Lessons Learned and Frequently asked Questions

Volume 1 Issue 1

Excel 5000 Open System

Technical Support
How to use this document
Common Questions
Software Installation
Software Licensing
LON Networks and Subsystems
The Device Library
Setting up an iLON1000 router in CARE and ACSELON/EBI/SymmetrE
LON Binding and Mapping
Plant Replication
EBI-SymmetrE-ACSELON and CARE 4.0
Related Hardware and Software/Firmware Issues
XL10 Commissioning
XL10 VAV II Balancing

Trademark Information Echelon, LON, LONMARK, LONWORKS, LonBuilder, NodeBuilder, LonManager,

LonTalk, LonUsers, LonPoint, Neuron, 3120, 3150, the Echelon logo, the LonMark
logo, and the LonUsers logo are trademarks of Echelon Corporation registered in
the United States and other countries. LonLink, LonResponse, LonSupport, and
LonMaker are trademarks of Echelon Corporation.
Windows, Windows Explorer are Trademarks of Microsoft Corporation
CARE, EXCELON, EBI, Enterprise Building Integrator, SymmetrE and ASCELON
are trademarks of Honeywell International.

Copyright © 2002 Honeywell Inc. • All Rights Reserved

 Excel 5000 Open System Technical Support

We are pleased that the launch of the Excel 5000 Open System LON Edition has been well received by the
entire industry. The increased functionality of SymmetrE/ACSELON, CARE 4.0 and the LON plant
controllers has provided more open solutions for customers through our open channel approach to the
market.

With this increased functionality has also come increased requirements for all involved to learn and master
new technologies and functionality. This requires increased commitment to training, continuous
learning on the job and through community learning relationships.

A key requirement of our assessment of distribution and contracting channel partners has been technical
capability. We value these skills highly as they are important to our joint success. Formal training and
the use of documentation form the foundation for engineering and supporting these new systems.

In 2003, we will be providing self-help, through a web-interface, case based reasoning tool. An initial pilot
will begin in January 2003.

In 2003 Q1, we will also be implementing our email/web based forum. This forum links a community of
technical specialists in all contractors and distributors to increase knowledge and provide opportunity for
broad Q&A on product application. This forum has been successfully deployed globally by the
Install/Service branches with the Enterprise Buildings Integrator product.

We have experienced a significant increase in the number of TAC calls since the
introduction of the Excel 5000 Open System. A review of these cases has revealed:

 25% have not been to training. (They expect TAC to provide training.)
 25% have not looked in the book or even tried to find the answer on their own. (They
may or may not have been to the training. This is really common across the product lines we
support. TAC for better or worse is their on-line Training Center.)
 20% did not retain learning from their training.
Long delays between training and project use can contribute to this category.
 15% just need coaching on what they have learned. General questions. Honeywell looks to educate
more on these issues.
 15% only, are legitimate technical defect issues.
e.g. Inadequate documentation, material not covered in depth in training, product defects.
Honeywell is addressing all of these issues

The TAC is staffed to be available to authorized customers who have been trained and have utilized the
available documentation to ask legitimate questions regarding the system.

Clearly, the 50% mis-use of TAC in lieu of training and basic self-help including reading documentation
limits our ability to properly support those who truly need our support.

We request that all channel partners examine the calls being made by their staff to ensure that
training has occurred, documentation is being utilized and basic fault finding techniques have been
applied prior to calling TAC. If the situation does not change, we will be forced to implement procedures
to filter out callers and calls that do not meet appropriate criteria.

Regards,
David Willett
Vice President
Honeywell Building Control Solutions

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 How to use this document

This document is intended as a collection of facts and procedures derived from many different
sources. It is not a substitute for the Product documentation nor is it intended as a substitute for
Training. This document answers many of the most common questions received during Training
and from calls for technical support. The supporting product documentation is listed below and
available on the EXCEL 5000 OPEN CD:

CARE 4.0 User Guide EN2B-0182 74-5587-4

Live CARE 4.0 User Guide EN2B-0183 74-3556-4
Control Icons User Guide EN2B-0184 74-5577-5
Care Software Release Bulletin SRB N/A N/A
XL 500 XCL5010 Control System Specification Data enob-0203 74-3666
XL 50 and XCL 5010 Wiring/ LED Overview en1b-0135 74-3667
XL 500/600 Control System Specification Data enob-0089 74-2036-2
XL 100 C Controller Specification Data en1r-0143 95-2035-2
XL 50 Controller Specification Data en0b-0088 74-3668
XL 500/600 Control System Installation Instructions en1r-1047 95-7524-2
XL 100 C Controller Installation Instructions en1r-0144 95-7665
XL 50 Controller Installation Instructions en1b-0101 95-7568-5
XL 50/500 LonWorks Mechanisms Interface Description en0b-0270 74-3669
XL 50/100/500/600 Controllers Software Description en2b-0092 74-3448
XL 50 Controller User Guide en2b-0137 74-3030-2
XI 581 AH / XI 582 AH User Guide en2b-0126 74-3670
XL 100/500/600 System Overview en0b-0091 74-3563-3
Distributed I/O Modules Product Data en0b-0090 74-2145
Smart I/O Modules Product Data en0b-0311 74-3671
Smart I/O Modules Installation Instructions en0b-0180 95-7666
Smart I/O Modules Installation Guide en0b-0294 95-7667
XILON User Guide en2b-0214 74-3672
System Integration Guide Integration Procedures N/A N/A

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 Common Questions

1. Is CARE compatible with X-Link/Open Link

Not in this release, we expect this to be added as a service pack upgrade some time in
the first quarter of 2003.

2. Is CARE compatible with old Zone Manger Projects

Care has essentially the same compatibility with the Zone Manger as previous versions
except the original series 1000 ( VAV1 ) is no longer supported.
There is a new procedure for creating and managing Zone Manger projects, the
procedure is in the SRB and the System Integration Guide. Both can be found in the
Literature section of the CARE CD.

3. Can projects from older versions of CARE be upgraded to Care 4.0

Yes, with a couple of exceptions. Series 1000 ( VAV1 ) Zone Mangers are not and will
not be supported in CARE 4.0. If a project contains this type of Zone Manger it MUST be
removed from the project before CARE 4.0 is used to upgrade the project.
The same is true for Xlink/Openlink. See item 1.

4. Can existing E-Vision jobs be converted into CARE 4.0 projects?

No, the project will have to be re-done in CARE 4.0.

5. Which Windows Operating systems is CARE 4.0 compatible with?

Windows 98SE/ME/NT 4.0 and 2000.

6. Will CARE run on Windows XP.

CARE 4.0 is currently in testing for compatibility with Windows XP. We hope to have this
by Mid. 2003.

7.What are the PC requirements for CARE 4.0

CARE 4.0 requires a Pentium III 500 MHz with 128 Meg of RAM and 200 Meg free disk
space at a minimum. Ideally a Pentium 4 with 256 to 512 Meg of Ram and 500 Meg free
disk space is preferred.

8. Will CARE 4.0 support 3rd party LON devices?

Yes, 3rd party LON devices are supported if they have an LNS Plug-in, or can be
uploaded on-line if CARE is only going to be used to monitor points but not configure the
device.

9. How do I obtain the Honeywell Plug-ins?

All of the currently available Honeywell Plug-ins are included on the CARE CD.

10. Do we need to Register CARE 4.0?

Yes, CARE 4.0 has a completely new Registration process that is done on-line via the
Internet. See the SRB for details or the section in this document on Registration.

11. Will I loose my registration if I change my machine configuration or reinstall CARE.

The new software security system in CARE 4.0 is much less susceptible to general
hardware and software changes than the previous version. If you do loose your
Registration because of a hardware failure or some other major change ( Reformatting
the Hard drive, changing the partition from FAT32 to NTFS or re-installing Windows etc. )
you are allowed one Lost License per Year so you can re-enable your CARE from the
same WEB Site used to do the original registration. This can be done at any time and
does not require you to call Honeywell for activation.
Changing from FAT32 to NTFS will also destroy your LNS Credits. There are only 2 ways

4
 around this if this occurs. Call Echelon and tell them what happened or reformat your
Hard Drive and re-install the LNS Database.

12. Can more than one version of CARE be run on the same machine as CARE 4.0?
Yes, the procedure is the same as before. Separate CARE.INI files must be used for
each version of CARE.

13. Can a Registered installation of CARE 4.0 be transferred to another machine?

Yes, this is done using the Terminate License function and is explained in the
documentation.

14. Is CARE 4.0 compatible with standard C-Bus devices?

Yes, CARE 4.0 is completely backward compatible with the standard C-Bus
configuration.

15. Will Care 4.0 support the E-Bus and C-Bus on the same controller.
Yes, the new versions of the XL50/500 and XCL5010 can have both C-Bus and E-Bus
connection terminals and can be used together.

16. Honeywell is using Explicit Messaging with the C-bus over LON. Will
this interfere with any 3rd Party devices, which may also be using explicit
messaging?
Unknown at this time.

17. There is a "FLASHER Program" which we use to flash the Q7300 devices.
This uploads all the devices with the same OS version all at once. Is
Honeywell working on doing the same thing for the XL5000 Open Lon
Controllers? Also will this feature be available for TCP/IP?
No, downloading OS images to XL5000 controllers or XL10 devices is currently not
available. The mechanism for doing this is very complicated over the LON bus, however it may be
added in the future. At this time CARE does not support TCP/IP, however this may also be added
sometime in the future.

18. Will setting the PCC10 or PCLTA-20 Card to VNI in CARE cause problems
in E-vision?
Yes, the setting for E-Vision will have to be changed to NSIPCLTA And then changed
back for use with CARE/EXCELON/EBI/SymmetrE/ASCELON.

19. Is there a documented/recommended process for balancing VAVII boxes on

the CARE 4.0/SymmetrE Project?
Yes, but the document is not available at this time.

20. Is Buswide MMI supported on the Virtual C-Bus ( C-Bus over LON )?
Yes, in version 2.06.01 controller OS.

21. Why does the Graphic for my VAV not display the data for some of the points such as
damper position?

The real point is the device name with the extension APP and the values such as the
damper position is one of the parameters. The likely cause is that the wrong device template
(XML) is chosen.
As an example for the VAV controller lps_USdefault_xl10VAV.xml was chosen and the
resource files were not chosen to be loaded when the plug-in was added to the point server
machine OR the plug-in was not installed on the point server machine. In this case you would

5
start up the point server plug-in and choose the lps_USnoresource_xl10VAV.xml or you could
load the plug-in with its resources on the point server.

22. What if I want different graphics for a couple of devices of the same type?

The graphics (see note 1) that is chosen for a device is specified in the XML for that
device that you choose in the point server plug-in. The default is the default named XML for that
device but you can change each instance of that device in the LNS database to a different XML
and each of those XMLS could have different graphics assigned (see note 2).

23. Where can I find help on the XMLs?

The best start for help is the compiled help menu (extension is .chm) in the program
choice. Then search for XML templates and follow the screens one at a time or print out this
section for later study.

24. What do I do if I have a third party device

(does not show up in the Point Server Plug-in)?

You will have to create a custom XML for this device and also custom graphics for them
also. There is a sample XML in the following directory:
\honeywell\pointservers\LPS\Templates\US\samples – you can double click on it to see the
structure but use notepad to modify and save it. After modification double click on it to see if there
are any errors in it (SYNTAX ONLY) and if there are use notepad to fix them. The system looks at
changes or additions to the XMLs only when the point server plug-in is started. Please Note:
XML files are CASE SENSITIVE!

25. I need data that is not on the standard graphic for my customer?

The graphic can be modified but are not recommended for the occasional user. Please
save the original graphic so you can recover from errors. The list of points available for the
graphic are in the XML files for that device or by using the point server plug-in and opening up
device and points. An example of a point not on a graphic but available in the XML is a VAV box
is the Free input. This could be added on a custom graphic.
Note 1:
There can be more than 1graphic per device. There should be 1 graphic per point in the
device. There are usually 2 points in an XML – each point uses one point in the available points
for that system. Some devices have so much data available that they have more than 2 points. In
the normal case the XMLs have 2 - one is the APP point and the other is unnamed. The complete
name of the point is the LNS database name for the device, with the XMLs point name added –
as an example in the LNS database there is a VAV controller named Box23 the point names
would be Box23 and Box23APP. In the XML there is a graphic that is specified for each point for
example for the VAV "PointDetailDisplay" dbDataType="char"
dbDefaultValue="sysDtlLpsVAVGen.dsp” and also the following
"GroupDetailDisplay" dbDataType="char" dbDefaultValue="sysDtllpsGroup.dsp"

Note 2:
The point server plug-in looks in the appropriate directory for the XMLs that have the
manufactures same program id for the VAV it is 80000C500A030403. So all the XMLs that used
the same id would be available in the point server plug-in to be assigned to that device. You could
change the graphic name for that device in the XML (notepad is used to modify the XML). The
creation of one of these graphics needs very good skills in display builder. Look at one of the
standard displays for examples of how to do it.

26. Can I use the NV-Booster on a Structured NV.

The NV-Booster function is not supported at this time on Structured Network Variables.

6
Please make allowances for the number of NVs and Data Points that will be used.
27. Can USB ports be used for downloads to the B-Port
Yes. When using any of these devices it is necessary to use the correct Device Driver for
the Machine type and the Windows version being used. These device drivers are available only
from the device manufacturer, usually on their WEB Site.

For installation the Adapter must be installed on COM Port 1…4.

We have tested the following:

USB Serial Adapter
Belkin Part Number: F5U103

http://www.belkin.com/

7
 Software Installation
1. It is very important to read the Release Notes on the CD.
2. If you have installed CARE 4.0 and for some reason need to remove it, BACKUP your
Projects to a safe place FIRST. If you run the SETUP program after CARE has been installed
you will be given the following choices:

a. Modify
b. Repair
c. Remove

3. If you choose “Remove” and have not backed up your projects they will be irretrievably lost.
4. If you have other versions of CARE installed, use the standard procedures for saving the
individual CARE.INI files and be sure to install CARE 4.0 in a new folder. NEVER install
CARE over an existing installation.

8
 Software Licensing
Care 4.0 introduces a new Licensing mechanism. With each copy of care a Voucher is included.
This voucher is used On-Line at the http://license.GE51.Honeywell.de WEB Site. This site is available 24
hours a day 7 days a week.

This site performs the following services:

1. Initial Registration
2. Registration of a second license
3. Termination of a license for transfer to another machine
4. Lost License

1. Initial Registration:
 Install CARE 4.0
 Under the HELP command select Registration.
 Copy the Reference ( Machine ) code.
 Go to http://license.GE51.Honeywell.de
 The first time you enter the WEB Site you will be required to create a user account.
Select New User and fill out the form.
 Once you have a user account you can log in using the User Name and Password you
chose.
 Select “Register New License”
 Past the Reference Code in the first field.
 Type, or Past the Voucher number provided with CARE into the Voucher line.
 Click Register
 The WEB Sit application will automatically generate your CARE Registration Code.
Copy this code.
 Past the Code into the Registration Code field in CARE and click “Register”.
 Your Care is Registered.
 Close Care and Re-Open, the Unregistered warning should not appear.

Second License:
 Install CARE on a second machine
 Using the procedure above copy the Registration code
 On the WEB Site http://license.GE51.Honeywell.de select the “Second License” Option.
 Paste the Reference Code for the second machine in the reference code field.
 Click Register.
 Copy the Registration Code and Paste into the Registration field in CARE.
 Your second machine is registered.
 NOTE: At this time the second license does not include LNS. We are working out the
details with Echelon.

9
Terminate License:
 This function is used to transfer a license from one machine to another
 Click on the Terminate button. Answer OK if you are VERY sure this is what you want
to do.
 CARE will respond by placing a new number in the Registration field. This is the
Termination Voucher. Copy this number.
 Care should already be installed on another un-registered machine. Go to the Registration
under the Help drop down.
 Copy the Registration code.
 Go to http://license.GE51.Honeywell.de
 Login and select Terminate License option
 Paste the Reference code from the destination machine
 Paste the Termination Voucher from the original machine
 Click Register.
 Copy the new Registration voucher to the Registration field of the destination machine.
 Your CARE registration has been transferred.

Lost License:
 You are allowed one unassisted Lost License per Year
 After reinstalling CARE copy the newly created Reference Code.
 Go to http://license.GE51.Honeywell.de
 Select the “Lost License” Option
 Copy the Reference code into the Reference code field
 Click Register
 The WEB application will generate a new Reference code for the original machine.
 Copy the Reference Code into CARE.
 Remember this can only be done ONCE a year.

10
 Networks and Subsystems
CARE 4.0 like LonMaker for Windows provides a method for grouping individual LON devices
in a Logical hierarchy.
In LonMaker for Windows this is done via the Sub-System network drawings. Devices can be
segregated according to use or location by placing them in a separated drawing “below” the Main network
drawing.
So for example the main drawing may contain the Network interface device along with any relevant items
to that view. Subsequent drawings are layered “underneath” this main drawing and contain the devices
relevant to the grouping hierarchy. For example: Building/Floor/Zone/Device(s).
Each LonMaker drawing contains the device(s) and the Function Blocks to receive the inter-
device Network Variable Bindings. These bindings are connected with lines drawn from; the respective
NVO and to the associated NVI network variables. The drawing tool used to do this is Microsoft VISIO*.
Each drawing is a representation of a fragment of the total network and displayed as devices sitting on a
central line representing the Echelon Network. This is very similar to the way E-Vision displayed the
Network: except E-vision did not allow for Sub-Systems.
In one sense this provides the user with a view of the network that, well, looks like a network.
This method of displaying the LON Network is not with out its drawbacks however.
For one, not only is the Network represented but also all of the bindings to the devices are also present. For
anyone that has used the CARE Control Strategy editor you will appreciate the fact that it is very easy to
create “spaghetti”. Drawings with so many interconnecting lines it is very difficult to trace which line is
connected to which function block. It is usually necessary to simplify these buy creating separate Control
Strategies, or, in the case of LonMaker separate Subsystems, such that each view of a particular segment
contains a minimum number of connections.
This process is referred to as segmentation and is implemented in both LonMaker and CARE 4.0.
With CARE 4.0 it was decided after doing some field trials that a different method could be used.
CARE 4.0 uses the standard Windows “Tree”. This is also a hierarchical view but rather than represent the
Network as a line on a drawing with devices attached; Care 4.0 uses the familiar Tree structure. The same
type as used in Windows Explorer*.
Creating Subsystems in the Network tree creates each segment of the network. By selecting which
sub-system in the Tree is to be the Default, any new devices created will be assigned to that subsystem.
In this implementation it is important to pay close attention to the naming conventions for the devices and
the subsystems they belong too. For example a Network may contain the following:

ROOT ( the base of the Tree )

Building One ( Subsystem 1)
First Floor
B1FL1Z1V1 ( Building 1 Floor 1 Zone 1 VAV 1)
And so on
Second Floor
B1FL2Z1V1 ( Building 1 Floor 2 Zone 1 VAV 1)
And so on
Roof ( Subsystem 2)
FL_1-4 RTU Roof Top Unit serving Floors 1 - 4
And so on

By naming each of the subsystems with relevant names, the task of finding any particular device is very
easy.
Each of the levels can be collapsed so that only the Subsystems ( Building 1 and Roof ) are visible.
Expanding each subsystem shows the devices associated with that subsystem.

11
 One must remember that this is a Logical view of the network, which can be arranged in any order
with as many subsystems as needed. It does not have to reflect the “actual” bus layout. The actual bus
layout should be rendered on a detailed system drawing including the device locations, neuron ID, Min and
Max Flow, junctions ( T-Taps ), transitions, routers/repeaters, EOLN location and approximate total bus
and segment lengths.
Another very useful feature of this layout is that individual devices can be Dragged and Dropped
between subsystems and the bindings associated with the device will remain intact. This means that
rearrangement of devices is greatly simplified.

12
 The Device Library
One of the new additions to CARE 4.0 is the Device Library. This library contains all of the
currently available Honeywell LON devices. Superficially its use is very simple. To place a device from the
library into the Terminal Assignment workspace you Drag the device from the Device Library and Drop it
into the workspace. A small graphical representation of the device will appear showing some of the most
commonly used SNVT’s. We attempted to make use of only one “page” of the device graphic, but in the
case of the VAV controller more than one page was needed; to view the next page click on the down arrow
in the bottom right of the device graphic.
If you double click on the bottom of the device graphic a Window will open showing all of the
available Network Variables for that device. The “Show In Care” column has check marks to indicate
which NVs are displayed once the device is placed in the Terminal Assignment tool. To add or remove an
NV simply check or uncheck the corresponding check box. When you close the NV-List Window the
device graphic will be updated. Note you may have to scroll down to view new NVs.
This is only one of the Device Library functions.
The Device Library has three other important functions.

1. Globally changing the NVs to be displayed in the Terminal Assignment Tool.

2. Storing pre-configured devices.
3. Adding 3rd party devices

Unlike many functions in CARE the Device Library can be opened without opening a Project. On the
command bar near the top of the CARE Window there is an Icon that looks like a Globe; it is one of the
only choices available if a Project has not been opened. Click on this Icon and the Device Library will
open.
1. Changing the default NV displays is very simple. Right click on the device you wish to
change and select NV-List from the context menu.
This will pop up the NV-List Window showing all of the available NVs. The ones that have a
check in the box next to their name in the Show in Care Column will be displayed in the
Terminal Assignment Tool.
To add an NV click the check box.

NOTE: when used in this way the changes made in the Device Library are Global. This means
that the NVs added or removed will be the same for all Projects.
To change just an individual device open the NV-List in the Terminal Assignment tool rather
than the Device Library. This will make the change local only.

2. One of the most powerful features of CARE 4.0 is the ability to store configured devices for
later use.
The procedure for this is also very simple. Once you have placed a device in the Terminal
Assignment Tool, open the Plug-in for this device. Using this device as a template, make all
of the changes relevant to that particular device.
Once the changes are complete: open the Device Library. With the device Library open create
a new Folder. For instance, if you need to store a pre-configured VAV ( or any other device )
create a Folder with the name “Smart actuators-No Reheat”. Move the Device Library so that
you have access to the Network View in CARE. Then Drag and Drop your new template
VAV onto the folder just created. The “Smart actuators-No Reheat” is now available to use
and completely configured for later use.

13
3. The last function permits you to bring any LON Works compliant device into the Library.
This can be done in one of 2 ways: On-Line, or from XIF file.
 On-Line: Again create a folder for the new device. If this is not a Honeywell Device
it would be best to create the folder as a ROOT folder using the name of the device
manufacture.
 Next create a new LON Device by right clicking on the new folder and selecting
New Device. ( If you have more than one type of Device create New Folders for
each of them. )
 The context menu gives you 3 choices here: From On-Line, from XIF.
If you do not have an XIF file ( one should be available from the device manufacturer )
you can up-load the device NV list On-Line. To do this you must be “Onnet” in CARE
and push the service pin on the device.
XIF File: If the XIF file is available select this choice from the context menu and brows
to the location where it was stored.
If a Plug-in was provided the XIF would be installed as part of the Plug-in installation,
browse to this location.
If the device manufacture has provided a Plug-in, the procedure outlined in step 2 can also be
applied enabling you to create pre-configured “models” of the 3rd party device.

14
 Setting up an iLON1000 router in CARE and ACSELON/EBI/SymmetrE

Step 1. Configure the iLON1000 router.

In order for the iLON1000 router to communicate using TCP/IP an IP address, subnet mask, gateway and
hostname must be assigned. This information is normally obtained from the customers IT department. In
order to set this information, the router console port must be connected to a PC COM port using a serial
cable. Using HyperTerminal software on the PC at 9600 baud, the following commands will set the
information:

hostname <assigned name> e.g. iLON1000A

ipaddress <assigned ip address> e.g. 192.168.1.20
subnetmask <subnet mask> e.g. 255.255.255.0
gateway <gateway address> e.g. 192.168.1.1

In order for these changes to take effect, the router must be rebooted with the following command:

reboot

When the router is connected to the network, communication to the SymmetrE point server computer can
be confirmed by issuing the following command from a command prompt window on the SymmetrE
machine:

Ping <assigned ip address>

Step 2. Create a virtual LonWorks channel on the network.

Configuration server software is provided on the iLON1000 installation CD. The recommended place for
this software to be installed is on the SymmetrE PC. This software MUST be running whenever changes
are made to the Virtual LonWorks channel. (e.g. whenever additional routers are added)
In order to create the channel:

 Make sure the Network is enabled in the main configuration server dialog.
 Select Channel>New channel from the configuration server menu.
 Assign a name to the channel.

Add iLON1000(s) to the channel using the following commands:

 Select the new channel

 Select Channel>New Device from the configuration server menu.
 Assign a name to the new device. (e.g. ILON1000A)
 Select Device>Device Properties from the configuration server menu .
 Assign the IP address of the iLON1000.
If communication is correctly configured, the icon next to the device will turn green.

15
Step 3. Add the routers to the CARE project.

After all of the iLON1000’s have been added to the configuration server, then the routers can be added to
the CARE project. CARE makes no distinction between this type of router and any other type of LonWorks
router such as the LPR devices.

CARE cannot connect directly on the IP channel. Only the SLTA, PCLTA, and PCC network interface
cards are currently supported by CARE 4.0.

In CARE,
 add a channel which corresponds to the IP channel.
 Set the transceiver type to IP-10L or IP-10W for either a LAN or WAN.
 Add a router between the current NI ( Network Interface ) channel and the IP channel on the far
side.
 Define the router as “configured”.
 Get the service pin from the router.
 Commission the router.
 Add additional routers as required in CARE using the same procedure.

Make sure that routers nearest to the CARE PC are commissioned first. In order for CARE to
communicate with a router, all other routers in the path to the target router must already be commissioned.

Step 4 Export the CARE database to LNS.

When using the CARE “Export to LNS” functionality it will be necessary to select the “NI Channel” in the
Export dialog, which corresponds to the channel, that SymmetrE uses to connect to the network. This will
typically be the IP Channel created in Step 1.

Step 5. Define the SymmetrE IP Channel interface.

The configuration server software must be active during this step.

 From the control panel on the SymmetrE PC,

 Select the LonWorks /IP Channels configuration utility:
 Push the “Add” button and fill in the dialog prompts.
 Enter the name of the LonWorks Network Interface. (e.g. MyIPInterface)
 The IP address will usually be set correctly to be the same as the PC .
 Accept the default port number (1628)

In the configuration server dialog:

 Add an additional device to the LonWorks channel
 The IP address will be that from the SymmetrE PC.
 The icon next to this device will remain red until SymmetrE connects to the network.

Step 6. Configure the SymmetrE LonWorks Point Server.

 If they are active, stop both the LonWorks point server and XL5000 direct or Scan Task.
 Activate the Honeywell LonWorks Point server plug-in.
 In the tools menu, “import the new LNS network created by CARE.
 Select the new network.
 Select “online”.

16
  Select the new network interface (MyIPInterface)
 Launch the plug-in as before and set required parameters.
 Exit the plug-in.
 Start the LonWorks Pointserver.
 Start XL5000 direct or Scan Task

(Note: the device icon in the Configuration server should turn green during these activities)

SymmetrE will now access the LonWorks network using the ILON1000 router(s).

17
 LON Binding and Mapping

Shared Wall Modules:

One common application is sharing a sensor between 2 or more devices. This application is most often
encountered with the VAV. Two VAVs must be controlled using a single Space Temperature or Return Air
Sensor.
The obvious way to do this is to use the NVOSpaceTemp and Drag and Drop it to the
NVISpaceTemp. This is not the proper way to do this.
The proper way is to use the NVOShare and the NVIShare these to NVs will transfer all of the information
from the Source device to the Destination device without having to also bind the Set points.

The methods is very simple:

For each device displayed in the network view there is a corresponding page in the Terminal
Assignment Tool. To access the page double click on the device that will be the Source ( The device that
has the physical Space Sensor connected ).
The Terminal Assignment Tool will display the single device.
Now from the Network view, ( this is the view in the bottom left pane of the CARE Window ), Open the
Device Object by clicking on the + sign. Then scroll down to NVOShare click on this then Drag and Drop
this NV to the NVIShare in the Destination device.

The “Slave” device will now follow the Damper position of the Source device. Also the Destination device
MUST not be configured with a sensor.

Structured NVs:

A Structured NV usually contains more than 3 elements but usually many more. These elements
contain information not found in the standard NVs.
Examples are:
 Damper Position
 Bypass Time
 Heat Load
 Cooling Stages
 Heating Stages
 And many more.

The names of the Structured NVs usually are of the form “cntlDataG”, in the VAV it is the last one in the
list on the second page of the device graphic.

At the time of this writing these values can only be mapped One to One. That is, for each element of the
Structred NV it can only be bound to one other point. The result of this its that the NV-Booster can not be
used on a single element. So for example it is NOT possible to Map and Bind the BypassTime through the
NV-Booster mechanism. This has the effect that if you need to bring the BypassTime from more than one
device to to determin if any devices are in the BypassMode you will need to map each individual
ByPassTime NV to an individual Pseudo point.

NV-Booster:
 This is the CARE name for the “Many to One function.
Its application is simple once you understand the mechanics.
As an example”
Lets say you want to bring back 25 Space temperature sensors ( the MAX number is 64 ), take the
MIN, MAX and Average and then, based on these values, alter the flow of your control logic.

18
  IN Care create 3 Pseudo Points and call them MIN, Max and Avg. In each points property sheet
change the NV Type to “Manual Mapping”. The reason for this is that you are going to assign the
mapping for the Pseudo point later.
 Open the Network Tree
 Find the XL5000 controller and open it to display its contents.
 Select and open the PLANT
 Right click on the controller and select “Create Input NV.
 An NV with the name nvi will be created.
 Change this name to something more useful, like SPtempStatus.
 Check the NV-Booster check box in the NV-Booster properties sheet.
 Select the Maximum number of Bindings ( 3 in this case )
 In the Mapped points section click in the white area in the first row. A Drop down will appear,
select the MIN ( this is the pseudo point created before ). Then on the right of the same row select
the arithmetic function you wish. MIN in this case.
 Repeat above process for each point to be included making sure to change the arithmetic function
as appropriate. MIN for MIN, MAX for MAX and Average for AVG.
 Make sure the Terminal Assignment Tool is visible.
 Locate the Devices that will supply the NV-Booster with the Space Temperature value, usually
nvoSpaceTemp.
 Now Drag and Drop the NV-Booster point created to all of the nvoSpaceTemp NVs in each of the
devices.

You now have 3 points in your XL5000 controller that will display the MIN, MAX and AVG of the 25
selected devices.

There is a very good write-up of the theory behind this in the LonWorks Mechanisms Guide contained
on the CARE CD in the literature section.
Also even though these points are mapped to pseudo points in the XL5000 controller the individual
points are still available for use on Graphics.

The big advantage here is that you have only used 1 NV to collect the average of 25 sensors!

Large Project with many LON Devices:

One question that has come up repeatedly is “Why do I have to Drag and Drop every point to every device
in the Terminal Assignment Tool?

At first site it would appear that you Drag and Drop all of your devices into the Default System and the
hunt for the device you want to configure.
In small applications this methodology will work fine, however in large jobs with say, hundreds of devices
having all of them in one view in the Terminal Assignment tool would be nearly useless.

This is why segregation and the creation of subsystems is so important. But another tool will help alleviate
many of these problems. Please see the next section on Plant Replication.

19
 Plant Replication

Mastering the New Plant Replicate is one of the most important operations you will learn.
One can think of this function as a Macro used to generate Unique Names for Plants, User Addresses, and
NV names.
This function is actually a combination of the old Plant Replicate and the Plant Copy. At first
glance it appears to be complicated and non-intuitive but I assure you that once you have spent a little time
experimenting with this you will be asking why this was not done before CARE 4.0. While the primary
function of Plant Replicate may seem to be… well, Replicating Plants, it’s primarily intended to help you
organize your LON project into useful and logical Subsystems.

The Plant Replicate layout is similar to a spreadsheet: each Row and Column having a specific
function.
With the exception of the “Counter” rows each line represents an immediate action to be preformed on the
Name by Appending or Suffixing a string of characters to the existing Name.

The difference with the Counter is that it acts on the Row immediately above the last row entered.
Appending or Suffixing an incremental value to the Name.

Here are the column Names and there function:

1. Option 1 ---- this can be the Plant Name, User address etc. or the function such as a
Counter or Custom Text.

2. Option 2 – The Column is not always used; it’s most common use is the Custom text
used as a Prefix or Suffix.

3. Start – Where to start the Prefix; given as a number starting at the left most character.
Or in the case of a Counter the number or character that will begin the sequence. For
example a start value of 1 will start incrementing from 1 a start value of 5 will start
incrementing at 5. The same holds true for Characters a Start value of “A” will start
at “A” and increment through B, C… a Start value of “V” would begin at “V” and
increment W, X, Y, Z.

4. Length – Determines how many characters will be used: starting from the first left
most character. The Variable check box is used to enable and disable this function.

5. Variable– By default the Prefix and Suffix always uses the entire character string.
Un-checking this box allows you to change the start position.

6. Example – is the result of each row where applicable.

At the bottom of the Plant Replicate just below the rows the result is displayed as if the rules setup in the
rows above had been executed. This field changes in real time so you can watch the results of the changes
as you change the rules.

Rows may be added or deleted as needed by Left Clicking and selecting Add or Delete Row.

20
While the Plant Replicate will work on any Plant it is most useful when working on LON projects.

Say you have a Project with 500 VAV controllers in a 20-story building each floor containing 4
types of VAVs with a total of 25 VAVs per floor.
The novice user is likely to try and put all 500 VAVs in the Terminal Assignment Tool all in a single Plant.
This would require Dragging and Dropping 500 VAVs into the Plant and scrolling and hunting for each
VAV to configure and bind NVs.
While it could be done this way, the Plant Replicate will speed this up significantly.

Usually a floor would be considered as a whole; one zone if you will. But if you were to divide
each floor into Zones containing say 10 VAVs that are all the same and 5 for the always-present odd ones.
Then start by making a Plant with 10 VAVs and use the Plant Replicate to duplicate the remaining Zone
and one extra plant for those controllers that do not fit the pattern. In this scenario it is likely that many of
the other floors will be similar if not identical. You already have the templates for this so it is probably just
a matter of changing the Custom Text prefix and replicating the additional floors.

Let’s look at one:

The first line represents the Plant Name, since the Start and Length are set to 1 the entire Plant
name will be used. If the Start position were changed to 2 the name would be”AVB1”, in other words
starting at the second character position. If the Variable check box was unchecked and since the length is
set to one the Name would just be “V”.
The Custom Text is set for “B” its placement will be at the end of the string because it is AFTER
the NAME making it a Suffix. If the Custom text were in the first row and the Plant Name in the second
row the “B” would become a Prefix. Since this is a Suffix the Start and Length do not apply and usually
would not be changed.

21
 There are 3 different Counters the first 2: Counter 1…n and Counter A…Z are used to increment
individual items. In our example the Plant Name is incremented by one for each replicated plant. This could
be done using the Letters A through Z.
The third type of counter is used when you want to only increment once for each Replication. So for
example using the Replicate counter on the name RTU1DA for 5 replications the first plant would have
RTU1DA as the prefix the next would be RTU2DA and so on to RTU5DA. If the Counter 1…n where used
the result would be 5 Plants containing RTU1DA.

Three important things to remember:

1. Custom Text before a Name is a Prefix
2. Custom Text after a Name is a Suffix
3. Counters always operate on the row immediately above.
4. Check the Length – If you have the Length set to 1 the counter will only be able to count to 9 then
it will roll-over. If it is set to 2 it will count to 99 and so on. If the Counter A – Z is used it will
roll-over back to “A” so you only have 26 unique names. The Length field cannot be changed with
this counter.

The example given used the Plant Name the operations are exactly the same for all of the other Names.

The default Plant Replicate will work “out of the box”, it is recommended that you create a Plant and run
the Plant Replicate without any changes. This will allow you to see the results and compare them with the
default set of rules.

As you can see the Plant Replicate is a very flexible tool, but it takes some practice to master.

There is a hidden way to save all of this work! Be advised that this requires some organization and
knowledge of Windows.
The setup of the Grids for the Plant Replicate is stored in a file called NameGen.ini it is located in
the ROOT directory of CARE. Every time you make a change to the Replication grid it is stored in this file
and becomes the new default. It would be better if you could store different configurations for later use.
A backup of the default NameGen.INI file is installed in the \CARE\Backup folder. DO NOT alter this file
it is there so you can return to the default setup.
To use this feature create and test a new Plant Restore Macro. Once you are satisfied with it’s
operation copy and paste the NameGen.INI file to a folder that will contain your archived Plant Replicate
Macros. If you are careful about naming these folders with descriptions of the Macro function it will be a
simple matter to copy and past the Macro needed to the ROOT directory of CARE and start out with a
Plant Replicate setup that will closely if not exactly match what you need.
If you ever find your self in the position of needing to return to the Default, simply copy and paste the
backup from the \CARE\BACKUP folder.
Currently this is the only way to save and reuse Project Replicate Macros, this may be added as a
standard feature in a future release.

22
 EBI-SymmetrE-ACSELON and CARE 4.0

With the introduction of the EXCEL 5000 Open architecture several new procedures are needed to
integrate the database created in CARE 4.0 and the Front-End servers.
Starting at the server end the Point servers and communications services have been upgraded to
include the Open Lon communications.
There are 4 main components here:
1. LNS Point Server
2. Excel 5000 Direct ( Virtual C-Bus )
3. Scan Task ( Virtual C-Bus )
4. LonWorks Point Server Plugin

From CARE 4.0 there is 1 new mechanism that links to these new components; this is the Export to LNS.

Once a CARE LON Project is ready, the CARE database must be converted into the LNS database format.
This is done using the Export to LNS function.

It is very important that all of the individual steps involved be followed exactly and in the sequence listed
below.

First the basic steps:

1. Export to LNS from CARE

2. Printout RTF file for later use in Quick Builder
3. Exit CARE.
4. In EBI/SymmetrE/ACSLON Open Station and login as Manager.
5. Configure Point Server(s): 1 Server when using Scan Task and setup as LonWorks; 2 Servers
when using EXCEL 5000 direct, 1 setup as LonWorks the other as EXCEL 5000.
6. Configure Areas
7. Configure Channel ( Scan Task only )
8. Configure Controller ( Scan Task only )
9. Close Station
10. Open LonWorks Point Server Plugin
11. From TOOLS Import LNS Database from CARE
12. Configure Plugin using the Imported file just created
13. Launch Plugin
14. Enter an Area and set the Report by Exception to 5 seconds.
15. Save the configuration
16. Set all devices On-Line
17. Close the LonWorks Point Server Plugin
18. Open Control Panel
19. Start the CBUS application
20. Configure a Virtual C-BUS
21. Close the CBUS application
22. Restart machine
23. Open Quick Builder
24. Create a Channel ( Scan Task only )
25. Create a Controller
26. Import points using the CARE Import Wizard from the RTF file created in CARE in step 2.
27. Download Quick Builder Database
28. Close Quick Builder
29. Optional: Open a Command Prompt Window and run PNTBLD.
30. Open Station

23
 31. Check Operation.

While at first this looks long and complicated there are actually only 3 new additions; The Export to LNS
in CARE, the configuration of the LonWorks Point Server and the C-Bus configuration used by ScanTask
or EXCEL 5000 Direct, all of the other steps were already necessary to set up the Point Servers and Station,
although the LonWorks or LON Point server Type is a new selection in the configuration of the Point
Servers.

Now lets look at each step one at a time and address the specific configuration details.

Export to LNS
Before this step is done the following must be completed in the CARE Project:
A. EXCEL 500/50 controllers must have the OS upgrade to version 2.06 these files are on
the CD in the Controller-OS-2.06 folder. Use the Upgrade Firmware in XL-Online to
download the upgrade. This must be done until the controllers start shipping with version
2.06.
B. The Virtual C-Bus number must be set in the controller using the MMI in XL-Online.
For most applications the BUS ID number will be set to 1. To do this the controller must
be reset; then navigate to the “Controller Setup” then “LON BUS” and set the BUS ID to
1. The mechanism in Care to do this automatically will be fixed in an up coming Service
Pack. Until then it must be done manually.

The purpose of this is to set the Virtual CBUS number; this uses Explicit Messaging to
communicate to the XL 500/50 over the LON bus. It is the same C-Bus number set in the
Controller Configuration.
C. All of the XL 5000 controllers that are to be brought on-line must be Translated and
downloaded.
D. All of the LON devices must be configured using the Plug-in.
E. All of the devices on the network must be Commissioned.
F. CARE must be set “Offnet”.

In the Network View of CARE Right Click on LON-Works and at the bottom of the Context menu select
Export to LNS.

The following is displayed:

24
 Once the database has been Exported any changes made in CARE to the LON devices will require
a new Export in order to keep the CARE database and the LNS database synchronized. This warning is
there to re-enforce this procedure.

If you are ready to Export: Click Yes to Proceed. The procedures for making changes once the Export has
been done are detailed in the System Integration Guide included on the CD. We will discuses these briefly
later in this document.

The following is Displayed:

25
By default the Export is configured to use the Machine CARE is installed on and assumes the LNS Server
resides on this machine. If this is not the case then the Exported Database must be moved or sent to the
machine where the LNS Database resides.

1. Select Remote LNS Server. To use this feature the machine will have to be connected to the
remote server via a TCP/IP connection and have the FTP protocol running. Enter the URL or
remote server name, the Target directory ( Usually C:\LM ) and a User Name and Password if
required. See the System Administrator for these details.
2. NI Channel: It is essential to set the Network Interface Channel to the proper location. The NI
Channel is the point at which the Network Interface Device ( PCLTA- 10 i.LON, etc. ) is
physically connected to the E-Bus.
3. Set To Commissioned: This is where the LNS Device Credits are deducted for each LON
Device used. Un-check this box for testing the Export. However if it is left Unchecked the
devices will not function when imported to the Point Server.
4. Use Template Database: normally this should be left checked unless you have a 3 rd party
device registered.
5. Export the Database Locally. By default the Exported Database is placed in the C:\LM folder
on the local machine. This folder is created when the LNS database is installed, it cannot be
changed. The transfer of the exported database will have to be done using external media such
as floppy disk , CD or by FTP transfer.
6. When the Export is completed the following will be displayed:

26
If the Export was successful click Close, if not Print the results for use when calling for Technical Support.
At this time the text can’t be copied and pasted.

Continuing from our basic steps:

 Printout RTF file for later use in Quick Builder

 From the Database\Print setup the Printout with only the “Point Data” and “Datapoint description
boxes checked. This is the only information the Quick Builder CARE Import Wizard will need.
 Exit CARE.
 In EBI/SymmetrE/ACSLON: Open Station and login as Manager.

 Configure Point Server(s): 1 Server is used when using Scan Task and setup as LonWorks; 2
Servers are used when using EXCEL 5000 direct, 1 setup as LonWorks the other as EXCEL
5000.

Setup the EBI LonWorks Point Server

1. Open Station.
2. Log in as a Manager.
3. Go to Configure -> System Hardware -> Controller Interface -> Point Servers.
4. In the first slot select LonWorks.
5. Click on the point server link (LONWORKS by default).
6. Enter your machine name (or ‘localhost’) for the Network Name.

27
7. Click on the Area Assignment link on the bottom of the display.
8. Add the LonWorks areas.
9. Select the LonWorks Point Server in the Server drop down.
10. Add area A1 (default area for points).
11. Click the Station Area Assignment link on the bottom of the page.
12. Enable the LonWorks area for the Station(s).
13. Repeat steps 3 through 12 if you are using EXEL 5000 Direct.
14. Close Station.

Configure the LonWorks Point Server Plug-in

1. Run the LonWorks Point Server Plug-in. located in the LonWorks Configuration tools.
2. From the TOOLS drop down select LNS IMPORT you will see the following:

Source is the location of the database created by the CARE Export. By default this is C:\LM\{CARE-
Project Name }.

Destination:
NAME: Name the database to be used by the Point Server it must be different than the Exported
CARE name.
Network Database Folder: C:\LM
3. Click Import: you will be prompted that the folder does not exist click Yes to Create the folder.
4. Follow the prompts.
5. Set the Network to your Care project name (if Network doesn’t show the project name, make sure
LNS has been exported from Care).
6. Set the Management Mode to online.
7. Set the Network Interface to LON1 (if Network Interface doesn’t show LON1, the card isn’t
configured properly).

28
 8. Click the Launch button.
9. Note the Point server and Server Host names.
10. In Area enter an area you will use for the LonWorks Point server (i.e. LW).
11. Set the Poll Interval to 5 seconds.
12. Check the Report by exception box.
13. From the TOOLS drop down select Set Devices On-Line.
14. From The TOOLS Menu select Backup LonWorks Point Server Settings.
15. Close the plug-in applet.

The following will need to be done if you are using EXCEL 5000 Direct or Scan Task.

Configure the CBus

1. Open Control Panel

2. Select CBus.
3. Click Add.
4. Set Type to LON.
5. Set CBus Address (i.e. 1).
6. In the Database field, enter the new file name created when doing the Import in the LonWorks
Point Server Plugin (the same name should be under C:\LM\<Import name>)
7. Set Driver to LON1.
8. Set Virtual CBus to 1.
9. Click Apply then OK.
10. Reboot the PC.

Configure Quick Builder

1. Create a new or open and existing Quick Builder project.

2. Select the Enable Components TAB.
3. Locate the EXCEL 5000 or EXCEL 5000 Direct under DEVICE and click on the Check Box.
4. Click OK
5. Add a Station with Operator Security (optional).
6. Add an Excel 5000 Channel. ( Scan Task Only )
7. Select the Port tab. ( Scan Task Only )
8. For the port, enter <machine name>:cbus1 (i.e. EBISRV:cbus1 or localhost:cbus1). ( Scan Task
Only )
9. Add an Excel 5000 Controller.
10. Enter required Address ID and set the Channel Name.
11. Go to Tools -> Care Import Wizard from the Quick Builder menu.
12. Follow prompts to select the newly added controller (or required controller).
13. Select the Care database printout created earlier.
14. Leave all default settings and continue to Finish.
15. Click the Download icon and select ‘All items relevant to selected server’.

Making changes in CARE after the Database has been Imported into the LNS Point Server.

In principle once the CARE Database has been Imported into the Front-End LNS Point Server you
can no longer make any changes to the LON configuration. However the reality of how systems are
installed require that changes must be made as the job installation progresses toward completion.
What follows is an overview of the methods you will have to use to make changes once the Front-
End server is brought on-line.
The central question is “Why is this so difficult”? The answer is that in it’s current implementation
we must deal with 2 independent databases: the CARE RAIMA database and the Echelon LNS Database
and Operating system.

29
 During the process of commissioning LON devices while “ONNET” in CARE, CARE has
assigned Domain, subnet and node ID numbers to each LON device. After the CARE database is Exported
this database is Imported into the LNS Database that will be used by the Front-End Point Server. This is
done using the LNS Point Server Plug-in. During this process the LNS Operating System puts all of the
LON devices into a “Soft Off-Line” State and creates new Domain, Subnet and Node Ids: it re-
commissions the entire network which may differ from what CARE, had generated during the
commissioning. This is why it is necessary to use the “Set On-Line” function in the LNS Point Server
Plug-in. This process is part of the LNS Operating System and as such is completely independent of CARE.
The obvious solution to this is to more closely integrate CARE with the LNS database, and in fact
this is being worked on now. Until then it is imperative that you understand the mechanics involved to keep
the system functional while changes are made.
The complete coverage of this topic is in the System Integration Guide on the EXCEL 5000 Open
CD. We will only cover the basics here.
If the network is segmented with routers it is best to disconnect the E-Bus on the segment(s) that
will require changes. These changes would include:
1. Adding a LON Device
2. Removing a LON Device
3. Re-commissioning a LON Device because of NV Biding changes made in CARE.

In short any change that will require that CARE be used to Commission or Re-Commission LON devices.
This would also include the XL5000 controller used. See the System Integration Guide for a complete
description.
Once you go back “ONNET” with CARE to make changes you MUST re-commission the
Network or the Network Segment first. This is necessary because the Subnet and Node ID numbers were
changed by the LNS Operating system when the devices were “Set On-Line” in the Point Server Plug-in.
So in reality if you do not re-commission the network you may not be connecting to the correct device.
Once the Network or Network Segment has been re-commissioned “ONNET” in CARE 2 things may
happen if the network is still connected. Communication with the devices will be lost and/or duplicate
Node Ids may exist. This is why it is best to disconnect the section of the bus that you will be updating; you
will of course loose communications with the disconnected segment but it will not cause bus problems
while the changes are being made.
After the Devices have been re-commissioned and in the case of an EXCEL 5000 controller
downloaded and commissioned do the following:
1. Go “OFFNET” in CARE
2. From the Database drop down go to Delete LNS Database
3. Delete the previous Export for this project.
4. If the Import database from the LNS Point Server Plug-in is present delete it as well. Write
this name down so you can use it later during the LNS Import.
5. Export to LNS and move the new LNS database to the Point Server as described in the
previous section.
6. Close CARE
7. Stop the LonWorks Point Server service.
8. Stop the Scan Task Daemon or the EXEL 5000 Direct service.
9. On the Front-End open the LNS Point Server Plug-in
10. From the TOOLS drop down IMPORT LNS again as described in the previous section. Use
the same name as before so the configuration remains intact.
11. The network segment must be reconnected by this time.
12. Launch The LNS Point Server Plug-in
13. From TOOLS: Restore the Plug-in configuration saved during the original configuration
14. Again from TOOLS: “Set Devices On-Line”. The LNS Operating system will now re-
commission the entire network. There is no way to have it just re-commission the segment or
devices that were changed.
15. If devices and/or points were added or removed Use Quick Builder to create a new point
database. If Points where added or deleted a new CARE Printout will be needed.
16. Download the new Quick Builder database.
17. Re-start the LonWorks Point Server and Scan Task or EXEL 5000 Direct services.

30
At the present time the LNS Operating System does not contain the hooks into the database that CARE
would require to automatically keep both the CARE and LNS databases synchronized in real time and thus
eliminate the need for the process outline above.
Honeywell and Echelon are working on the CARE/LNS integration for a 2003 deliverable.

Related Hardware and Software/Firmware Issues

Do not plug in or pull out application modules under power

Many application modules are destroyed by inserting or removing these modules in the XL
controllers while the power is on.
Note: The controller must be switched off, before you insert or remove any
modules.

The problem can also occur in following hardware types:

XD50-FCS; XD52-FCS
XD50-FC; XD52-FC
XD50-FCL
XF50-FL
XD50-F
XD50-E
XDL505 of XCL5010

Please inform your installer to exercise caution when handling such modules in the future.

Known XL OS 2.06.01 issues.

1. Controller system alarm 62 when C-Bus number has not been set
As long as no C-Bus number has been set for a XL50; XL100 or XL500 controller, there will
be a system alarm number 62 “C-Bus error”.
Solution: Should not appear again after setting the C-Bus number on the controller once.

2. Controller with distributed I/O module cannot commission I/O module in local mode:
A distributed I/O module with the same module number as the Controller C-Bus number
cannot be commissioned by the controller.
In shared mode, however, this is not an issue.
Solution: Contact the Technical Assistance Center if a temporary fix is required.

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We have planned the final release with the above-mentioned issues fixed during the first quarter
of the year 2003.

1. XL controller digital output data points shows “NO REPONSE”.

2. XSL 513 Terminal Block for XFL523 can have contact problems.

1. XL controller digital output data points show “NO REPONSE”.

Digital output data points engineered with Care 4.1 (Care autobinding 2.6, XFL524B and XL-
controller 0S 2.6) can stay in “NO RESPONSE” condition.

Background: The existing XFL524B needs one change of state in order to send a response to
the controller.

Work-around: Change the point status one time at the start-up of the application

Final solution: A new firmware will be released next week for the XFL524B module.

2. XSL 513 Terminal Block for XFL523 can have contact problems
We have recognized some contact problems with terminal 17 on the terminal block XSL513.
In some critical cases when the terminal is not fixed mounted, the terminal 17 can loose the
contact to the XFL523.
.
Work-around: Please make sure that the terminal block is fixed and properly mounted.
Terminal 17 is internally connected to terminals 13 to 16. We would recommend using one of
these other terminals at this time.

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 XL10 Commissioning
W7750 CVAHU, W7753 Unit Vent, W7761 RIO, Q7300 Thermostat and Q7790 Wireless Wall
Module

Standard Commissioning process for XL10s

1. XL10 controllers are configured with Plug-ins Offline using the same procedure as all
other XL10 devices. The default engineering units for the plug-ins is Metric. If users
will want to change this to English. Start by selecting Plug-ins Offline. Choose
“Honeywell Project Settings” and select English. Refer to Fig 3. This task is done
once and changes the Engineering units for all Honeywell Plug-ins used in this
project.
2. Configure the XL10 Controller. Launch Plug-ins Offline and select “Honeywell
XL10 Configure”. The will present information in a similar format to E-Vision or
LonSpec Software. Make sure the Controller Type under the Configuration tab is set
to appropriate type, Standard or Smart. The flow Pickup Table and duct area must
also be entered. Select OK and allow time for the Plug-Ins to close when completed
with selections. Refer to Fig. 1.

Figure 1.

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3. Power up the controllers and connect each via the LonWorks network to the CARE
computer.

4. Open the project in CARE 4.0 and go Onnet. Under LON select Onnet or select the
icon in the upper left portion of the screen.

5. Get the Service pin for the Variable Air Volume controller. Right-click the controller
and select Get Service Pin. Refer to Figure 1. This will allow the user time to hit the
service pin on the XL10 to set the Neuron ID. When successful, half of XL10
controller icon will turn green.
Note: The bypass button on the wall module does not send the Service Pin for the XL10 controllers
when used with Care 4.0 or LonMaker. Pushing the service pin on the controller or manually typing
the neuron ID is required. The bypass button service pin functionality will return with future XL10
controller firmware upgrades.

Figure 2.

6. Commission each XL10 individually or all at the same time. This is done by either
highlighting the desired XL10 and selecting Commission under the LON menu, or by
right-clicking the device and selecting Commission. Refer to Figure 2.

7. When the full XL10 icon changes color to Green the controller is commissioned and
communicating properly. If the controller changes color to red the XL10 is not
communicating properly and the process may need to be started over.

8. Go Offnet by selecting Offnet under the LON menu or by selecting the icon in the
upper left portion of the screen.

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Airflow Calibration Procedure using Plug-in 4.1.0 with
CARE 4.0

Standard Commissioning process for XL10s

1. VAV controllers are configured with Plug-ins Offline using the same procedure
as all other XL10 devices. The default engineering units for the plug-ins is
Metric. If users will want to change this to English. Start by selecting Plug-ins
Offline. Choose “Honeywell Project Settings” and select English. Refer to Fig
3. This task is done once and changes the Engineering units for all Honeywell
Plug-ins used in this project.
2. Configure the VAV Controller. Launch Plug-ins Offline and select “Honeywell
VAV2 Configure”. The will present information in a similar format to E-Vision
or LonSpec Software. Make sure the Controller Type under the Configuration tab
is set to appropriate type, Standard or Smart. The flow Pickup Table and duct
area must also be entered. Select OK and allow time for the Plug-Ins to close
when completed with selections. Refer to Fig. 1.

35
Figure 1.
3. Power up the controllers and connect each via the LonWorks network to the
CARE computer.

4. Open the project in CARE 4.0 and go Onnet. Under LON select Onnet or select
the icon in the upper left portion of the screen.

5. Get the Service pin for the Variable Air Volume controller. Right-click the
controller and select Get Service Pin. Refer to Figure 1. This will allow the user
time to hit the service pin on the VAV to set the Neuron ID. When successful,
half of VAV controller icon will turn green.
Note: The bypass button on the wall module does not send the Service Pin for the XL10 controllers
when used with Care 4.0 or LonMaker. Pushing the service pin on the controller or manually typing
the neuron ID is required. The bypass button service pin functionality will return with future XL10
controller firmware upgrades.

36
Figure 2.

6. Commission each VAV individually or all at the same time. This is done by
either highlighting the desired VAV and selecting Commission under the LON
menu, or by right-clicking the device and selecting Commission. Refer to Figure
2.

7. When the full VAV icon changes color to Green the controller is commissioned
and communicating properly. If the controller changes color to red the VAV is
not communicating properly and the process may need to be started over.

8. Go Offnet by selecting Offnet under the LON menu or by selecting the icon in the
upper left portion of the screen.
DownLoading Flow Pickup Tables (Extra step required for VAV).
1. The steps highlighted above in the Standard XL10 commission process must be
completed before executing this task. The VAV controller needs to be full green
(commissioned).
2. Right-click the controller and select Plug-Ins Online. Refer to Figure 2. A dialog box
will open after selecting Plug-Ins Online read it, select OK and continue.
Note: Plug-Ins Online is only available when the network is Offnet.

Figure 3.

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3. Highlight “Honeywell VAV2 Check Model Type” and select OK. Refer to Figure 3.
This will check the model type of the VAV to make sure it matches the database. If
the model type is correct you will be able to select OK to download the appropriate
flow chart table. If the model type is not correct you will need to return to step 2 of
standard commissioning procedure to enter the proper model type. The Download
Flow Pickup Table procedure is done for every VAV controller.

AIR FLOW BALANCING PROCEDURE

1. The standard commissioning and Flow table download steps must be completed
before starting this task.

2. Right-click the controller and select Plug-Ins Online. Highlight “Honeywell VAV2
Calibrate” and select OK. Select the Flow Calibration tab on the Sensor Calibration
Screen for XL10 VAV2. Allow time for VAV Controller to reboot may take a few
minutes. Refer to Figure 4.
Figure 4.

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3. Begin Calibration by selecting “Zero” under the Action menu then selecting “Start”.
Refer to Fig. 5.
Figure 5.

4. After zero calibration is complete and control is returned to the user. Select
“Maximum” under the Action menu then select “Start”.

5. When stable flow is reached (Measured flow white), enter the measured value then
select “Calibrate”.

6. When Max Calibration is completed select “Minimum” under the Action menu and
select “Start”. Refer to Figure 6.
Figure 6.

7. When Stable flow is reached and Measured Flow field under Air flow Minimum
Calibration is white, enter the measured flow and select “Calibrate”.

8. With Minimum calibration completed the controller is calibrated. Select Close to

return to CARE 4.0. The Air Balance procedure is completed for each VAV box.

39