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CDWeb Manager

System Manual
6510020204 Rev 01

CDWeb Manager System


Manual

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
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Contents

3.1.

Introduction ............................................................................................................................ 3-1


3.1.1.
CDWeb Explorer ........................................................................................................ 3-1
3.1.2.
Hybrid Control Designer .......................................................................................... 3-2
3.1.3.
Internet Explorer ........................................................................................................ 3-2
3.1.4.
Windows Remote Desktop....................................................................................... 3-2
3.1.5.
Personal Computer .................................................................................................... 3-2
3.2. CDWeb Explorer .................................................................................................................... 3-3
3.2.1.
The .web File............................................................................................................... 3-3
3.2.2.
Connecting to the System Using CDWeb Explorer .............................................. 3-6
3.2.2.1. Connection through Da Vinci or CDWeb Processor ....................................... 3-8
3.2.2.2. i.LON Direct Connection ..................................................................................... 3-8
4. Common Tasks ................................................................................................................................ 4-1
4.1. View and Log CDWeb Diagnostic Information ................................................................ 4-1
4.2. Configure and Tune Actuators ............................................................................................ 4-3
4.2.1.
Configuring Actuators .............................................................................................. 4-3
4.2.2.
Tuning an Actuator ................................................................................................... 4-5
4.3. Save and Restore Configuration and Tuning .................................................................... 4-7
4.4. Download New Actuator Firmware ................................................................................... 4-8
4.5. Reconfigure or Replace an i.LON 100 Router.................................................................... 4-9
4.6. Replace a LONWorks Router............................................................................................. 4-12
4.7. Establish a Network Connection to the HC900 ............................................................... 4-13
4.8. Modify the TCP/IP Settings of the HC900....................................................................... 4-14
4.9. Create a Backup of HC900 Configuration and Logic ..................................................... 4-18
4.10.
Load an HC900 Processor............................................................................................. 4-20
4.11.
Install the LON Server Software.................................................................................. 4-22
4.11.1. Introduction .............................................................................................................. 4-22
4.11.2. Installing the LON drivers...................................................................................... 4-23
4.11.3. Creating the CDWeb profile................................................................................... 4-23
4.11.4. Adding the LON Server.......................................................................................... 4-27
4.11.5. Setting up the HC900 communications ................................................................ 4-29
4.12.
Modifying the CDWeb Processor IP Addresses........................................................ 4-34
4.12.1. Remote Desktop Connection.................................................................................. 4-34
4.12.2. CDWeb Processor Address .................................................................................... 4-37
4.12.3. ODX Server Host Address...................................................................................... 4-37
4.12.4. HC900 Address ........................................................................................................ 4-38
4.12.5. i.LON Address ......................................................................................................... 4-40
5. Glossary ............................................................................................................................................ 5-1
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A. CDWeb Configuration Files ........................................................................................................ A-1


A.1.1.
Actuator Alarm Enumeration ................................................................................. A-1
A.2.
CDWeb.ini........................................................................................................................ A-1
A.2.1.
host gauge .................................................................................................................. A-2
A.2.2.
actuator type .............................................................................................................. A-2
A.2.3.
Number of actuators................................................................................................. A-2
A.2.4.
Actuators per node ................................................................................................... A-3
A.2.5.
Interlock Mask ........................................................................................................... A-3
A.2.6.
Setpoint/position send mask .................................................................................. A-3
A.2.7.
Powerup bit................................................................................................................ A-3
A.2.8.
Powerup reset bit ...................................................................................................... A-4
A.2.9.
Flushable..................................................................................................................... A-4
A.2.10. Database ..................................................................................................................... A-4
A.2.11. Node name ................................................................................................................. A-4
A.2.12. Beam id ....................................................................................................................... A-5
A.2.13. Actuator map file ...................................................................................................... A-5
A.2.14. Alarm map file........................................................................................................... A-5
A.2.15. Sample CDWeb.ini file ............................................................................................. A-6
A.3.
Database (CSV) file ......................................................................................................... A-6
A.3.1.
:NODE:........................................................................................................................ A-7
A.3.2.
:SUBNET_NODE:...................................................................................................... A-7
A.3.3.
:NODE_NV: ............................................................................................................... A-7
A.4.
Actuator Map File ........................................................................................................... A-8
A.5.
Alarm Map File................................................................................................................ A-8
B. System and Actuator Alarms ........................................................................................................B-1
B.1. System Alarms........................................................................................................................B-1
B.2. Actuator Alarms.....................................................................................................................B-1
B.3. Status and Alarm Word Structures .....................................................................................B-1
B.3.1.
Aqualizer .....................................................................................................................B-2
B.3.2.
AutoSlice CDW/ProCoat CDW...............................................................................B-4
B.3.3.
Calcoil CW...................................................................................................................B-6
B.3.4.
IDP (Devronizer XP7, Calendizer XP).....................................................................B-8
B.3.5.
ProFlow II..................................................................................................................B-10
B.3.6.
AutoSlice/ProCoat...................................................................................................B-12
B.3.7.
ProFlow......................................................................................................................B-14
C. Host Communications................................................................................................................... C-1
C.1.
ODX................................................................................................................................... C-1
C.1.1.
CDWeb Manager Network Communication Specification................................. C-1
C.1.1.1. Introduction ......................................................................................................... C-1
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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
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Table B-12 AutoSlice/ProCoat Actuator Alarm Word Mapping ............................................... B-13


Table B-13 ProFlow System Status Words...................................................................................... B-14
Table B-14 ProFlow Actuator Alarm Word Mapping .................................................................. B-15
Table C-1 Supervisory Control System Symbol Names ................................................................. C-7
Table C-2 RTU Functions .................................................................................................................... C-9
Table C-3 Modbus Registers Up To 200 Actuators .................................................................... C-10
Table C-4 Modbus Registers 201 To 400 Actuators.................................................................... C-10
Table C-5 RTU Actuator Types ........................................................................................................ C-11
Table C-6 OPC Tagnames ................................................................................................................. C-13

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Introduction

This manual provides an introduction to the CDWeb Manager.

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.

About This Manual


This manual contains 5 chapters and 3 appendixes.
Chapter 1, System Overview, describes the function of the CDWeb
Manager and gives an overview of the system components.
Chapter 2, Installation Requirements, describes the site specifications
for installing the CDWeb Manager.
Chapter 3, Utilities, describes the function of various utilities that may
be used during installation or maintenance.
Chapter 4, Common Tasks, describes basic duties performed by the
CDWeb Manager.
Chapter 5, Glossary, describes terms and acronyms used in this
manual.
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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

Document Title / Description


SCL User's Manual
Hybrid Controller Installation and User Guide
Hybrid Control Designers User Manual
Installation Requirements for Conformance to Standards
i.LON 100 Internet Server Users Manual

Conventions
The following conventions are used in this manual:

NOTE:

Boldface
Special Type

Italics

Boldface

lowercase

Type
Press

1-2

Text may appear in uppercase or lowercase except as specified in these


conventions.
Boldface characters in this special type indicate your input.
Characters in this special type that are not boldfaced indicate system
prompts, responses, messages, or characters that appear on displays,
keypads, or as menu selections.
In a command line or error message, words and numbers shown in
italics represent file names, words, or numbers that can vary; for
example, file name represents any file name.
In text, words shown in italics are manual titles, key terms, notes,
cautions, or warnings.
Boldface characters in this special type indicate button names, button
menus, fields on a display, parameters, or commands that must be
entered exactly as they appear.
In an error message, words in lowercase are file names or words that
can vary. In a command line, words in lowercase indicate variable
input.
Type means to type the text on a keypad or keyboard.
Press means to press a key or a button.

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[ENTER]
or [RETURN]

[CTRL]

Conventions

[ENTER] is the key you press to enter characters or commands into the

system, or to accept a default option. In a command line, square


brackets are included; for example:
SXDEF 1 [ENTER]
[CTRL] is the key you press simultaneously with another key. This key

is called different names on different systems; for example,


[CONTROL], or [CTL].
[KEY-1]-KEY-2

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.

The caution icon appears beside a note box containing information


that cautions you about potential equipment or material damage.
The warning icon appears beside a note box containing information
that warns you about potential bodily harm or catastrophic
equipment damage.

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Honeywell, Vancouver Operations Part Numbers


Honeywell, Vancouver Operations assigns a part number to every
manual. Sample part numbers are as follows:
6510020004
6510020048 Rev 02
The first two digits of the part number are the same for all Honeywell,
Vancouver Operations products. The next four digits identify part type.
Type numbers 1002 designates technical publications. The next four digits
identify the manual. These digits remain the same for all rewrites and
revision packages of the manual for a particular product. Revision
numbers are indicated after the Rev.

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1. System Overview

A Honeywell CDWeb actuator system consists of three main components:


the CDWeb Manager, a communications bus, and the actuators.
The CDWeb Manager acts as the interface between the supervisory
control system and the actuators via the communications bus. The
communications bus, also known as the local operating network (LON), is
based on the LONWorks standard with custom messages created
specifically for Honeywell CD actuator control. This bus uses Echelon
FT/10a transceivers to allow robust actuator communications at 78kBps.
Other functions of the CDWeb Manager include actuator power
distribution and system interlock monitoring.

1.1. Supervisory Control System


Communications Interface
A supervisory Quality Control System (QCS) receives paper
measurements (for example, weight, moisture, caliper) from a scanner
system and calculates actuator setpoints using a variety of control
algorithms. The QCS then transmits these setpoints to the actuator system
and in return receives actuator status and position information.
The CDWeb Manager supports a number of different communication
protocols for communications with the QCS. The standard protocol used
with Honeywell Performance CD control systems is a LON protocol over
TCP/IP. This protocol is converted to LON FT/10a by a router in the
CDWeb Manager known as the i.LON 100.
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To support communications to QCS systems other than Performance CD,


the CDWeb Manager also support ODX, RTU Modbus, and SCL protocols.
These protocols are supported by the addition of an industrial computer,
called the CDWeb Processor, to translate between the QCS protocol and
the LON over TCP/IP protocol for connection to the i.LON 100 router.

1.2. The LON Server Software


Actuator communications direct from the Performance CD server is
achieved through the LON server software. This software consists of two
executables (CDWebnet.exe and CDWebRTDR.exe), communications
drivers (OpenLDV) and configuration files (CDWeb.ini, export.csv,
zone.map, alarm.ini).
CDWebRTDR continuously reads actuator setpoints from the RTDR
database and sends this information to CDWebNet. CDWebNet provides
the interface to the OpenLDV communication driver, which converts the
messages to a format suitable for transmission over the LAN. Actuators
receive these setpoints and periodically respond with their status
information. This data is sent from OpenLDV to CDWebNet and from
there to CDWebRTDR, which populates the appropriate locations in the
RTDR database for use by the Performance CD control software.

1.3. The i.LON 100


Combined with the LON server software, the i.LON 100 is the heart of the
CDWeb Manager. This device provides the hardware interface between
the actuators operating on the LON, and the QCS operating on the 10/100
base-T LAN. The i.LON 100 has many features, such as an internet server
and a modem, which are not used in the CDWeb Manager, and will not be
discussed further in this document.

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The i.LON 100

Figure 1-1 i.LON 100

1.3.1. i.LON Status Lights


The following LEDs provide status information for the i.LON 100 server:

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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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.

1.4. The CDWeb Processor


CDWeb Managers that are required to communicate to CD control
systems other than Honeywells Performance CD system require the
addition of a CDWeb Processor. This processor acts as a protocol
translator between the QCS and the i.LON 100, converting the ODX, RTU,
or SCL host messages to LON over TCP/IP and vice versa.
The CDWeb Processor is an industrial PC running Windows XP with a
minimal RAE 4.0 installation. ODX client, RTU slave, or SCL slave
applications communicate with the host QCS placing (and retrieving)
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HC900 Hybrid Controller

information directly in the RTDR database. The CDWeb LON server


application provides the interface between the database and the actuators
through the i.LON.

1.5. HC900 Hybrid Controller

Figure 1-2 Honeywell HC900 Hybrid Controller (configuration may


vary)
CDWeb systems that require interlocks may include a Honeywell HC900
controller for this purpose. The HC900 monitors and controls system
interlocks using discrete I/O and reports system status back to the
performance CD or CDWeb Processor via a Modbus TCP communications
link. Alternatively, any customer-supplied PLC or DCS that is capable of
reporting system status through Modbus TCP can be configured to control
the system interlocks.
The HC900 controller is programmed and configured using the Hybrid
Control Designer software package. This software provides a user
interface to allow programming of the HC900 through block logic.
Instructions for loading an HC900 controller using Hybrid Control
Designer are included later in this manual. For further information on the
use of Hybrid Control Designer please refer to the Hybrid Control
Designer user documentation.
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Although the HC900 includes a lithium backup battery to save run-time


data and power the real-time clock in the event of a power loss, this
feature is not used on CDWeb Manager systems. In the event that the
battery is removed or discharged, the CDWeb system will continue to
function correctly, however a red warning LED on the HC900 processor
will blink five times to indicate the fault.

1.5.1. Controller Mode Switch


The three-position mode switch is located inside the door of the HC900
CPU. The left position is Run-locked mode, the middle position is Run &
Program mode, and the right position is Program-locked mode. The
normal position for operation in a CDWeb system is either Run-locked, or
Run & Program.

1.5.2. Status LED


The HC900 status LED gives an indication of the controllers mode.
Flashing green indicate Run mode, solid green indicate Program Mode,
while flashing red indicates and error code. Refer to the Hybrid Controller
Installation and User Guide for more details.

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2. Installation Requirements

2.1. CDWeb Manager Environmental Specification


All Honeywell CDWeb Managers have the following environmental
specification:
Cabinet Rating:
Operating Temp.:
Storage Temp.:
Operating Humidity:
Storage Humidity:

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.

2.2. CDWeb Manager Electrical Specification


2.2.1. Mill Power Requirements
This specification defines the requirements for AC source power for the
operation of the CDWeb Manager. For more details on power
requirements, see the Installation Requirements for Conformance to Standards
manual, part number 65 1002 0134, shipped with the CDWeb Manager.
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2.2.2. Voltage, Current and Frequency Ratings


The required source voltage for the CDWeb Manager is 100/120 VAC or
200/230 VAC. The current requirements for the various CDWeb Managers
depend on actuator type and system size. Consult Engineering drawings
to determine the requirements for a specific system.
The source frequency should be 60 Hz 2 Hz, or at 50 Hz 2 Hz. Short or
long term variations outside these limits degrade system reliability.
The voltage supply must not deviate from these specifications. Condition
the supply to correct for any drift that may occur from facility load
changes, or starting and running current requirements.

2.2.3. Installation of Distribution Circuits


Selection of wire sizes, cable type, color, conduit, switch panel, breakers,
transformers, and miscellaneous hardware, must conform to local
electrical codes and to standard practice. Circuit breakers must be sized
according to Honeywell equipment power requirements and installed in
close proximity to the equipment they power. Refer to the cable/conduit
schedule included with the system drawings for specific details.

2.3. CDWeb Manager Installation


2.3.1. Enclosure Installation
The CDWeb Manager enclosure is shipped from the factory unchanged
from the original manufacturers NEMA 4 condition. Any modifications
done to the enclosure during installation can compromise the seal
integrity of the enclosure and reduce the enclosure performance to below
NEMA 4. Consult Honeywell if a non-standard installation method is to
be used.
All CDWeb Managers are equipped with grounding terminals to be
connected to mill ground during installation as per standard practice or
regional regulations. Failure to provide a primary ground connection to
the grounding terminals (consult system electrical drawings for exact
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CDWeb Manager Installation

locations) can lead to personal injury and may be in violation of local


electrical code.

2.3.2. Cable Installation


Where possible, cable entry into the CDWeb Manager enclosure should be
from the bottom to prevent condensation or moisture in the cable conduit
from dripping into the enclosure. All cables and conduits must use watertight cable glands or fittings to preserve the NEMA 4 rating of the
enclosure.
Cables and wires are to be terminated according to the control cabinet
electrical wiring diagrams supplied with the system. Refer to the wire and
cable schedule provided with the system for minimum recommended
cable sizes and types.

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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.

3.1.1. CDWeb Explorer


CDWeb Explorer is a software utility designed and created specifically for
the installation and maintenance of a CDWeb actuator system. Its major
functions include:

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Installing new or replacement actuator controllers

Viewing runtime diagnostic information

Configuring/tuning/calibrating actuator controllers

Monitoring actuator controller status messages

Updating actuator firmware

Defining and generating network layout (.csv and .map files)

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3.1.2. Hybrid Control Designer


Hybrid Control Designer is a software utility designed specifically for the
HC900 series of controllers. Its major functions include:

Viewing and modifying interlock block logic

Viewing and modifying I/O configuration

Changing the network parameters of the HC900 processor

3.1.3. Internet Explorer


Internet Explorer, or any other standard internet browser, is required to
access the maintenance features of the i.LON100. The major functions it is
used for in a CDWeb system are:

Modifying network parameters of the i.LON100

Updating the firmware of the i.LON100

3.1.4. Windows Remote Desktop


Windows Remote Desktop, a standard feature with Windows XP, is used
to configure a CDWeb Processor when connecting a monitor and
keyboard directly to the processor is not possible. It can be used for the
following functions:

Modifying CDWeb processor communications parameters

Configuring a replacement CDWeb Processor

3.1.5. Personal Computer


All of the utilities previously described in this chapter require a personal
computer. The minimum requirements for this PC are:

3-2

CPU: Pentium, 300MHz

Operating System: Windows 2000, Windows XP


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CDWeb Explorer

Display Color: Minimum resolution (256 color x 1024 x 768


resolution)

Pointing Device: Mouse, Trackball or compatible device

RAM: 128MB Minimum

Removable Disk Drive: CD ROM Drive

Ports: Ethernet

3.2. CDWeb Explorer


The main utility used for configuring and maintaining a CDWeb actuator
system is CDWeb Explorer.

3.2.1. The .web File


CDWeb Explorer is based around a system specific .web file. Normally this
file is name CDWeb.web, but any standard file name with the .web
extension will work. In general, there should be no need to modify a .web
file for a CDWeb system as it is set up at the time of manufacture.
The .web file is simply a text-based database that contains information
relevant to a specific CDWeb system. It describes how many, and what
type of actuators are present in the system. Each section of the .web file
refers to a specific element of the CDWeb system.
[CDWeb Explorer]
The CDWeb Explorer section allows you to set the default view of the
system when the .web file is first loaded. This view can be changed
dynamically at any time during a CDWeb Explorer session, but each new
session will start with the default view defined in the .web file.
[CDWeb Explorer]
View=location

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[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)
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LDV address = X.CDWEB.CP1


LON Link Type = Processor or SLTA)
The address defined in this section is simply the default IP address
where CDWeb Explorer looks for the LON server application
(CDWebNET.exe). If the IP address of the LON server has been changed it
can be found using the Locate option from the context menu. This
function also dynamically updates the .web file to look at the new address.

++

[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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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

3.2.2. Connecting to the System Using CDWeb Explorer


CDWeb Explorer provides several ways to connect to the actuator system
for installation and maintenance. With the .web file open, right click in the
LON interface and select configure link.

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From the link configuration window, you can select various options to
communicate through CDWeb Explorer.

Available options include:

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DaVinci : for connection through the Da Vinci server. This


connection is required in order to view system diagnostic
messages, as they are generated by the LON server software
residing on the Da Vinci server. Select this option when connecting
through a CDWeb Processor.

FC: for connection through a PMD field controller. This option is


included to support the previous generation of CDWeb Manager.
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3.2.2.1.

EPC-8: for connection through a CDWeb Manager with an EPC-8


CDWeb Processor. This option is included to support the original
style of CDWeb Manager.

SLTA: for connection through a Serial LONTalk Adapter (SLTA).

i.LON Direct: This option is for connection to the actuators directly


through the i.LON, bypassing the LON server software on the Da
Vinci server. Installation of the i.LON driver software on the
maintenance PC is required.

Connection through Da Vinci or CDWeb Processor


In order to connect through either a Da Vinci server, or the CDWeb
processor when Da Vinci is not the QCS, select DaVinci in the Interface
Type drop-down list in the configuration window, enter the IP address of
the Da Vinci server, and choose the interface index. The interface index is
usually named after the gauge ID for the given actuator system. In the
example shown it is WP1.

3.2.2.2.

i.LON Direct Connection


If the Da Vinci server is offline or otherwise unavailable, it may be
necessary to connect using the i.LON direct connection type. With the
connection type selected, select the name of the i.LON you wish to connect
to from the Interface Name drop down list. The interface names are
normally set to contain the gauge ID of the actuator system to avoid
confusion.

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In order to use the i.LON direct connection the i.LON communication


drivers (OpenLDV) must be installed and configured on the computer
running CDWeb Explorer (see Subsections 4.11.2 and 4.11.3 ).

NOTE:

The i.LON can support only one OpenLDV connection at a time,


meaning that if the Da Vinci server is on-line and connected to the
i.LON then CDWeb Explorer will not be able to make an i.LON direct
connection.
The IP address field for the i.LON Direct option is actually the IP address
of the Da Vinci server. This field is only used in the event that a second
i.LON has been connected for troubleshooting purposes. In this case,
choose the alternate i.LON in the interface name field and fill in the IP
address field with the Da Vinci address. This enables communication to
the actuators through the alternate i.LON, while viewing diagnostic
messages from the LON server software on the Da Vinci.

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4. Common Tasks

This chapter contains descriptions of how to perform common tasks for


CDWeb systems. Basic instructions are given for loading and
communicating with the HC900 controller, but for a fuller understanding
of its capabilities and features, reading the HC900 documentation is
recommended. Before attempting these procedures, ensure that the
software tools have been properly installed on a suitable maintenance
computer.

4.1. View and Log CDWeb Diagnostic Information


CDWeb diagnostic information can be viewed only when connected
through a computer running the LON server application
(CDWebNET.exe). The LON Server software will be running on either on
the Da Vinci server or on the CDWeb Processor required for legacy and
MXOpen systems
To see the diagnostic messages: using CDWeb Explorer, right-click on the
CDWeb Processor and select View Diagnostic Messages from the
context menu.

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Figure 4-1 Diagnostic Messages Menu


The diagnostics window appears.

Figure 4-2 Diagnostic Messages Window


Diagnostic messages are color coded according to severity level, with a
key displayed each time a diagnostic window is opened (see Figure 4-2).
Priority level 0 messages are critical, while priority level 4 through 7
messages are routine information.

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Configure and Tune Actuators

The display can be paused using the

button in the top left corner of the

window. A file log can be enabled using the


corner of the window.

button in the top right

The filter button


can be used when there are multiple CD actuator
systems connected in order to filter out messages for systems which do
not require troubleshooting.
The slider bars
at the top are used to
filter the message severity level. Moving the slider to the left filters out
lower priority messages, while moving it to the extreme right allows all
messages through. The left slider is used to filter message shown on the
display, while the right slider is used to filter messages sent to the log file
(if active).

4.2. Configure and Tune Actuators


Each actuator needs certain information in order to operate correctly. This
information includes how often it should communicate with the CDWeb
Manager.
Configuring an actuator lets it know what type of actuator it is and gives it
certain values required for LON communications. Tuning provides
operational limits and alarm thresholds. Calibration consists of the values
required to transform sensor inputs into useful outputs.
An actuator is configured by sending it a network variable message for
nci_ActConfig with meaningful values. Similarly, tuning an actuator
consists of sending it a new nci_ActTuning network variable.
For detailed information regarding the tuning and configuration of
specific actuators please refer to the appropriate actuator system manual.

4.2.1. Configuring Actuators


1. Start CDWeb Explorer and load the .web file for the system.
2. Configure the CDWeb Explorer link (see Chapter 3).

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3. Select the actuator that requires configuration from the tree


structure and highlight it by clicking on it.

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.

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5. Enable edit mode by pressing the edit mode button


bar.

on the tool

6. Edit the values that require changing.


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, press Copy to All
or Copy to

4.2.2. Tuning an Actuator


1. Start CDWeb Explorer and load the .web file for the system.
2. Configure the CDWeb Explorer link (see Chapter 3).
3. Select the actuator that requires tuning from the tree structure and
highlight it by clicking on it.

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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.

5. Enable edit mode by pressing the edit mode button


bar.

on the tool

6. Edit the values that require changing.


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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

4.3. Save and Restore Configuration and Tuning


In some cases it can be useful or even necessary to save the actuator
tuning and configurations values. For example, if the actuator firmware is
being upgraded to take advantage of some new actuator features, the
tuning and configuration data can be saved, and then restored to the
actuators when the process is complete.
To save configuration or tuning information:
1. Start CDWeb Explorer and load the .web file for the system.
2. Ensure the Actuator communication interface is functional.
3. Select an actuator from the tree structure and highlight it by
clicking on it.
4. Select the tuning or 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.
5. Press the Save Data
prompted.

button, and enter a file name when

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.

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7. Press OK and the data will be saved.


Repeat this procedure for each type of data (tuning, configuration,
calibration) that you want to save.
To restore data to an actuator, follow the same procedure, but use the
Restore Data

button in Step 5.

4.4. Download New Actuator Firmware


1. To download the application software into a CDConnect, CDWeb
Explorer must first be in Expert Mode. To do this, select
View Options from the menu and check Run CDWeb Explorer
in expert mode in the dialog box.

2. Save configuration, tuning, and configuration network variables to


a file before commencing with firmware download, so that this file
may be restored later. See Section 4.3 for instructions.
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3. Right click the zone that requires new application software, and
choose Download Application. Choose the .nxe to download.

4.5. Reconfigure or Replace an i.LON 100 Router


The i.LON 100 needs no modification from its default settings except to
configure the IP address and subnet as per the TCP/IP parameters
configured in the Supervisory Control System.

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.

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2. Reset the i.LON 100 to factory defaults:


a.

Press and hold the service switch on the top of the


i.LON 100.

b.

While holding the service pin switch, use a wire to


momentarily press the reset button located directly
below the output status LEDs.

c.

Continue to hold the service pin while the LEDs


become steady, then flash, then remain on steadily for
the second time (approximately 30 seconds).

3. Type the following command from a Windows command prompt:


route add 192.168.1.0 mask 255.255.255.0
%computername%

4. In the address field of a web browser enter: 192.168.1.222

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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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pin message is generated by the i.LON whenever the service button


in the recessed hole on the front panel is pressed.

4.6. Replace a LONWorks Router


Some systems may have a router in addition to the i.LON100. To replace
the router:
1. Start CDWeb Explorer and load the .web file for the system.
2. Select the router that requires replacement from the tree structure
and highlight it by clicking on it.
3. Right-click on the router and select the Install function from the
context menu. Follow the on-screen prompts. A service pin
message is generated by the router whenever the service button in
the recessed hole on the front panel is pressed.

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4.7. Establish a Network Connection to the HC900


To modify settings, logic, or configuration on the HC900, first establish a
connection between the maintenance PC running Hybrid Control
Designer and the HC900 Controller. To establish this connection:
1. Connect a straight through Ethernet cable between the PC and the
HC900.
2. Inside Hybrid Control Designer, open the configuration file (*.cde).
If you do not have the .cde for the system, see Section 4.9.
3. Select the Utilities tab.

4. Under the PC Port Setup menu click on Network.

5. If the IP address of the HC900 does not appear in the list click on
Add, otherwise proceed to step 7.
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6. Enter the HC900 IP address

7. Highlight the address of the HC900 in the list and click on Loop
Back to test communications.

4.8. Modify the TCP/IP Settings of the HC900


To change the IP address or any other TCP/IP settings of the HC900
Hybrid Controller:
1. Create a backup copy of the existing HC900 logic and configuration
(see Section 4.9).
2. Establish a network connection with the HC900 Controller.
3. Add the new IP address for the controller by clicking on Network
in PC Port Setup.

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4. Add the desired new IP address.

5. From the Utilities screen, select Set Controller Network


Parameters.

6. Select the third setup option allowing you to modify TCP/IP


settings.

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7. Press Next and Next again to access the controller.


8. Press Yes to a dialog box asking whether to change Program mode.

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.

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10. Set the controller back to run mode, by selecting Set Controller
Mode from the Utility menu.

11. Change the controller mode to Run mode.

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4.9. Create a Backup of HC900 Configuration and


Logic
Before modifying interlock logic it is important to back up the existing
logic. The following procedure lists the steps necessary for uploading the
existing configuration to save as a backup. Perform this procedure before
changing the HC900s Logic:
1. Ensure that all configuration files have been closed. The Hybrid
Control Designer window should be empty with no open windows.
2. Select: File

New.

3. Select HC900-C30, and the correct controller revision. Click OK.

4. Establish a network connection with the HC900 Controller (see


Section 4.7).
5. Click on upload
file menu.

or select Upload Configuration from the

6. The Upload File dialog appears. Select Network for the Port and
select the IP address for the HC900. Click Start.

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7. A warning message may appear stating that any changes made to


any variables or code while uploading may not be captured. Click
OK.

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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9. Save the configuration by selecting Save As from the File menu.


Modifications can now be made safely to the logic located in the Function
Block Diagrams or to the configuration located in the Utilities menu.
Additional features such as e-mail notification may also be added. Please
read the Hybrid Control Designers User Manual for details.

4.10.

Load an HC900 Processor


In the event that an HC900 processor must be replaced, or logic has been
modified, the controller must be loaded.
1. Ensure the HC900 mode switch is in the center position (Run &
Program)
2. With Hybrid Control Designer open, select File Open from the
menu.
3. Select the logic for the system.

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4. Establish a network connection with the HC900 controller.


5. Press Download, or select File Download from the menu.
6. If the IP address shown in the address box is incorrect, choose the
IP address of the HC900 from the drop-down list. Click Start.

7. When the download is complete, if the controller is in Run mode


the next screen appears. Choose the option that suits your needs
best. Cold start is recommended, unless the CD actuator system is
currently online, as it may change the state of the logic
unexpectedly. A cold start may take several seconds.

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8. Close the Download File Window.

4.11.

Install the LON Server Software

4.11.1.

Introduction
Installation of the LON Server software involves a few basic steps:

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1. Installing the LON drivers


2. Creating the CDWeb profile
3. Adding the LON server
4. Setting up the HC900 communications

4.11.2.

Installing the LON drivers


Run the installation file OpenLDV210.exe and follow the on screen
prompts, installing the files in their default directories.

4.11.3.

Creating the CDWeb profile


1. Find xdriverprofileeditor.exe in the C:\Lonworks\Bin directory
and double-click to run it.

2. Highlight the Default profile and click Copy.


3. Enter CDWeb as the Profile name.

4. Highlight the new CDWeb profile, and click Properties.


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5. Enter a Profile description on the General tab.

6. On the Uplink Sessions tab, check the Enable Uplink Sessions


box.

7. Leave all other settings at the default and click Apply, then OK.

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8. Close the xDriver Profile Editor window.


9. From the Windows Control Panel, choose LonWorks Interfaces.

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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12. Select Other as the interface type.

13. Enter the IP address of the i.LON.

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14. Repeat for any additional i.LON interfaces.

4.11.4.

Adding the LON Server


If the control system is Performance CD 4.0 with Update 6 or greater, add
a CD actuator using the CDWeb Manager for ODX option.
Under the cdlinkinterface cdwebmanager select the option mask, and
check use LDV interface.
If the Performance CD system is version 3.0, or 4.0 without update 7, then
perform the following:

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NOTE:

Performance CD 4.0, with Update 6 and above include versions of


CDWebNet.exe and CDWebRTDR.exe. Obtain the latest versions of these
files from the FTP site, or the system CD and install by performing step
2 below.
1. Using config browser, add a CD actuator using the CDWeb
Manager for ODX option.
2. Run the self-extracting zip file: CDWebServer.exe, which installs the
necessary files into the proper directories.
The executable files into C:\Honeywell\HMX\Performance CD\Bin\

CDWebRTDR.exe

CDWebNet.exe

The configuration files into C:\Honeywell\Database\CDWeb

CDWeb.ini

WP1.csv (file name will vary with gauge ID)

WP1.map (file name will vary with gauge ID)

Alarm.ini (file name will vary with actuator type)

3. Modify the startlinks.cmd file to include CDWebnet.exe and


CDWebRTDR.exe.
rem --------------------------------------rem CDWebNet Startup
if NOT DEFINED CDWebNet goto DOCDWebNet
if %CDWebNet% == 0 goto NOCDWebNet
:DOCDWebNet
start /min /high /i "CDWeb Net"
"%mxroot%\Performance CD\bin\CDWebNet.exe"
:NOCDWebNet
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rem ----------------------------------------rem CDWebRTDR Startup


if NOT DEFINED CDWebRTDR goto DOCDWebRTDR
if %CDWebRTDR% == 0 goto NOCDWebRTDR
:DOCDWebRTDR
start /min /high /i "CDWeb RTDR"
"%mxroot%\Performance CD\bin\CDWebRTDR.exe"
:NOCDWebRTDR
4. Add the following lines to the end of the BuildSite.mac for the
system to ensure that the startlinks changes are not lost when the
system is recrunched:
.AddListUnique StartLinks `|CDWebNet|,|start
/min /high /i "CDWeb Net"
"%mxroot%\Performance CD\bin\CDWebNet.exe"|`
.AddListUnique StartLinks `|CDWebRTDR|,|start
/min /high /i "CDWeb RTDR"
"%mxroot%\Performance CD\bin\CDWebRTDR.exe"|`

4.11.5.

Setting up the HC900 communications


For systems using the HC900 controller for interlocks, it is necessary to set
up a Modbus TCP link to the Performance CD server to retrieve system
status information for the CD actuator system.
1. In Configbrowser set the link up (note the Read address is
register 45056):

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2. Set up a viomap:

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3. Add the PLC Link alarm:

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Modifying the CDWeb Processor IP


Addresses

4.12.1.

Remote Desktop Connection


In order to make changes to the CDWeb Processor configuration, a
keyboard, mouse, and monitor must be connected, or a Windows Remote
Desktop connection must be established. Windows Remote Desktop is a
standard feature in Windows XP Professional. It can also be added to
earlier versions of Windows through a download from the Microsoft
website.
To establish a Remote Desktop connection the the CDWeb Processor:
1. Start the Remote Desktop application (Start All
Programs Accessories Communications Remote Desktop
Connection)
2. Enter the name of the CDWeb Processor (usually CDWEBPROC),
or its IP address.

3. Click Options>>.

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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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6. Click Connect.
7. Click OK to the Remote Desktop Security Warning

8. The Remote connection is now established. Note that this action


logs out the currently logged in user of the CDWeb Processor and
the processor must be restarted after the Remote desktop
connection has been terminated.

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4.12.2.

Modifying the CDWeb Processor IP Addresses

CDWeb Processor Address


1. Establish a Remote Desktop connection.
2. Using the Windows Control Panel set the computers IP address as
you would with a standard Windows computer.
3. Restart the CDWeb Processor.

4.12.3.

ODX Server Host Address


1. Establish a Remote Desktop connection.
2. Open C:\Honeywell\Database\Build\ODXClient.txt.
3. Edit the |hostname| line to the correct IP address of the ODX
server.

4. Save and close the file.


5. Run the RAE Browser (Start All
Programs RAE Browsers RAE Browser)
6. Select File Load Local DR

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7. Select the build file (C:\Honeywell\Database\build\BldDB.txt).

8. Close RAE Browser.


9. Restart the CDWeb Processor for the changes to take effect.

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.

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4. Save and close the file.


5. Run the RAE Browser (Start All
Programs RAE Browsers RAE Browser)
6. Select File Load Local DR

7. Select the build file (C:\Honeywell\Database\build\BldDB.txt).

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8. Close RAE Browser


9. Restart the CDWeb Processor for the changes to take effect.

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.

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3. Highlight the i.LON you wish to edit and click Properties.

4. Click RNI Device.


5. Edit the static IP address and click Apply.

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6. Click OK, OK, and Close to complete the procedure.

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5. Glossary
Actuator

Mechanical or electronic device that performs the control action in a


control loop.

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

A Quality Control System.

QCS

Quality Control System


A computer system which manages the quality of the paper
produced.

RAE

Real-Time Application Environment


The system software used by Da Vinci QCS to manage data
exchange between applications (with Performance CD being one of
them).

RTDR

Real-Time Data Repository


The database managed by RAE to store system data and data for
individual applications.

Setpoint (SP)

Target value (desired value). Setpoints are defined process values


that can be modified by entering new values through the monitor,
loading grade data, and changing a supervisory target.

VIO

Virtual Input/Output

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A. CDWeb Configuration Files

To operate correctly, the CDWeb LON server applications (CDWebNet.exe


and CDWebRTDR.exe) require configuration information in the form of
several text-based files. This appendix provides a description of the
contents of each of these files.

A.1.1. Actuator Alarm Enumeration


Some configuration parameters reference the raw actuator alarms arriving
as part of the actuator status messages. In these configuration files the
alarm bits are enumerated right to left within every byte of raw actuator
alarms. Bytes are used in their natural order, from left to right. This
enumeration differs from all other systems currently used for actuator
alarm documentation. For example, AutoSlice CDW alarm enumeration
uses bits within bytes in the same sequence, but swaps every pair of bytes.

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.
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All names are not case sensitive

Any number of spaces is allowed between keywords

Parameter values containing spaces must be enclosed in double


quotes

Comments start with the semicolon character (;)

Comments are allowed at the end of any line, or as a separate line.

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.2.1. host gauge


Defines the symbol used to find CD Control profile related information in
the RTDR database.
Example:
host gauge = CP1

A.2.2. actuator type


[not currently used]
Defines the expected actuator type. This type must correspond to the type
defined in the RTDR and the type reported by the actuator.
Example:
Actuator type = autosliceCDW

A.2.3. Number of actuators


Defines the number of control zones in the CD control profile. This
number must be the same as defined in the RTDR database.

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CDWeb.ini

Example:
Number of actuators = 65

A.2.4. Actuators per node


Defines the number of actuator per node on the LON network. For most
actuator types this number is 1, however, the IDP actuator uses 8 actuators
per node.
Example:
Actuators per node = 8 ; IDP actuator

A.2.5. Interlock Mask


Defines the condition when set interlock command is sent to the
actuators and is used only for actuators that support interlocks. The mask
is defined as a 16 bit word used to check bits in the system status word
located in the RTDR database. It can be presented in two formats: as a
binary string, or as a hexadecimal constant. This parameter is optional,
with a default value of zero (no interlocks).

A.2.6. Setpoint/position send mask


Defines the conditions under which the RTDR database receives actuator
setpoints instead of actual positions. The mask is defined as a 16 bit word
used to check bits in the system status word located in the RTDR database
and can be presented as a binary string or as a hexadecimal constant. This
parameter is optional, and the default value is zero (always send
positions).
Examples:
Setpoint/position send mask =
0000010100010100 ; binary string
Setpoint/position send mask = 0x0514;
hexadecimal constant

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A.2.7. Powerup bit


Defines the bit number in the raw actuator alarms used as the power up
flag. This bit is checked every time a status message arrives from an
actuator. This parameter is optional, with a default value of 255 (powerup
bit is not used).
Example:
Powerup bit = 40; Calcoil CW actuator power
up bit

A.2.8. Powerup reset bit


Defines the bit number to put in the reset command for the powerup bit.
This number is different from the powerup bit because of different
systems of actuator alarm enumeration.
This parameter is optional, but must be present if powerup bit is defined.
Example:
Powerup reset bit = 1 ; Calcoil CW

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

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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.

Actuator map file


Defines the name, and optionally the location, of the file containing the
zone mapping information.
Example:
Actuator map file = zone.map

A.2.14.

Alarm map file


Defines the name of the file containing the actuator alarm mapping
configuration.
Example:
Alarm map file = alrmsAutosliceCDW.ini

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A.2.15.

CDWeb Manager System Manual

Sample CDWeb.ini file


[X.CDWeb.MP1]
host gauge = MP1
actuator type= Aqualizer
database = MP1.csv
beam id = 1
number of actuators = 88
actuators per node = 1
node name=cdweb_proc_1
alarm map file = alarmsAqualizer.ini
powerup bit = 23
Powerup reset bit = 16

A.3. Database (CSV) file


The database file contains the types of LON messages expected for each
actuator. The file is in CSV (comma separated variable) format, and is
normally created using CDWeb Explorer based on the specific CDWeb.web
file for a system.
There are three types of records in the database:

A-6

:NODE:

:SUBNET_NODE:

:NODE_NV:

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Database (CSV) file

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.4. Actuator Map File


The actuator map file defines the relationship of CD control zones within a
profile to the actuators defined on the LON network. Each line of the map
file contains two or three space-separated values:

CD Profile zone number

LON beam actuator or controller number

ID of the actuator within the controller (for multiple actuator


controllers only) designated by a letter.

Example section from .map file:


1 1 A
2 2 A
3 3 A
4 4 A
5 5 A
6 1 D
7 2 D
8 3 D
9 4 D
10 5 D
In the example, zone 10 is on controller number 5, output D.

A.5. Alarm Map File


The alarm map file defines the construction of the 16 bit actuator status
word from general and actuator specific alarms. The file contains bit
formulas that are binary logical expressions in standard conjunctive BNF
format.
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Alarm Map File

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.

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A-9

B. System and Actuator Alarms

This appendix outlines the system alarms and actuator alarms that may
appear on operator displays.

B.1. System Alarms


Interlocks represent conditions that must be satisfied in order for the
actuator system to safely and accurately operate. These conditions are
defined in terms of digital and/or analog signals provided by related
systems or instruments to the optional I/O subsystem in the CDWeb
Manager cabinet. The CDWeb Processor organizes the information from
the I/O subsystem as four status words, with each word 16 bits in size, for
re-transmission to the host system.
For systems that do not require interlocks, or where the interlocks are
handled by another means, the system status words will be unused except
for Not Ready For Control or Waiting For Actuator Startup.

B.2. Actuator Alarms


Individual actuators have either 32 bit or 48 status words; the CDWeb
Manager application summarizes these actuator alarms into one 16-bit
word per actuator for use by the QCS.

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B.3. Status and Alarm Word Structures

NOTE:

Bit order is shown in Intel format in the tables in this Appendix.

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

Low Water Level


High Water
Temperature
Water Control Unit
Ready
not used
Emergency Stop
Air Pressure in Boom
not used
ACU Ready
not used
not used
not used

8
9
10
11
12
13
14
15
16

B-2

Major System Status


Word

Minor System
Status Word

Major PLC Status


Word

Minor PLC Status


Word

Mill Interlock Bypass


Clogged Water Filter
Clogged Air Filter
High Water Pressure
Beam Purge Air
Temp Above Upper
Limit
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
not used

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Table B-2 Aqualizer Actuator Alarm Word Mapping

P/N 6510020204 Rev 01

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

[a5] Not moving

15

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Corresponding Actuator Status from


CDWeb Explorer

[a22] Invalid Calibration


[a18] Open limit
[a19] Close limit
[a20] Invalid Configuration
[a21] Invalid Tuning

Based on actuator communications


timeout

B-3

System and Actuator Alarms

CDWeb Manager System Manual

B.3.2. AutoSlice CDW/ProCoat CDW


Table B-3 AutoSlice CDW/ProCoat CDW System Status Words
Bit
Position
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

B-4

Major 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

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

Major PLC 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

Minor PLC 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

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Status and Alarm Word Structures

Table B-4 AutoSlice CDW/ProCoat CDW Actuator Alarm Word


Mapping

P/N 6510020204 Rev 01

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

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Corresponding Actuator Status from


CDWeb Explorer
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

Based on actuator communications


timeout

B-5

System and Actuator Alarms

CDWeb Manager System Manual

B.3.3. Calcoil CW
Table B-5 Calcoil CW System Status Words
Bit
Position

Major System Status


Word

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

Major PLC Status


Word

Minor PLC 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

* 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

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Status and Alarm Word Structures

Table B-6 Calcoil CW Actuator Alarm Word Mapping

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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

A26 - Hardware interlock (Enable)


A29 - Module shutdown
A28 - Phase loss
A38 - Heat sink temperature limit

A40 - Workcoil temperature limit

A30 Workcoil overcurrent; A34 Workcoil current high limit

7
8
9
10
11
12
13
14
15

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Corresponding Actuator Status from


CDWeb Explorer

A19 - Local override


A18 - Invalid command
A17 - Invalid configuration

Based on actuator communications


timeout

B-7

System and Actuator Alarms

CDWeb Manager System Manual

B.3.4. IDP (Devronizer XP7, Calendizer XP)


Table B-7 IDP System Status Words
Bit
Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

B-8

Major System Status


Word
System Ready
Steam Ready
not used
not used
Beam Advanced
not used
Steam On Request
System Available for
Control
not used
Emergency Stop
not used
not used
not used
not used
not used
not used

Minor System
Status Word

Major PLC Status


Word

Minor PLC 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

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Table B-8 IDP Actuator Alarm Word Mapping

P/N 6510020204 Rev 01

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

Incorrect supply pressure

7
8
9
10
11
12
13
14
15

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Corresponding Actuator Status from


CDWeb Explorer

Open limit
Close limit
Invalid configuration
Invalid tuning
Feedback disabled
Based on actuator communications
timeout

B-9

System and Actuator Alarms

CDWeb Manager System Manual

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

Major 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

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

Major PLC 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

Minor PLC 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

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Status and Alarm Word Structures

Table B-10 ProFlow II Actuator Alarm Word Mapping

P/N 6510020204 Rev 01

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

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Corresponding Actuator Status from


CDWeb Explorer
Actuator Disabled

Actuator not moving


Actuator moving too slowly
Actuator feedback error
Actuator Setup Parameter Invalid
Actuator at Open Limit
Actuator at Closed Limit

Based on actuator communications


timeout

B-11

System and Actuator Alarms

CDWeb Manager System Manual

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

Major 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

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

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Major PLC 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

Minor PLC 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

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Status and Alarm Word Structures

Table B-12 AutoSlice/ProCoat Actuator Alarm Word Mapping


Alarm Description

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Alarm
Bit

Corresponding Actuator Status from


CDWeb Explorer

Disabled
Hardware Failure
Sensor Under Voltage

0
1
2

Sensor Over Voltage

Moving Too Slow


Wrong Direction
Runaway
Invalid Calibration
Locked
Open Limit
Close Limit
Bend Limit
Invalid Configuration
Invalid Tuning
Not Used
Lost LON Communications
or Waiting For Bumpless
Transfer

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

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Based on actuator communications


timeout

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B.3.7. ProFlow

NOTE:

These alarms refer to the legacy ProFlow actuators with AC


synchronous motors. They are not applicable to the ProFlow II actuator.
Table B-13 ProFlow System Status Words

Bit
Position

B-14

Major System Status


Word

Minor System
Status Word

Major PLC Status


Word

Minor PLC 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

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

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Status and Alarm Word Structures

Table B-14 ProFlow Actuator Alarm Word Mapping

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Alarm Description

Alarm
Bit

Corresponding Actuator Status from


CDWeb Explorer

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

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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

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symbols, which contain numeric or character data,

ordinals, which are boolean flags, and

events, which may be scheduled thereby causing some action to


happen on the Supervisory Control System.
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For the ODX server, read requests may be on demand, periodic, or


triggered by an ordinal change on the Supervisory Control System. Write
requests are always on demand and have the option of specifying an event
to be scheduled on the Supervisory Control System after the write is
complete.
Each read or write request may contain multiple symbols and any given
symbol may be associated with multiple read or write requests. Before any
read or write request is attempted, all necessary symbols and ordinals are
looked-up through the ODX server to determine the data type and array
size on the Supervisory Control System. The ODX server sends and
expects a value for each element in an array, regardless of whether or not
the full array is valid from an application point of view.
The CDWeb Manager ODX client has hard-coded read and write request
templates that contain required symbol, ordinal, and event names. All
symbol and ordinal names used for communication by a given CDWeb
Manager are prefixed by a common 6 character actuator identifier. This
actuator id has the form PxCyyy,
Where
x represents the process number
yyy represents the actuator type and gauge number, for example, WP1
for the first weight control actuator.
The remainder of the symbol name (for example, ASP) identifies the
parameter type. Some small amount of information about the symbol can
be extracted by examining the character(s) which separate the actuator
and parameter identifiers. An underscore ( _ ) indicates an array and a
period ( . ) indicates an ordinal. An ordinal array is therefore indicated by
a period followed by an underscore ( ._ ).
In general, the CDWeb Manager does not use ordinal arrays. Instead,
individual boolean flags are compacted into 16-bit status words that are
transmitted to the Supervisory Control System as unsigned integers. It is
the responsibility of the application software on the Supervisory Control
System to break these unsigned integers out into the appropriate ordinal
arrays for alarm and status reporting.
Event names are of the form LPNz\EVTnnn, where z represents the LPN
number of the master Supervisory Control System, and nnn represents the
event number. In general, all status changes for all possible LAN based
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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:

bit 0: a symbol lookup failure occurred

bit 1: a mismatch was found in the number of configured zones

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.
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Write System Status


The ODX client writes the four system status words PxCyyy_SST on a
periodic basis. The four system status words are defined as: Major System
Alarms, Minor System Alarms, Major PLC Alarms, and Minor PLC
Alarms, and all correspond with older systems.
In some CDWeb systems an I/O subsystem is present for the management
of interlocks or other digital inputs. When such a device is present but not
communicating, the ODX client sets the PLC Not Ready For Control alarm
(bit 2) in the Major PLC Alarm word. When the device is communicating,
the I/O points are read directly from the device and mapped to the status
words.
As with all status words, the associated status change ordinal PxCyyy.SST
is set and the status change event LPNz\EVT586 is scheduled by this
write request.
Read Set point and Position Scaling
The scaling information consists of the slope (slope (PxCyyyACTSLP) and
offset (PxCyyyACTOFF). These values are used to convert between the
position and set point scales used on the Supervisory Control System and
the position and set point scales used by the actuators. These values are
read whenever a connection is established with the Supervisory Control
System.
A potential problem exists for any ODX client which reads these values.
The Supervisory Control System stores these values in the ISR data. When
the Supervisory Control System is starting up after a shutdown or reset,
the ODX server is initialized before the ISR data is loaded. It is possible for
a client to log in and read these values before they have been properly
loaded. To remedy this potential situation, the CDWeb Manager not only
reads these values when a connection is established, but continues to read
them on a timed basis.
Read Actuator Set points
The ODX client reads actuator set point information on a periodic basis.
The set point information consists of the actual set point array
(PxCyyy_ASP). The time period between reads is hard-coded at 5 seconds.

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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.
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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).

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Read Actuator Reset Array


The Actuator Reset array is an array of integers set to 1 to indicate if a
given zone should be reset or set to 0 to indicate if a given zone should be
left in a failed condition.
On startup, the ODX client issues a triggered read request to read the
PxCyyy_ARST array from the Supervisory Control System whenever the
PxCyyy.ARST ordinal on the Supervisory Control System changes state.
Note that the actual data from this request is transmitted asynchronously
to the request. The client, therefore, constantly checks for a new response
to this request and transmits the information as required to the affected
actuators.
Write Communications Active
Since the ODX client initiates all communications with the server, a
heartbeat that allows the Supervisory Control System application software
to detect a LAN network failure has been implemented. This heartbeat is
in the form of an integer value, PxCyyyACOM, which is incremented by
the ODX client on a periodic basis. The heartbeat is set to 0 on startup
through an ODX write request and increments up to 32767 before
wrapping back to -32768. The Supervisory Control System application
software is responsible for checking the heartbeat every 10 seconds. A
non-changing symbol indicates communications have stopped. The time
period between successive symbol writes is configured for two seconds.
Table C-1 Supervisory Control System Symbol Names
Description

Number of Zones
Communications
Active
Supervisory Control
System On Control
Actuator Set points
Set point Scaling
Slope
Set point Scaling
Offset
Actuator Positions

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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

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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.

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Modbus

In normal operation information is transferred between the CDWeb


Manager system and the Host by sending commands which read and
write memory locations called registers using the Modbus protocol. The
data transferred consists of eight bit binary characters with an optional
parity bit. No control characters are added to the data block, however
there is an error check (Cyclic Redundancy Check (CRC)) included as the
final field of each query and response to ensure accurate transmission of
data.
Function Code
The function code identifies the command being issued to the station. It is
one byte in length and is defined for the values 0 to 255:
Table C-2 RTU Functions
Function
Code
0
1
2
3
4
5
6
7
8
9 - 14
15
16
17
18 - 66
67
68 - 127
128 - 255

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

C.2.2. CDWeb Manager Registers


The registers in Table C-3 and Table C-4 are applicable for all Honeywell
CD actuators. It is permissible for the Host, using standard Modbus
protocol, to read from any of these registers or write to those indicated.
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Table C-3 Modbus Registers Up To 200 Actuators


%R Address Range

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

Table C-4 Modbus Registers 201 To 400 Actuators


%R Address Range

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.

Number of Actuators Register


This register is a single word that contains the number of actuators
configured in the CDWeb Manager.

C.2.2.2.

System Status Registers


These registers contain the CDWeb Manager system status. The four
system status words are defined as Major System Alarms, Minor System
Alarms, Major PLC Alarms, and Minor PLC Alarms to correspond with
older systems. See Appendix B for details.

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C.2.2.3.

Modbus

Actuator Type Register


This register contains a value indicating the type of actuator the CDWeb
Manager is controlling. Possible values are in Table C-5.
Table C-5 RTU Actuator Types

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

Host Set point Registers


These registers contain the set points for the actuators. For AutoSlice or
ProCoat the values are in microns. For AutoSlice CDW and ProCoat CDW
the values are in 0.2 micron increments. For Calcoil CW actuators, the
values are in Watts. For Aqualizer and IDP actuators the values are in
0.1% increments. These values should be written on a periodic or event
drien basis.

C.2.2.5.

Actuator Position Registers


These registers contain the current actuator position. The units are the
same as the units for the set point registers.

C.2.2.6.

Actuator Status Registers


These registers contain one 16-bit word for each actuator. Each word is a
bitmap which indicates the actuator status as indicated in Appendix B.

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C.2.2.7.

CDWeb Manager System Manual

Zone Enable/Disable Registers


These registers are used by the Host system to selectively enable and
disable individual actuators. Writing a 1 to a register enables the
corresponding actuator and writing a 0 disables the actuator. These values
should be updated on system start-up, then on an event-driven basis as
needed.

C.2.2.8.

Zone Reset Registers


These registers allow the host to reset individual actuators. Writing a one
to a reset register causes a reset of the corresponding actuator. These
values should be written on on system start-up and then on an eventdriven basis as needed.

C.3. OPC Communications


C.3.1. Introduction
CDWeb Managers with CDWeb Processors installed can be configured to
communicate with a host QCS using OPC communications. In this
configuration the CDWeb Manager is the OPC server and the Host is the
OPC client.

C.3.2. OPC Client Setup


In order to communicate with the CDWeb Manager the OPC client needs
the following registry entries:
[HKEY_CLASSES_ROOT\Hx.RaeServer_O]
@="Hmx.RaeServer_O"
[HKEY_CLASSES_ROOT\Hmx.RaeServer_O\CLSID]
@="{89E9A700-4FB9-11d1-BD6C-00A0C91648AF}"
[HKEY_CLASSES_ROOT\CLSID\{89E9A700-4FB9-11d1-BD6C00A0C91648AF}]
@="Hmx.RaeServer_O"
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"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."

C.3.3. OPC Tagnames


The following tags are used for CDWeb Manager Control:
Table C-6 OPC Tagnames
Tag Name

Data
format

Data
Type

Read/Write

Description/Usage

act.setpoint

array

double

Write/Read

Actuator setpoints: Update periodically, or when


new setpoints are available.

act.position

array

double

Read

Actuator positions: Read periodically (positions are


updated every 10 seconds).

act.enable

array

word

Write/read

Actuator Enable: 1 indicates enabled, 0 indicates


disabled. Host must enable actuators on startup,
then event driven.

act.reset

array

word

Write/read

Actuator Reset: 1 indicates that the actuator is to


be reset. This value is set to clear any actuator
alarms.

Act.sys.status

Array [4]

word

Read

System Status: see actuator specific system status


word definition (Appendix B)

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Tag Name
Act.status

CDWeb Manager System Manual

Data
format

Read/Write

Description/Usage

word

Read

Actuator Status: see actuator specific status word


definition (Appendix B)

Act.num.zones

Int[32]

Read

Number of zones: represents the number of zones


configured in the cdweb manager. Typically read
on startup

Act.sys.mode

byte

Write/read

System Mode: represents the system mode auto =


1 manual = 0

Act.watchdog

word

Read

System Watchdog: value will change every second


varying between 1 and 8.

Act.scale.slope

double

Write/read

Actuator scale slope: represents the slope for


scaling the setpoints to be sent to the actuators, for
the setpoint, and position. (see actuator specific
scaling info for definition)

Act.scale.offset

double

Write/read

Actuator scale offset: represents the offset for


scaling the setpoints, and positions to be sent and
received by the actuators. (see actuator specific
scaling info for definition)

C-14

array

Data
Type

9/21/06

P/N 6510020204 Rev 01