ControlEdge 900IO using PROFINET Integration Center … · 3.2 Customer IO Configuration xls ... 48 9.4 EPM Label ... #For only REDU Power Supply requirements ~Customized Parts?

Connected Plant

ControlEdge 900IO using PROFINET

R100

___________________________________

Integration Center

User Guide

___________________________________

PMDOC-X364-en-100A

April, 2018

2

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 Thirdparty 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 2018- Honeywell International Sàrl

PMDOC-X364-en-100A 3

Table of contents

1 ABOUT THIS GUIDE............................................................................................................................ 5

1.1 Scope ................................................................................................................................................... 5

1.2 Revision history ................................................................................................................................. 5

1.3 Intended audience............................................................................................................................ 5

1.4 Related documents .......................................................................................................................... 5

2 INTEGRATION CENTER WORK FLOW DIAGRAM & TOP-LEVEL ORDERING BOM ................ 6

3 CABLE DIAGRAM SW TOOL ............................................................................................................ 8

3.1 ThirdParty Module Interface .......................................................................................................... 9

3.2 Customer IO Configuration xls .................................................................................................... 10

3.3 Terminal Block Label:..................................................................................................................... 11

3.4 Output Files ..................................................................................................................................... 12

3.5 BOM (Bill of Material) .................................................................................................................... 13

3.6 Cable Drawing ................................................................................................................................. 15

4 IOCB ................................................................................................................................................. 17

4.1 IOCB1: ............................................................................................................................................... 17

4.2 IOCB2: ............................................................................................................................................... 20

5 THIRDPARTY MODULES AND THEIR INTERFACES DETAILS: ................................................... 23

5.1 Conditions for ThirdParty Modules Usages .............................................................................. 23

5.1.1 SP Code: SP3 ................................................................................................................................24

5.1.2 SP Code: SP4 ................................................................................................................................25

5.1.3 SP Code: SP5 ................................................................................................................................27

5.1.4 Thirdparty Module Cable Drawing ...........................................................................................28

6 RPIM MODULE............................................................................................................................... 30

6.1 RPIM Specification and Features................................................................................................ 31

6.2 P2 Connection Details (To backplane) ...................................................................................... 33

6.3 Power Supply Specs ....................................................................................................................... 35

6.4 RPIM Input Cable drawing ............................................................................................................ 37

6.5 RPIM Module Product Label ........................................................................................................ 38

6.6 RPIM Input Power Connector Label ........................................................................................... 39

7 MIGRATION STEPS.......................................................................................................................... 40

8 SAFETY AND GENERAL GUIDELINES:.......................................................................................... 44

9 EPM BOARD CONVERSION .......................................................................................................... 45

9.1 Prerequisites .................................................................................................................................... 45

9.2 Package Installation....................................................................................................................... 45


9.3 Conversion Procedure from PLC to ControlEdge 900IO-PROFINET ................................. 48

9.4 EPM Label ........................................................................................................................................ 55

10 TEST AND CERTIFICATION: ............................................................................................................ 56

11 NOTICES............................................................................................................................................ 57

ABOUT THIS GUIDE


1 About this guide

1.1 Scope

This guide describes conversion of ControlEdge 900IO using PROFINET Integration and

upgrading the Firmware.

1.2 Revision history

Revision Supported Release

Date Description

A 100 April 2018 Initial release of ControlEdge 900IO using

PROFINET Integration Firmware.

1.3 Intended audience

This guide is primarily intended for Honeywell field personnel who install and configure the

product.

1.4 Related documents

NA

INTEGRATION CENTER WORK FLOW DIAGRAM & TOP-LEVEL ORDERING BOM


2 Integration Center Work Flow Diagram & Top-level ordering

BOM

The following is the Integration Center Work Flow Diagram:

~ThirdParty Module Cable Assembly

Integration Center Work

Flow

(Projects Team & Buyer)

#Redundancy Power Supply Assembly

~HC900ModulesBOM(#51454980)

~ThirdParty Modules BOM & Cable Assembly

~IO Cable Assembly (#51308275)

‘ControlEdge 900 IO using Profinet’ – Integration Center Work Flow

Integration Center Work Flow (Projects Team)

-FAT Testing-

PLC-EPM ModulesVendor

(WELCO)EPM Module-Upgrade

PNIO FW

PLC Rack(8 Slot)Vendor

(Tontek)

PLC PSU ModuleVendor

(SFO)

RPIM

(#51308252)

Vendor

(SFO?)

~IOCableAssembly &

IOCB(#51308254)

Vendor

(Caverion?)

Mechanical Parts

-EPOR1 Mechanical Kit

(#51454978-001)

Vendor

(?)

ThirdParty Modules

BOM(#tbd)OEMs

Module

Testing

PLC IO ModulesVendor

(WELCO)

~ThirdParty Modules

Cable Assembly

(#51308277)

Vendor

(Caverion?)

RPIMCableAssembly x 2

(#51308276)

Vendor

(SFO?)

Mechanical Parts-REDU

PSU Mechanical Kit

(51454979-001)

Vendor

(?)

Verify the Modules

Customer

Wiring Tool

Software

Wiring Diagrams

Date: 05Dec2017

Note:

#For only REDU Power Supply requirements

~Customized Parts

? Preferred vendor OR ISC to finalize

IOCB: I/O Cable Board

RPIM: Redundancy Power Supply Module

BOM

BOM

Diagrams

Verify the Package

Verify the cable Assemblies

according to wiring diagram &

Repack

Verify the Package

Verify the Package

BOM

Buyer

Buyer

Shipment

Field IO Configuration

Field IO Configuration

New Product

Label

INTEGRATION CENTER WORK FLOW DIAGRAM & TOP-LEVEL ORDERING BOM


The following is the Top-Level Ordering BOM


3 Cable Diagram SW Tool

Cable Diagram Software Tool is designed to perform migration at module and I/O level.

This tool understands old and new system in detail, and makes appropriate choice of

modules based on predefined conditions and rules. The tool reads a comprehensive

database having details of both old and new system, and provides output files that are

necessary for migration. Below is the block illustration of the Cable Diagram SW Tool:

‘ControlEdge 900 IO using Profinet’ – Cable Diagram SW Tool

RFQ

Customer IO Configuration Details

like Module Type, IO Type and

Field Device details

-To be filled in template xls file

-By Projects Team

Alcont & Control Edge 900 IO

Map Database xls file

-Technology Team

Cable Diagram SW Tool

-Handled by Projects Team

-from Projects team to Buyer

Cable Connection Diagram(Pdf)

Xls file

Xls file

Pdf file

-from Projects team to Buyer

-Control Edge 900 Modules BOM(xls)

-Thirdparty Modules BOM(xls)

-Cable Assembly BOM(xls)

Xls files

Input files to Tool:

• Customer IO configuration xls file

• Alcont & ControlEdge 900IO Module & IO pin map xls file

Output files from Tool:

• Cable connection diagram (for cable harness vendor)

• BOMs (for buyer)

ControlEdge 900IO Modules BOM

ThirdParty Modules BOM

Cable assembly BOM

Steps to perform migration using cable diagram software tool

1. Feed in the customer IO configuration file to the tool.

2. Click required settings:

a. ControlEdge 900IO PSU – AC or DC

b. Optimize – Yes/No

3. Click Migration button.

4. Defined output files will be generated.

CABLE DIAGRAM SW TOOL


XLS Database Tool User Guide (For tool designer use):

• TableA= Alcont IO Module to ControlEdge 900IO Module map

• TableB= Alcont IO Modules and their pin details

• TableC= ControlEdge 900IO modules and their pin details

• TableD= ThirdParty modules and their pin details

• 'Codes & Guidelines' table to learn about rules & codes to pin map.

• This page explains about 'Cable diagram tool' work flow, input details required to

operate and output files.

NOTE

Cable Connection Diagram is used by Cable Vendor for cable

creation and Projects team for debug purpose.

Honeywell P/N Document Title/Description

51156521 Cable Diagram SW Tool

51308268 Cable Connection Diagram

3.1 ThirdParty Module Interface

Some of the Alcont IO types are not supported by ControlEdge Modules. So, ThirdParty

modules are used to bridge that gap. This kind of IO types are known as special I/O’s in the

SW tool a unique code called ‘SPCode’ is reserved for every ThirdParty module to identify

them in the SW tool. Details of the code and the ThirdParty module are given in below

table.

SPCode Alcont IO

Module Type

Input Description Reason

SP2 MAI MAI channel can have Sink (Passive) or

Source (Active) field device, is field

device source type?, then mark those

I/O with this code

This will

help

introduce

appropriate


SPCode Alcont IO

Module Type

Input Description Reason

SP3 BOU Does IO have >0.5A load current

requirement? Then mark those I/O with

this code

ThirdParty

Module and

define

connection

diagram SP4 PBI Does I/O require channel to channel

isolation? Then mark those I/O with this

code

SP5 SWI Does I/O require channel to channel

isolation? Then mark those I/O with this

code

3.2 Customer IO Configuration xls

Customer IO configuration has the I/O details of the plant. It is an xls file goes as input to

the tool. Against every IO that is special type (not supported by ControlEdge modules),

needs to be marked in a column as SPx, with this special code, tool is trigged to assign

appropriate ThirdParty modules and also make suitable connection diagram.

Customer IO Configuration File - Example Template:



NOTE

• Sp1 or Blank means normal IO (Supported by ControlEdge

modules). By default, Cable Diagram Software Tool assigns default

SPCode that is SP1. Project team need to edit this special code to

redefine an I/O that is not supported by ControlEdge modules

(Special Type of IO).

• BOU module supports two types of connection cards, CCCA or

CCCH. Connections are different in both cases; hence it is

important to inform the Cable diagram SW tool for creating

appropriate connection diagram. By default, the tool will assume

CCCH as the connection card for BOU module. Projects team

needs to change it if it is CCCA, with this tool makes appropriate

connection diagram.

3.3 Terminal Block Label:

Terminal block label contains details of Alcont IO slot# and ControlEdge Rack & its slot#.

Refer to drawing: 51308275 for details. This label is located behind the door on terminal

block. It guides service engineer/user to appropriately plug the Terminal Block to

ControlEdge system at one end and the SAMTEC connector to IOCB board (CCC card slot)

on Alcont IO system at the other end.

Similarly, there is a text ‘1’,’2’ written on SAMTECH connector that will be mounted on IOCB

board to interface with Alcont IO System. This happens when more than one CCC/IOCB

needs to be connected to single Control Edge Module.

For example: Two Alcont IO’s BOU (16 Chs) modules connected to one ControlEdge 900’s

DO (32 Chs) module. (Please see the IO cable image).

Details of Terminal Block Label

• Drawing Name: Terminal Block Label

• HPN: 51156518-001

• Size: 2CM x 1CM? (as appropriate to door size and readable)

• Color: White

• Label Content:

AL_Slot#: ASxx (1 to 19) 900IO_Slot#: TR/BRx (TR-1 to 8 or BR-1 to 8)

• Exact Content on Label with example1:

AS1

TR1

• Exact Content on Label with example2:

AS19


BR8

NOTE

In case if there are two or more SAMTECH connectors connected to one single

terminal block, the SAMTECH connectors are numbered with a marker pen

displaying the slot number on it. This helps in making connection.

3.4 Output Files

Below are list of output files with an example:

“Cable Diagrams for wiring vendor and Field Engineer” are used by Cable harness vendor

for creating cables and Honeywell Field Engineer for debug purpose. These cable

connection diagrams have different columns detailing the module type, channel type, CCC

card pin#, IOCB pin number etc.

For cable connection and mapping, below columns are important:

• Alcont IO Side: ALCModule#, IOCB, WC, WG, IOCBSetting and

IOCBConPin#

• Control Edge Side: PLCModule#, PLCTB and PLCTBPin#

For cable connection below columns to be considered (yellow highlighted):

• Alcont IO Side: WC, WG, IOCBConPin#

• Control Edge Side: PLCTB, PLCTBPin#

Wire column shows the channel level connection map.



3.5 BOM (Bill of Material)

Cable Diagram Tool generates below listed BOMs.

• ControlEdge 900 Modules BOM

EPOR1 Rack level BOM

Plant Level BOM

• ThirdParty Modules BOM

EPOR1 Rack level BOM

Plant Level BOM


• Cable assembly BOM

Plant Level BOM

EPOR1 Rack level BOM: This BOM will have items required for rack level. This will be used

to prepare rack level materials/modules/cables for rack by rack migration.

Plant Level BOM: This BOM will have consolidated quantity for one complete plant

migration. This is for buyer to make one comprehensive material purchase plan.

This BOM is for cable vendor for preparing comprehensive purchase plan to stock raw

materials.

Example Output BOMs:

(‘I1’ column is for tool designer use; it will not be part of the BOM)



3.6 Cable Drawing

Cable Diagram Image


NOTE

Cable diagram Software (SW) tool: Kindly go through the database xls file

for all details including tool design guidelines.

IOCB


4 IOCB

IOCB (I/O Cable Board), these boards are used as an interface between Alcont IO CCC card

and ControlEdge 900IO modules. There are two types of IOCB boards to interface with

different types of Alcont IO modules. Details are provided below.

4.1 IOCB1

This board is used along with only MAI module for both, sink and source type of Analog

Inputs. It has two switches (S1 and S2) to make appropriate connection for sink and

source type of Analog current input type. Each switch has 10 positions, totalling to 20

positions. MAI module has 10 channels, and each channel is provided with 2 positions to

make connection for sink or source type. Switch setting is explained below for two types of

configuration.

• Switch Electrical Specifications:

Operating voltage: Max 24V

Operating current per channel: Min=10uA and Max=25mA

Operating temperature: 0 to 60degC

Isolation between channels: None

• Sink Type of Analog Input:

This type of channels can be interfaced to two types of modules at ControlEdge 900 side,

To ThirdParty module

To HLAI module of ControlEdge 900

NOTE

HLAI module needs ground reference for each channel, to offer this, free

pin/connection in the IOCB1 is connected to Ground and extended to HLAI

Module. This setting is not necessary if ThirdParty Module is involved.

IOCB1 setting information is captured in a column named as ‘IOCBSetting’

in Cable diagram file against each IO.


• Source Type of Analog Input:

This type of channels can be interfaced to ControlEdge 900’s UIO module only.

Switch setting for the same is explained below:

MAI Channel# Switch# Switch Position#

For Sink Type of Field IO

Ch1 S1 1 OFF

S1 2 ON

Ch2 S1 3 OFF

S1 4 ON

Ch3 S1 5 OFF

S1 6 ON

Ch4 S1 7 OFF

S1 8 ON

Ch5 S1 9 OFF

S1 10 ON

Ch6 S2 1 OFF

S2 2 ON

Ch7 S2 3 OFF

S2 4 ON

Ch8 S2 5 OFF

S2 6 ON

Ch9 S2 7 OFF

S2 8 ON

Ch10 S2 9 OFF

S2 10 ON

:

IOCB


Board Dimension and Layout


4.2 IOCB2

This board is used with below listed Alcont IO Modules for interface with ControlEdge 900

IO module through CCC cards. This Board has a berg jumper connector for making

required connections based on module and IO type. Supported modules are: ACO, MSI,

SWI, BOU, PBI and PBO. Jumper setting is required only for PBI module when ch-ch

isolation is not required, for all other modules jumper short need to be DNP.

Electrical Specifications

• Operating Voltage: 24V DC or 230V AC

• Operating current per channel: Max=2A for signals connections, 3A for Supply

connections.

• Operating temperature: 0 to 60degC

• Isolation between channels: 600 VAC

P2’s Pins: A2, C2,A4,C4,A30,C30,A32,C32 have 3A of current carrying capacity, advised to

use them as common signals like reference ground, return or supply line. All other pins can

carry max of 2A and should be used for signal connections.

Jumper Settings

Jumper setting to be DNP for all modules except PBI module.

PBI Module: For PBI Module input type, Mount jumper on J1 for a channel as marked SP4

in Customer IO configuration xls , if the jumper short is mounted, ch-ch isolation is lost. If

IOCB


isolation is required for a particular channel, then the jumper needs to be DNP so to isolate

the return line. Isolated channels are passed through Thirdparty Module.

Read ThirdParty Module section for more details.

DO Module(CCCA Card): For BOU module with CCCA connection card combination, there

is one power supply connection for every BOU channel (2 connections per channel). But,

ControlEdge 900's DO module has 4 common power supply connections for all DO

channels. Hence ICOB2’s J1 jumper shorts all power supply connections on CCCA card

and helps route only 4 wires to ControlEdge 900's DO module to extend power supply from

field wire to Control Edge DO module.

Board Dimension and Layout


THIRDPARTY MODULES AND THEIR INTERFACES DETAILS


5 ThirdParty Modules and their Interfaces details

Below list of ThirdParty Modules will be used in Migration.

SL# SP Code HPN DESCRIPTION MPN MFR

1 SP2 51509126-

001

MODULE,MTL

CURRENT

REPEATER, 2CH

MTL5544AS MTL

2 SP3 51509127-

001

MODULE,ISOLAT

ED RELAY

OUTPUT - 2CH,

2A

MTL5526 MTL

3 SP4 51509157-

001

MODULE,SIGNAL

CONVERTER/INS

ULATOR,1CH

ACT20P-

VM-AO-S

WEIDMU

LLER

4 SP5 51509224-

001

MODULE,ISOLAT

ED SWITCH

INPUT, 2CH

MTL5513 MTL

5.1 Conditions for ThirdParty Modules Usages

SPCode: SP2

Alcont IO Module: MAI Module

ThirdParty Module: MTL5544AS (MTL)

Brief Electrical Specification

• Channels: 2

• Supply Voltage: 20 to 35V DC

• Signal Range: 1 to 21.5mA

• Operating temp: -20 to +60degC

• HART: Yes

• Wire: 2.5mm2

Conditions

• SPLCh=SP2 is for Source Type of Field device/active field devices.


• Check total count of SP2, if >16, then go for 900A16-0101 Module ONLY, if total

Control Edge 900 module count per EPOR1 rack is <=16 at the end of migration.

Else chose this ThirdParty Module.

• SPLCh=SP2 is for MAI Input with sink type IO marked in Customer IO configuration xls.

Wiring Details

There are few fixed connections marked as ‘@’ in the below diagram, this means, wiring

connection to these terminals are predefined and follow them as given in figure. And other

connections with symbol ‘#’ will be defined in cable diagram as per IO configuration, and

make connections accordingly.

Wire dimension and specifications are provided in Drawing:

51308271_Rev00_31Jan2018

Module Connections Diagram:

HC900 Side>><<Field Side

(@)24-(Ground)

(@)24+

Power Supply

# -- Wire connection defined by ‘Cable Diagram SW Tool’

@ --Fixed Connections

(@)24-(Ground)

#

(@)24-(Ground)

#

No Connection

No Connection

(@)24-(Ground)

(@)24-(Ground)

#

#

No Connection

No Connection

Module#: MTL5544AS

5.1.1 SP Code: SP3

Alcont IO Module: BOU Module

ThirdParty Module: MTL5526 (MTL)

Brief Electrical Specifications

• Channels: 2

• Supply Voltage: 20 to 35V DC(This also has loop powered option)

• Relay Off Voltage: <17V

• Relay ON Voltage: >20V

• Relay Max Current: 2A


• Wire: 2.5mm2

• Use ‘2Ch’ option in Function



Conditions

SPLCh=SP3 is for BOU output with >0.5A requirements. Choose this module if SP3 is

marked against IO in Customer IO configuration xls.

Wiring Details


connection to these terminals are predefined and follow them as given in figure. Other

connections with symbol ‘#’ will be defined in wiring diagram as per IO configuration, and



51308271_Rev00_31Jan2018

NOTE

Either external power supply can be used to power the module or choose

loop powered mode (since this module is interfaced to DO module at

Control Edge 900 side, it can work with loop powered mode as well)

Module Connections Diagram



Module#: MTL5526

(@)24-(Ground)

(@)24+

Power Supply

(@)24-(Ground)

#

(@)24-(Ground)

No Connection

No Connection

#

#

No Connection

(@)24-(Ground)

No Connection

#

(@)24-(Ground)


5.1.2 SP Code: SP4

Alcont IO Module: PBI Module

Thirdparty Module: ACT20P-VM-AO-S (Weidmulluer)


• Channels: 1

• Supply Voltage: 20 to 35V DC or Line voltage

• Input Voltage: 0 to 300 VAC or 0 to 300 VDC


• Output Voltage: 0 to 10V DC / 0 to 20mA

• Isolation Voltage: 2.2K VAC


• Wire: 2mm2

Conditions

• SPLCh=SP4 is for PBI with Ch to Ch isolation need. Choose this module if SP4 is

marked against IO in Customer IO configuration xls.

• IOCBSettings for these Channels is displayed in cable diagram, so that the jumper

short is removed on IOCB2 for these channels.

Wiring Details


connection to these terminals are predefined and follow them as given in figure. And other




51308271_Rev00_31Jan2018

NOTE

This module needs to be configured before use, thus require

configuration tools (CBX200 USB & FDT/DTM software) to be procured

from Weidmuller. Or Weidmuller has agreed to ship preconfigured

modules based on request with some additional cost.


#

#

No Connection

No Connection

#

(@)24-(Ground)

(@)24+

(@)24-(Ground)

Power Supply




Module#: ACT20P-VM-AO-S



5.1.3 SP Code: SP5

Alcont IO Module: SWI Module

ThirdParty Module: MTL5513 (MTL)


• Channels: 2

• Supply Voltage: 20 to 35V DC

• Open collector output on Safe side (Vmax: 35V DC)

• Input is a switch type with no voltage feed to it


• Switch type input needs resistors if LFD is required

• Wire: 2.5mm2

Conditions

• SPLCh=SP5 is for SWI with Ch to Ch isolation need. Choose this module if SP5 is

marked against IO

• IOCBSettings for these Channels is displayed in cable diagram, so that the jumper

short is removed on IOCB2 for these channels

Wiring Details


connection to these terminals are predefined and follow them as given in figure. Other




51308271_Rev00_31Jan2018


(@)24-(Ground)

(@)24+

Power Supply



#

#

#

#

#

#

(@)24-(Ground)

Module#: MTL5513

No Connection

No Connection

No Connection


5.1.4 Thirdparty Module Cable Drawing

51308271-001: This cable is used to connect 24V+ of all modules to Power supply’s ‘+’.

Terminal ‘N’ in the drawing refers to number of connections, which are total number of

modules per EPRO1 rack provided in Thirdparty Module BOM.

51308271-002: This cable is used to connect 24V- of all modules to Power supply’s ‘_’.

Terminal ‘N’ in the drawing refers to number of connections, which are total number of

modules per EPRO1 rack provided in Thirdparty Module BOM.

51308271-003: This is cable between ControlEdge 900 module and control side of the

Thirdparty Module.

51308271-004: This cable is used to make connection between field side of the Thirdparty

module and field connections (IOCBx).

NOTE

Details of preparing these cables are provided in below drawing. Buyer

has to order the cables based on BOM quanity generated by ‘Cable

diagram SW tool’.




6 RPIM Module

ControlEdge 900 offers both non-redundant and redundant power supply solution for the

rack. Due to space restriction in EPOR1 rack, redundant power supply solution does not fit

into it. Thus, a new approach is developed for redundant power supply need.

RPIM (Redundant power supply Interface module) is a new design to support redundant

power supply needs within the same size of 8 slot rack. Here are the details.

This design basically has ‘Power supply Oring Circuits’ with same spec as a Control Edge

900’s non-redundant power supply. Externally, this module needs pair of supplies to

source 2 x 5V and 2 x 24V.

Block Diagram

8 Slot-Rack

Din-Rail

5V1

230V/Line PS

5V2 24V1 24V2

RPIM EPM IO1 IO2 IO8

5V

1

5V

2

24

V1

24

V2

5V1n2_Status

245V1n2_Status

RPIM module form-factor is same as ControlEdge 900’s 24V PSU. RPIM PCB is a new

design and all other mechanical parts are re-use from Control Edge PSU module. Hence it

looks like PSU module with a new product label on it.

Sample, RPIM PWA images:

RPIM MODULE


6.1 RPIM Specification and Features

• Form factor is same as Control Edge 900’s 24V PSU module (900P24-0301)

• Most of the mechanical parts are re-used from ControlEdge 900 24V PSU

• It needs 2 pair of 5V DC and 24V DC Din-rail mountable PSUs. (5V: MDR-60-5,

MEANWELL, 24V: MDR-60-24,MEANWELL)

• 5V

Input Voltage Range: 5V DC Type (4.73 to 5.22V DC, +/-5%)


Max Operating Current: 8A

Fault Time: 2.4mS

• 24V

Input Voltage Range: 25V DC Type (22.11 to 25.66V DC,+/-5%)

Max Operating Current: 2.1A

Fault Time: 2.4mS

• Operating Temp: 0 to 60degC

• A 10 pins connector has Power supply inputs and status signals on it.

• A 20 pins connector has backplane power supply connections

• There are four green color LEDs to display 4 power supply unit status.

• Status Signals: There are two status signals with different voltages levels referring

to the working status of external power supply rails. Here are the details:

For 5V: Voltage at 5V1n2_STA

If both are OK: 1.24V

If one is OK and other is open: 0.7V

If one is OK and other is short to ground: 0.62V

For 24V: Voltage at 24V1n2_STA

If both are OK: 3.66V

If one is OK and other is open: 1.98V

If one is OK and other is short to ground: 1.83V

P1 Connection details (External Power Supply Connector)

RPIM MODULE


6.2 P2 Connection Details (To backplane)

Meanwell Power Supply Connection Details for both 5V and 24V:

Line connections

• Earth: Earth Connection

• L: Line

• N: Neutral

Low Voltage Connections

• +V: +5V or +24V

• -V: -5V or -24V

• -V: OV or GROUND

Status

• DC OK Switch output: Status signal

• DC OK LED: Green LED to show the status

Voltage Adjust

• +V ADJ: Voltage can be varied thru this knob.

• For 5V: 5 to 6V

• For 24V: 24 to 30V


Pin Connection Image

RPIM MODULE


6.3 Power Supply Specs

Part#: MDR-60-5 and MDR-60-24, Make: Meanwell.


3D images of External Power Supply mount and wiring reference:

RPIM MODULE


6.4 RPIM Input Cable drawing


RPIM Output Cable Drawing:

6.5 RPIM Module Product Label

Drawing Name: RPIM Module Product label

• HPN: 51156519-001

• Size: tbd (please fix the label size based on space availability and the readable font

size)

• Color: White

Guidelines:

• Consider all those listed in orange table and ignore remaining.

• include only CE marking, remove all other

• Retain all other notes that pertaining to this label and its printing needs.

RPIM MODULE


Label

A RPIM MODULE

B 51454984 (PWA:51156519-176)

C 0 TO 60 DEGC

C1 DATE CODE

J n/a

H SERIAL#: xxxx

K SERIAL NUMBER BARCODE

D

5V1 & 5V2 INPUT: 5VDC TYP (+/‐4%)

24V1 & 24V2 INPUT: 24VDC TYP (+/‐5%)

5VDC OUTPUT: 5VDC TYP (4.73‐5.22VDC @8A)

24VDC OUTPUT: 24VDC TYP (22.11‐[email protected])

6.6 RPIM Input Power Connector Label

Drawing Name: RPIM Input Power Connector Cable

• HPN: 51156519-002 • Size: tbd (please fix the label size based on space availability and the readable font

size)

• Background Color: White, Text: Black, LED area to be transparent.

Label Content

10

9

8

7

6

5

4

3

2

1

5V1

5V1-GND

5V2

5V2-GND

24V1

24V1-GND

24V2

24V2-GND

5V1n2_STA

24V1n2_STA

5V1

5V2

24V1

24V2


7 Migration Steps

Step 1 & 2

1. Dismantle the EPOR1 rack to remove all Alcont IO module. Bring to the state shown

above.

2. Mount IOCB Boards (Red colored PCB boards).

Step 3 & 4

3. Assemble IOCB SECURING BRACKET.

4. Assemble, BACK PLATE DUAL ControlEdge 900.

MIGRATION STEPS


Step 5 & 6

5. Assemble Top ControlEdge 900 Rack (without modules in it).

6. Assemble Second ControlEdge 900 Rack (without modules in it).

Step 7 & 8

7. Assemble ControlEdge 900 Modules.

8. Assemble Cables between Control Edge modules and IOCB boards.


Step 9

9. Module view with open doors and assemble ThirdParty Module Din Rail Bracket

Step 10 & 11

10. Make ThirdParty Module cable connection and secure them as shown in figure.

11. Assemble ThirdParty Modules

MIGRATION STEPS


Step 12

12. ThirdParty Modules bracket at its closed position. And completely assembled view…


8 Safety and General Guidelines

Safety Guidelines

• IOCB2 board is fixed with a plastic cover at P2 side as insulator from line/high

voltage. Do not remove it.

• For PBI and PBO modules, IOCB2 board will be handling line voltage. To protect

users from accidental touch to unused/exposed P2 connector, user should insert

dummy connector to insulate exposed pins. Use Part#: 51509141-001 (IPD1-16-

D-K, SAMTEC).

• Follow wire gauge recommendations as per the cable diagrams to avoid damage

due to incorrect cable specification.

General Guidelines

• For below two modules field side power supply connection (either 24V+ or 24V-) are

not part of IOCB cable connections. Hence additional wiring needs to be done to

make connection. For this reason, there is a din-rail mountable terminal block

provided in between two Control Edge 900 racks, kindly use them to make 24V+

and 24V-(Ground) connections as required. Module and connection details are

listed below.

ControlEdge’s DO Module (Equ BOU module in Alcont IO System): DO module

needs 24V- (Ground) connection but same is not present in BOU module. Hence

an external wire connection need to be made, use 20AWG wire gauge for this

purpose.

ControlEdge’s DI Module (Equ SWI module in Alcont IO System): DI module

needs 24V+ connection but same is not present in SWI module. Hence an

separate wire connection need to be made, use 20AWG wire gauge for this

purpose.

In case of two/more Alcont IO modules/Slots interface to one Control Edge 900

Module, use power supply connections from first Alcont IO module to connect to

Control Edge 900 module. Ignore the power supply connection of

second/remaining Alcont IO Module/Slot

In case of two/more Control Edge 900 modules interface to one Alcont IO

Module, use power supply connections from first Control Edge 900 module to

connect to Alcont IO Module/Slot. Remaining/Second Control Edge 900

Module Power supply need to be connected to Terminal Block Distributor

located between Control Edge racks.

EPM BOARD CONVERSION


9 EPM Board Conversion

This section provides the instructions to convert EPM Board to ControlEdge 900IO-

PROFINET device. The EPM board contains the PLC firmware from factory.

9.1 Prerequisites

The following is the list of software prerequisites:

• Windows7 - 64-bit host ( IP Address of this machine should be 192.168.0.1).

• Required packages as described in section 9.2 Package Installation (that involves

installation of CPMSimulator.exe, ControlEdge Builder release version 140.1-22.0

and firmware files).

9.2 Package Installation

Tools for EPM Board conversion are packaged in folder PNIOFirmwareConversionTool.

1. Go to the package folder and double-click on “ControlEdge 900IO using PROFINET -

Firmware Conversion Tool.msi” to run the installer.

2. Click Next on Welcome InstallShield wizard.

3. Enter User name and organisation information under Customer Information dialog

box and Click Next.


4. Under Setup Type dialog box, select Complete for complete package installation or

select Custom to choose and install required features and Click Next.

5. Click Install.



6. Click Finish to complete the installation.

7. Once Installation is completed, check the below path for installed packages.

“C:\Program Files\Honeywell\PNIO_FirmwareConversionTool” (in case of 64 bit

machines, the path will be “C:\Program

Files(x86)\Honeywell\PNIO_FirmwareConversionTool”). Under which three subfolder

will be created.

• ControlEdgeBuilder


• CPMSimulator

• FirmwareFiles

NOTE

ControlEdge Builder can be installed from the below path.

For detailed installation steps on ContolEdge builder, refer to

“ControlEdge Builder installation manual”.

9.3 Conversion Procedure from PLC to ControlEdge 900IO-PROFINET

Conversion of EPM Board from PLC to ControlEdge 900IO-PN involves the following

three steps in sequence:

1. Upgrade PLC Product Firmware (part of package)

Firmware filename: epmv1_prod_signed_external_r ls.pkg.

2. Upgrade PNIO Recovery Firmware (part of package)

Firmware filename: Firmware Image: pn900recovery_emp_pn_mrp_signed_prod.pkg.

3. Upgrade PNIO Product Firmware (part of package)

Firmware filename:

ControlEdge_900IO_using_Profinet_R100.1_Product_Signed.pkg.

Upgrade PLC Product Firmware

To upgrade PLC Product Firmware follow the below steps:

1. Launch CPMSimulator.exe from “ :\Program Files (x86)\Honeywell\ PNIO_FirmwareConversionTool\CPMSimulator” to run CPM simulator.



NOTE

On launching the CPM simulator for the first time Firewall

window pops up. Select the settings for CPM simulator as

below and click Allow access.

2. CPMSimulator simulator windows appears as below.

3. Launch ControlEdge Builder from Start menu.

4. In ControlEdge Builder, click Connect button under ControlEdge Configuration

window to open Connect Controller dialog box.


5. In Connect Controller dialog box, select IP Address option.

6. Enter following credentials and click Connect .

• IP Address: 127.0.0.1

• User name: Administrator

• Password: Admin@1234



7. Now, Click Upgrade Firmware under Maintenance tab to check the EPM details.

8. In Left Pane, Select EPM and make a note of Boot and Application version.

• Boot Version represents the recovery Image version.

• Application version represents the product Image version.

9. Select Radio button for EPM Module Name. Click Transfer.


10. Press Browse to select the. pkg file. Select the appropriate .pkg file, Click Open.

Sequence of upgrade is given in section EPM Board Conversion from PLC to

PNIO

11. Check Full Transfer. Click Transfer.

12. Firmware Transfer status screen will appear.



13. On completion of Firmware transfer, Click Upgrade.

14. Click OK on Upgrading Firmware dialog box.


15. Click Yes to upgrade the firmware.

16. Firmware upgrade status window will appear.



17. EPM board reboots once the upgrade is complete.

18. Close CPMSimulator and ControlEdge Builder.

Now, The Board contains the upgraded firmware version. To verify the new version

follow Step one to nine.

9.4 EPM Label

EPM module needs to be upgraded with PNIO software at Integration center. After the

upgrade this label is to be put on it for identification and for tracking (EPM) PNIO-EPM in

the field.

. This label will also help for tracking (EPM) PNIO-EPM in the field.

Drawing Name: PNIO EPM Label

• HPN: 51121627-001

• Color: White

• Label Content:

HPN: 51121627-001

DATE: xx-xx-xxxx

FW VERSION: xxxx


10 Test and Certification

IOCB boards have not been evaluated for any certification needs as these are passive

boards used for extending the connections.

IOCB2 has been qualified for 600VAC isolation test.

RPIM Module is tested for CE conformity (IEC: EN61326-1:2013)

NOTICES


11 Notices

Trademarks

Experion ® Process Knowledge System (PKS) is a registered trademark of Honeywell International Inc. All other brand or product names mentioned in the document are trademarks of their respective owners.

Other trademarks

Trademarks that appear in this document are used only to the benefit of the trademark

owner, with no intention of trademark infringement.

ThirdParty licenses

This product may contain or be derived from materials, including software, of third parties.

The ThirdParty materials may be subject to licenses, notices, restrictions and obligations

imposed by the licensor.

The licenses, notices, restrictions and obligations, if any, may be found in the materials

accompanying the product, in the documents or files accompanying such ThirdParty

materials, in a file named third_party_ licenses on the media containing the product, or at

http://www.honeywell.com/ps/thirdpartylicenses.

Documentation feedback

You can find the most up-to-date documents on the Honeywell Process Solutions support

website at:

http://www.honeywellprocess.com/support

If you have comments about Honeywell Process Solutions documentation, send your

feedback to:

[email protected]

Use this email address to provide feedback, or to report errors and omissions in the

documentation. For immediate help with a technical problem, contact your local

Honeywell Process Solutions Customer Contact Center (CCC) or Honeywell Technical

Assistance Center (TAC).

How to report a security vulnerability

For the purpose of submission, a security vulnerability is defined as a software defect or

weakness that can be exploited to reduce the operational or security capabilities of the

software.

Honeywell investigates all reports of security vulnerabilities affecting Honeywell products

and services.

http://www.honeywell.com/ps/thirdpartylicenses

http://www.honeywellprocess.com/support

mailto:[email protected]


To report a potential security vulnerability against any Honeywell product, please follow the

instructions at:

https://honeywell.com/pages/vulnerabilityreporting.aspx

Submit the requested information to Honeywell using one of the following methods:

Send an email to [email protected].

or

Contact your local Honeywell Process Solutions Customer Contact Center (CCC) or

Honeywell Technical Assistance Center (TAC) listed in the “Support” section of this

document.

Support

For support, contact your local Honeywell Process Solutions Customer Contact Center

(CCC). To find your local CCC visit the website, https://www.honeywellprocess.com/en-

US/contact-us/customer-support-contacts/Pages/default.aspx.

Training classes

Honeywell holds technical training classes that are taught by process control systems

experts. For more information about these classes, contact your Honeywell representative,

or see http://www.automationcollege.com.

https://honeywell.com/pages/vulnerabilityreporting.aspx

mailto:[email protected]

https://www.honeywellprocess.com/en-US/contact-us/customer-support-contacts/Pages/default.aspx

https://www.honeywellprocess.com/en-US/contact-us/customer-support-contacts/Pages/default.aspx

http://www.automationcollege.com/

PMDOC-X364-en-100A

April 2018

© 2018 Honeywell International Sàrl

Honeywell Process Solutions

Contact: Honeywell Oy GTAC P3-DCS

Navitas 1, B-block, 4.kerros

Wredenkatu 2

FI-78250 Varkaus, Finland

Phone: +358 20 752 2000

E-mail: DL HPS_Q_GTAC_P3_DCS

Documents

ControlEdge 900IO using PROFINET Integration Center … · 3.2 Customer IO Configuration xls ... 48 9.4 EPM Label ... #For only REDU Power Supply requirements ~Customized Parts?