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
9/21/06
Alarm Description
Alarm
Bit
Disabled
Hardware Failure
Sensor Under Voltage
Sensor Over Voltage
Moving Too Slow
Wrong Direction
Runaway
Invalid Calibration
Not Used
Open Limit
Close Limit
Not Used
Invalid Configuration
Invalid Tuning
Not Used
Lost LON Communications
or Waiting For Bumpless
Transfer
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Disabled
A/D failure, Runaway relay, Output Driver
Sensor undervoltage
Sensor overvoltage
Moving too slow
Moving wrong direction
Runaway
Invalid calibration
9/21/06
Open limit
Close limit
Invalid configuration
Invalid tuning
Based on actuator communications
timeout
B-15
C. Host Communications
C.1. ODX
C.1.1. CDWeb Manager Network Communication
Specification
This specification assumes that the CDWeb Manager contains client
software for ODX communication. The CDWeb Manager is responsible for
initiating all network communications between itself and the Supervisory
Control System. The content of all messages adheres to the ODX
Functional Specification.
If a discrepancy exists between this document and the ODX Functional
Specification, use this document.
C.1.1.1.
Introduction
The ODX client initiates all communications between the CDWeb
Manager and the ODX server running on the Supervisory Control System.
The communications between the client and server consists of
6510020204 Rev 01
Host Communications
9/21/06
ODX
CDWeb Managers are funneled through a single event, EVT586. For this
reason, each write request made by the client that requires a status update
on the Supervisory Control System also sets a corresponding control
ordinal prior to scheduling the Status Change event. In this way the chain
which runs off the Status Change event can decipher which data needs to
be updated. All symbol, control ordinal, and event names required for a
single ODX client are listed in Table C-1.
The ODX client logs into the Supervisory Control System with a user
name of IDS and a password of RESULTS.
If the ODX client detects that communications have been lost, it resets
itself to a startup condition. When communications are re-established, all
data that is specified to be transferred on a startup condition is
transferred.
Read Number of Actuator Zones
The ODX client reads the number of actuator zones from the Supervisory
Control System (PxCyyyNUMACT) once on startup. This value is
compared against the number of actuator zones in the CDWeb Manager
configuration. If a discrepancy is found the client sets the corresponding
bit in the LAN alarm word (see below) and attempts to write this word to
the Supervisory Control System.
Write LAN Alarm Word
The ODX client writes the LAN alarm word PxCyyyLALM to the
Supervisory Control System to identify possible problems with the LAN
configuration. Currently there are only two bits defined in the status
word:
This word is written once after the symbol lookup and the comparison of
actuator zones has been completed. This write either clears or sets the
corresponding alarm states on the Supervisory Control System. As with
all status words, the associated status change ordinal PxCyyy.LALM is set
and the status change event LPNz\EVT586 is scheduled by this write
request.
P/N 6510020204 Rev 01
9/21/06
C-3
Host Communications
C-4
9/21/06
ODX
The set point array always contains floating point values. The slope and
offset required to go from the Supervisory Control System to the actuator
set point format is also read from the Supervisory Control System. The
actuator task scales the set points appropriately before forwarding them to
the actuators. The ODX client assumes that the actuators ignore set points
when disabled.
Due to the asynchronous nature of the communication between the
actuators and the CDWeb Manager and between the CDWeb Manager
and the Supervisory Control System, set points can become corrupted
when performing a bumpless transfer. When the Supervisory Control
System performs a bumpless transfer, it copies its position array into its
set point array. Similarly, on receiving a reset, an actuator copies its
position into its control set point. However, there is no guarantee that the
entry in the AMs position array corresponds to the current actuator
position because of the time lag in communication between the actuator
and the Supervisory Control System. The CDWeb Manager guards against
this situation by discarding set points for any actuator which has not
reported its position within a time limit defined in the CDWeb Manager
configuration. This situation is indicated by setting the Lost LON
Communications bit in the actuator alarm word. Set points continue to be
discarded until the position has been successfully reported to the
Supervisory Control System and the Supervisory Control System has
acknowledged the new position by sending a reset. This acknowledgment
normally involves an operator invoking a Reset Failed Actuator or a
Reset All Actuators command.
Write Actuator Positions and Status
The ODX client writes actuator positions, PxCyyy_APOS, and status,
PxCyyy_ASTAT, to the Supervisory Control System on a periodic basis.
As with all status words, the associated status change ordinal
PxCyyy.ASTAT is set and the status change event LPNz\EVT586 is
scheduled by each write request. The time period between transmissions
is hard-coded at five seconds.
The position array always contains floating point values which are in the
same units as the set point array. As with the set point array, the CDWeb
Manager scales the positions appropriately before writing them to the
Supervisory Control System. Positions are written to the Supervisory
Control System regardless of the state of the Supervisory Control System
Auto/Manual ordinal to facilitate bumpless transfer between modes.
P/N 6510020204 Rev 01
9/21/06
C-5
Host Communications
The zone by zone actuator status words are actuator dependent and are
outlined in Appendix B.
Read Mode Flag
The mode flag is an ordinal value. It is 1 if the actuators should obey, if
possible, the set points in the set point array, and 0 if the actuators should
cease all control. This flag is read immediately on startup and thereafter a
triggered read request causes the information to be transmitted to the
CDWeb Manager whenever the flag changes state. The flag is expected in
the symbol PxCyyy.LODON.
Read/Write Actuator Enable Array
The Actuator Enable array is an array of integers which are set to 1 or 0 to
indicate if a given zone is enabled or disabled, respectively. The actuator
enable array is read from the Supervisory Control System immediately on
startup in order to synchronize the Supervisory Control System and the
actuators. Once the two copies of the array match, the client issues a
triggered read request that reads the PxCyyy_AED array from the
Supervisory Control System whenever the PxCyyy.AED ordinal on the
Supervisory Control System changes state. The actual data from this
request is transmitted asynchronously to the request. The client constantly
checks for a new response to this request and transmits the information as
necessary to the actuators.
This exchange suffers from a problem similar to the problem noted under
Read Set point and Position Scaling. Unlike the previous case, the problem
does not arise from a time lag between the startup of the ODX Server and
the load of the ISR data, but from incorrect initialization of the Enable
Array by the Supervisory Control System. The Supervisory Control
System assumes that all actuators are enabled and does not ever initialize
this array until a change is made in the array. Consequently, until a
change is made in the array, it contains whatever default values it had at
startup. If any of the default values are 0, then the corresponding actuators
are disabled when the CDWeb Manager reads the symbol, even though
the actuator is regarded as enabled by the Supervisory Control System.
As in previous case, the problem is fixed by changing the default values
for the array to the desired startup values (usually 1 in this case).
C-6
9/21/06
ODX
Number of Zones
Communications
Active
Supervisory Control
System On Control
Actuator Set points
Set point Scaling
Slope
Set point Scaling
Offset
Actuator Positions
Direction
Supervisory
Control System
Ordinal
Supervisory
Control System
Symbol
Supervisory
Control System
Event
Read
Write
N/A
N/A
PxCyyyNUMACT
PxCyyyACOM
N/A
N/A
Read
PxCyyy.LODON
N/A
N/A
Read
Read
N/A
N/A
PxCyyy_ASP
PxCyyyACTSLP
N/A
N/A
Read
N/A
PxCyyyACTOFF
N/A
Write
N/A
PxCyyy_APOS
N/A
9/21/06
C-7
Host Communications
Description
Actuator Status
(Actuator Dependent
Bit Pattern)
PLC System Status
(Actuator Dependent
Bit Pattern)
LAN Alarm Status
bit 0:
symbol_lookup
bit 1: num_zones
Reset Actuators
Enable/Disable
Actuators
Direction
Supervisory
Control System
Ordinal
Supervisory
Control System
Symbol
Supervisory
Control System
Event
Write
PxCyyy.ASTAT
PxCyyy_ASTAT
LPNz\EVT586
Write
PxCyyy.SST
PxCyyy_SST
LPNz\EVT586
Write
PxCyyy.LALM
PxCyyyLALM
LPNz\EVT586
Read
Read /
Write
PxCyyy.ARST
PxCyyy.AED
PxCyyy_ARST
PxCyyy_AED
N/A
N/A
C.2. Modbus
C.2.1. Modbus Communication Specification
This specification assumes that the CDWeb Manager contains client
software for Modbus communication. The Supervisory Control System is
responsible for initiating all communications between itself and the
CDWeb Manager. The content of all messages should adhere to the
Modbus Protocol Specification available at www.modbus.org.
The CDWeb Manager can be configured for communications using either
Modbus RTU serial communications or Modbus TCP Ethernet
communications.
C.2.1.1.
Introduction
The Modbus protocol is a query-response protocol used for
communication between the Modbus device and a supervisory computer
(Host). The Host is defined as the master device and it transmits a query
to the client, which then responds. The client cannot query the Host, it can
only respond to queries from the Host.
C-8
9/21/06
Modbus
Description
Illegal Function
Read Output Table
Read Input Table
Read Registers
Read Analog Input
Force Single Output
Preset Single Register
Read Exception Status
Loopback Maintenance
Unsupported Function
Force Multiple Outputs
Preset Multiple Registers
Report Device Type
Unsupported Function
Read Scratchpad Memory
Unsupported Function
Reserved for Exception Responses
9/21/06
C-9
Host Communications
Number of
Words
Data Description
Host Read/Write
0
100-103
109
400-599
600-799
800-999
1000-1199
1400-1599
1
4
1
200
200
200
200
200
Number of actuators
System Status
Actuator Type
Host Setpoints
Actuator Position
Actuator Status
Zone Enable/Disable
Zone Reset
Read
Read
Read
Read/Write
Read
Read
Write
Write
Number of
Words
Data Description
Host Read/Write
0
100-103
109
400-799
800-1199
1200-1599
1600-1999
2400-2799
1
4
1
400
400
400
400
400
Number of actuators
System Status
Actuator Type
Host Setpoints
Actuator Position
Actuator Status
Zone Enable/Disable
Zone Reset
Read
Read
Read
Read/Write
Read
Read
Write
Write
C.2.2.1.
C.2.2.2.
C-10
9/21/06
C.2.2.3.
Modbus
C.2.2.4.
Value
Actuator Type
1
2
3
13
14
15
16
17
18
19
20
23
AutoSlice
ProCoat
ProSlice
Rotary ProFlow
Linear ProFlow
Calcoil CW
AutoSlice CDW
ProCoat CDW
Devronizer IDP
Calendizer IDP
Aqualizer
ProFlow II
C.2.2.5.
C.2.2.6.
9/21/06
C-11
Host Communications
C.2.2.7.
C.2.2.8.
9/21/06
OPC Communications
"AppID"="{89E9A700-4FB9-11d1-BD6C-00A0C91648AF}"
[HKEY_CLASSES_ROOT\CLSID\{89E9A700-4FB9-11d1-BD6C00A0C91648AF}\LocalServer32]
@="%mxroot%\\rae\\bin\\OpcServer.exe"
[HKEY_CLASSES_ROOT\CLSID\{89E9A700-4FB9-11d1-BD6C00A0C91648AF}\ProgID]
@="Hmx.RaeServer_O"
[HKEY_CLASSES_ROOT\AppID\{89E9A700-4FB9-11d1-BD6C00A0C91648AF}]
@="HMX RAE OPC COMPONENT - exe Server"
[HKEY_LOCAL_MACHINE\SOFTWARE\Classes\Hmx.RaeServer_O\O
PC]
@=""
[HKEY_LOCAL_MACHINE\SOFTWARE\Classes\Hmx.RaeServer_O\O
PC\Vendor]
@="Honeywell IAC Inc."
Data
format
Data
Type
Read/Write
Description/Usage
act.setpoint
array
double
Write/Read
act.position
array
double
Read
act.enable
array
word
Write/read
act.reset
array
word
Write/read
Act.sys.status
Array [4]
word
Read
9/21/06
C-13
Host Communications
Tag Name
Act.status
Data
format
Read/Write
Description/Usage
word
Read
Act.num.zones
Int[32]
Read
Act.sys.mode
byte
Write/read
Act.watchdog
word
Read
Act.scale.slope
double
Write/read
Act.scale.offset
double
Write/read
C-14
array
Data
Type
9/21/06