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Honeywell Process Solutions

Honeywell RC500 RC-SCONTRL RTU

User's Guide RC-DCX211

R100 July 2011

Release 100 Honeywell

ii Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

Notices and Trademarks

Copyright 2011 by Honeywell International Sárl. Release 100 July 2011

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.

Honeywell, PlantScape, Experion PKS, and TotalPlant are registered trademarks of Honeywell International Inc.

Other brand or product names are trademarks of their respective owners.

Honeywell Process Solutions

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Phoenix, AZ 85027 USA

1-800 822-7673

R100 Honeywell RC500 RC-SCONTRL RTU User's Guide iii July 2011 Honeywell

About This Document This document describes how to configure Honeywell RC500 SCONTRL Remote Terminal Unit (RTU).

This documentation is intended for the following audience:

• System engineers who would configure the RC500 RTU modules, create associated applications, and operate the run-time RC500 RTU modules.

• Field engineers who would install and maintain RC500 RTU modules.

Knowledge of Experion control system and exposure to Microsoft Windows environment is necessary for configuring the RTUs.

Release Information

Document Name Document ID

Release Number

Publication Date

Honeywell RC500 RC-SCONTRL RTU User's Guide

RC-DCX211

100 July 2011

Support and Other Contacts

iv Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011


United States and Canada Contact:

Phone: Facsimile: Mail:

Honeywell Solution Support Center 1-800-822-7673 (outside Arizona) 602-313-5558 (in Arizona) Calls are answered by dispatcher between 6:00 am and 4:00 pm Mountain Standard Time. Emergency calls outside normal working hours are received by an answering service and returned within one hour. 602-313-3293 Honeywell TAC, MS P13 2500 West Union Hills Drive Phoenix, AZ, 85027

Europe Contact:

Phone: Facsimile: Mail:

Honeywell TAC-EMEA +32-2-728-2732 +32-2-728-2696 TAC-BE02 Hermes Plaza Hermeslaan, 1H B-1831 Diegem, Belgium

Pacific Contact:

Phone: Fascimile: Mail: Email:

Honeywell Global TAC – Pacific 1300-300-4822 (toll free within Australia) +61-8-9362-9559 (outside Australia) +61-8-9362-9564 Honeywell Limited Australia 5 Kitchener Way Burswood 6100, Western Australia [email protected]

India Contact:


Honeywell Global TAC – India +91-20- 6603-9400 +91-20- 6603-9800 Honeywell Automation India Ltd 56 and 57, Hadapsar Industrial Estate Hadapsar, Pune –411 013, India [email protected]


R100 Honeywell RC500 RC-SCONTRL RTU User's Guide v July 2011 Honeywell

Korea Contact:


Honeywell Global TAC – Korea +82-80-782-2255 (toll free within Korea) +82-2-792-9015 Honeywell Co., Ltd 4F, Sangam IT Tower B4-4 Block 1590, DMC Sangam-dong, Mapo-gu, Seoul, 121-835, Korea [email protected]

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Phone: Mail: Email:

Honeywell Global TAC – China +86- 21-5257-4568 Honeywell (China) Co., Ltd 33/F, Tower A, City Center, 100 Zunyi Rd. Shanghai 200051, People’s Republic of China [email protected]

Singapore Contact:


Honeywell Global TAC – South East Asia +65-6580-3500 +65-6580-3501 +65-6445-3033 Honeywell Private Limited Honeywell Building 17, Changi Business Park Central 1 Singapore 486073 [email protected]

Taiwan Contact:


Honeywell Global TAC – Taiwan +886-7-536-2567 +886-7-536-2039 Honeywell Taiwan Ltd. 17F-1, No. 260, Jhongshan 2nd Road. Cianjhen District Kaohsiung, Taiwan, ROC [email protected]


vi Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

Japan Contact:


Honeywell Global TAC – Japan +81-3-6730-7160 +81-3-6730-7228 Honeywell Japan Inc. New Pier Takeshiba, South Tower Building, 20th Floor, 1-16-1 Kaigan, Minato-ku, Tokyo 105-0022, Japan [email protected]

Elsewhere

Call your nearest Honeywell office.

World Wide Web

Honeywell Solution Support Online:

http://www.honeywell.com/ps

Training Classes Honeywell Automation College:

http://www.automationcollege.com

http://www.honeywell.com/ps�

http://www.automationcollege.com/�

Symbol Definitions

R100 Honeywell RC500 RC-SCONTRL RTU User's Guide vii July 2011 Honeywell

Symbol Definitions The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

ATTENTION: Identifies information that requires special consideration.

TIP: Identifies advice or hints for the user, often in terms of performing a task.

REFERENCE -EXTERNAL: Identifies an additional source of information outside of the bookset.

REFERENCE - INTERNAL: Identifies an additional source of information within the bookset.

CAUTION

Indicates a situation which, if not avoided, may result in equipment or work (data) on the system being damaged or lost, or may result in the inability to properly operate the process.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in serious injury or death.

WARNING symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

WARNING, Risk of electrical shock: Potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60 VDC may be accessible.

Symbol Definitions

viii Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

Symbol Definition

ESD HAZARD: Danger of an electro-static discharge to which equipment may be sensitive. Observe precautions for handling electrostatic sensitive devices.

Protective Earth (PE) terminal: Provided for connection of the protective earth (green or green/yellow) supply system conductor.

Functional earth terminal: Used for non-safety purposes such as noise immunity improvement. NOTE: This connection shall be bonded to Protective Earth at the source of supply in accordance with national local electrical code requirements.

Earth Ground: Functional earth connection. NOTE: This connection shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements.

Chassis Ground: Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements.

R100 Honeywell RC500 RC-SCONTRL RTU User's Guide ix July 2011 Honeywell

Contents

1. RC-SCONTRL RTU INTRODUCTION ......................................... 13

1.1 Overview ........................................................................................................ 13

1.2 RC-SCONTRL RTU specifications ............................................................... 14 Technical features ................................................................................................................ 14 Watchdogs and monitors...................................................................................................... 15 Redundancy ......................................................................................................................... 16 Ethernet ports ....................................................................................................................... 16 Serial ports ........................................................................................................................... 17 RS232 Port A and RS232 Port B Features .......................................................................... 18 RS485 Features ................................................................................................................... 18 Honeywell RC500 I/O Tool Kit .............................................................................................. 19

2. RC-SCONTRL RTU CONFIGURATION ....................................... 21

2.1 Overview ........................................................................................................ 21

2.2 Adding an RC-SCONTRL RTU ..................................................................... 23

2.3 Configuring RC-SCONTRL RTU communication ports ............................. 24 Configure Ethernet ports ...................................................................................................... 24 Configure serial ports ........................................................................................................... 27

2.4 Redundant RTUs ........................................................................................... 29 Overview .............................................................................................................................. 29 Redundant RTU switch over conditions ............................................................................... 29 Station Status Module variables ........................................................................................... 30 Configure a redundant RTU ................................................................................................. 32 Create and load ISaGRAF program for redundancy ............................................................ 37 Configure synchronization .................................................................................................... 38 Add an I/O module to a redundant RTU ............................................................................... 41

2.5 Configuring peer-to-peer RTU communication .......................................... 42 Configure I/O transfer ........................................................................................................... 42 Configure conditional transfer .............................................................................................. 46

2.6 Assigning I/O module to RTU ...................................................................... 51 Add virtual I/O modules ........................................................................................................ 51 I/O tag names and restrictions ............................................................................................. 54

2.7 Configuring I/O modules .............................................................................. 55

2.8 Configuring DNP3 Slave driver in Honeywell RC500 I/O Tool Kit ............ 58

Contents

x Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

Configure DNP3 slave driver ............................................................................................... 58 Map I/O types to DNP points ............................................................................................... 64

2.9 Establishing communication between Experion and RTU using DNP3 .. 73 Prerequisite ......................................................................................................................... 73 Enable components in Quick Builder ................................................................................... 75 Add a DNP3 Protocol channel ............................................................................................. 76 Add a DNP3 Protocol controller ........................................................................................... 77 Configure Experion Points ................................................................................................... 78 Configure an Experion Analog Point ................................................................................... 78 Configure an Experion Status Point .................................................................................... 79

2.10 Establishing communication between Experion and RTU using Modbus 80

Enable components in Quick Builder ................................................................................... 80 Add a Modbus Protocol channel.......................................................................................... 82 Add a Modbus Protocol controller ....................................................................................... 83 Configure Experion Points ................................................................................................... 83 Configure an Experion Analog Point ................................................................................... 83 Configure an Experion Status Point .................................................................................... 85

2.11 Configuring RTU as Modbus Master ........................................................ 86

2.12 Configuring RTU as Modbus Slave .......................................................... 89

2.13 Configuring datalogging ........................................................................... 90 Configure Host transfer ....................................................................................................... 90 Execute Host transfer .......................................................................................................... 93 Configure Client transfer ..................................................................................................... 94 Configure Datalog Server for specific stations .................................................................... 97 Configure Datalog Server for any station ............................................................................ 98 Copy datalog configuration ................................................................................................ 100

2.14 Configuring alarms in RTU ...................................................................... 101 Add discrete alarms ........................................................................................................... 101 Add analog alarms ............................................................................................................ 102 Add periodic alarms ........................................................................................................... 104 Add a recipient .................................................................................................................. 105

3. LOAD RC-SCONTRL RTU CONFIGURATION ......................... 107

3.1 Overview ....................................................................................................... 107

3.2 Startup operations ....................................................................................... 107 Start an RTU ..................................................................................................................... 107 Establish communication between Honeywell RC500 I/O Tool Kit and RTU .................... 108

3.3 Load options ................................................................................................ 109

Contents

R100 Honeywell RC500 RC-SCONTRL RTU User's Guide xi July 2011 Honeywell

3.4 Loading basic configuration to RTU ......................................................... 109

3.5 Loading DNP3 protocol configuration to RTU ......................................... 111 Load DNP3 protocol configuration to secondary RTU ........................................................ 111

3.6 Loading all configuration files ................................................................... 112

3.7 Loading an ISaGRAF program to RTU ...................................................... 113

4. RC-SCONTRL RTU OPERATIONS ........................................... 115

4.1 Overview ...................................................................................................... 115

4.2 Replacing/upgrading redundant RTUs ..................................................... 115

4.3 Verifying the loaded configuration data ................................................... 116

4.4 Retrieving the configuration data .............................................................. 116

4.5 Monitoring RC-SCONTRL RTU .................................................................. 117 Monitor I/O modules ........................................................................................................... 117 Change I/O values using Test I/O ...................................................................................... 118 Monitor the communication between I/O modules and RTU .............................................. 119 Monitor the heartbeat register ............................................................................................ 119 Monitor redundancy ........................................................................................................... 120

4.6 Monitoring the ring switch status.............................................................. 121 Monitor the ring switch status using RTUs ......................................................................... 121 Monitor RTU Status ............................................................................................................ 125

4.7 Resetting the RTU ....................................................................................... 126 Set the real-time clock for an RTU ..................................................................................... 126

5. MAINTENANCE AND TROUBLESHOOTING ........................... 127

5.1 Upgrading firmware .................................................................................... 127 Considerations ................................................................................................................... 127

5.2 Resetting System Com Port ....................................................................... 130

5.3 Formatting Battery Backed RAM ............................................................... 131

5.4 LED Status ................................................................................................... 132

5.5 Diagnostics and troubleshooting .............................................................. 133

Contents

xii Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

R100 Honeywell RC500 RC-SCONTRL RTU User's Guide 13 July 2011 Honeywell

1. RC-SCONTRL RTU introduction

1.1 Overview RC-SCONTRL RTU is a modular and scalable controller capable of remote automation and control applications. The module, combined with Honeywell’s powerful and feature-rich SCADA products, provides an integrated solution that solves remote automation requirements.

You can install RC-SCONTRL RTU either in a non-redundant configuration or in a redundant configuration.

Figure 1: RC-SCONTRL RTU

1. RC-SCONTRL RTU introduction 1.2. RC-SCONTRL RTU specifications

14 Honeywell RC500 RC-SCONTRL RTU User's Guide R100 Honeywell July 2011

1.2 RC-SCONTRL RTU specifications Technical features

Feature Description

Unique station addresses (unit Ids) Address range 0-247 (Modbus)

Dynamic memory (RAM)

(for program execution, dynamic variables, dynamic file system)

32-bit, 0 wait states

64 Megabytes

Program memory (Flash)

(For program storage and file system)

128 MB

NVRAM (Non-volatile RAM)

(for datalogging and retained variables)

Battery-backed rechargeable lithium

2 MB

Battery backup time / life 1 year / 10+ years

Real-time clock resolution 10 mS

Real-time clock accuracy +/-15 seconds per month

I/O expansion RC500 Ethernet I/O-1, RC500 Ethernet I/O-2

Datalogging support Yes – Honeywell RC500 Datalog

Datalogging modes Host transfer and Client transfer

Programming High level C and others

Number of applications allowed Depends on memory available

IEC 61131 PLCopen programming Yes –ISaGRAF

Languages supported Ladder logic, function chart, function block, instruction list, structured text, and flow chart.



Feature Description

Number of programs allowed to be run in RTU at same time

One ISaGRAF program is allowed.

Cycle time 10 mS minimum (depending on user requirement).

Communication capabilities Master, slave, peer-to-peer, report on exception, store, and forward.

Communication media supported Serial, Ethernet, telemetry, telephone (dialup and leased line), radio (dumb and smart), other wireless, fiber optic, short haul and more.

Fault Tolerant Ethernet (FTE) Not supported

Size 4.75″L x 3.25″W x 3.15″H

(121mm x 83mm x 80mm)

Weight 0.840 Lbs

Watchdogs and monitors

Watchdogs and monitors Description

CPU watchdog CPU resets automatically if error is detected. Status LED indicates the error.

Communication watchdog When this watchdog is enabled, the RTU monitors all the communication ports (RS232, RS485, Ethernet) for I/O update commands. If the ports do not send any command for more than the specified watchdog timeout period, then the station either drops the outputs to zero or holds them in their last known state.



Watchdogs and monitors Description

Heartbeat watchdog When this watchdog is enabled, the RTU monitors a heartbeat register (toggling physical or virtual discrete output) sent from the Windows application or other source. If the heartbeat stops changing state for more than a specified timeout period, the discrete outputs and analog outputs in the station drop to zero or held in their last known states.

Redundancy

Feature Description

Redundant RTU Automatic switchover is supported with in-built redundancy scheme.

Redundant Ethernet links Yes – 2 unique MAC and IP addresses with different subnet masks support 2 unique network connections. Configuring the IP address in the same subnet may result in undesired behavior.

Redundant power inputs Yes – automatic switchover on failure. Ethernet ports

Feature Description

Connection RJ45 (auto-crossover)

Isolation 1500 Volts RMS 1 minute (60 Hz)

Message response time (typical) 5mS

Diagnostic LEDs Indicates speed, link, and activity

Protocols supported TCP/IP, ARP, UDP, ICMP, DHCP, Modbus TCP/IP Master and Slave, and DNP3 TCP/IP Slave



Feature Description

Independent networks • One network with unique MAC and IP address

• Two networks with unique MAC and IP addresses

Ethernet 1 One shielded RJ45 connector

Ethernet 2 Four shielded RJ45 connectors Serial ports

Feature Description

RS232 Port A RJ45 (TD, RD, CTS, RTS, CD, DTR, DSR/RI, GND)

RS232 Port B RJ45 (TD, RD, CTS, RTS, CD, DTR, DSR/RI, GND)

RS485 Port C Screws (GND, 485+, 485-, termination) (2-wire half-duplex)

RS485 network Up to 32 (full-load) stations

RS485 distance Up to 0.5 miles (1 km)

Protocols Modbus RTU Master, Modbus RTU Slave, Modbus ASCII Master, Modbus ASCII Slave, DNP3 Slave, RC500 (Peer-to-peer / RTU to IO)

Diagnostic LEDs on each port Transmit Data (TD) and Receive Data (RD)



RS232 Port A and RS232 Port B Features

Feature Description

Protocols RC500, Modbus ASCII Slave, Modbus RTU Slave, User Mode, Modbus ASCII Master, Modbus RTU Master, PPP, DNP3 V3.00, IEC-60870-5-101

Baud rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

Parity None, Odd, Even, Mark, Space

Data bits 8, 7

Stop bits 1, 2 RS485 Features

Feature Description

Protocols RC500, Modbus ASCII Slave, Modbus RTU Slave, User Mode, Modbus ASCII Master, Modbus RTU Master, DNP3 V3.00, IEC-60870-5-101

Baud rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

Parity None, Odd, Even, Mark, Space

Data bits 8, 7

Stop bits 1, 2



Honeywell RC500 I/O Tool Kit

Feature Description

Operating systems Windows XP

Minimum system requirements Pentium or equivalent, 32 MB RAM, 100 MB hard disk space

Functionalities Configuration, calibration, diagnostics, importing and exporting of I/O definitions, peer-to-peer I/O transfers, and I/O map shared database.

Datalogging capability and datalog server.




2. RC-SCONTRL RTU configuration

2.1 Overview The Honeywell RC500 I/O Tool Kit is a Windows software, and it is used to configure and maintain RTUs and I/O modules. Before you begin with RTU configuration, ensure that the Honeywell RC500 I/O Tool Kit is already installed and registered.

REFERENCE - INTERNAL

Refer to the Honeywell RC500 SIUG for more information regarding Honeywell RC500 I/O Tool Kit installation and registration.

ATTENTION

In the Honeywell RC500 I/O Tool Kit, RTUs and I/O modules are known as station.

RC-SCONTRL RTU configuration involves the following tasks.

• Basic RTU configuration

− Creating an RC-SCONTRL RTU

− Configuring Ethernet ports

− Configuring serial ports

− Configuring a redundant RC-SCONTRL RTU

− Creating and loading ISaGRAF program for redundancy

− Configuring synchronization

• I/O configuration

− Configuring I/O transfer

− Configuring conditional transfer

− Assigning I/O modules to RTUs

− Adding virtual I/O modules

− Configuring I/O modules

2. RC-SCONTRL RTU configuration 2.2. Adding an RC-SCONTRL RTU


− Configuring I/O module in a redundant RTU

• Protocol configuration

− Configuring DNP3 slave driver

− Mapping I/O types to DNP points

− Enabling components in Quick Builder

− Adding a DNP3 Protocol channel

− Adding a DNP3 Protocol controller

− Configuring Modbus Protocol

− Adding Modbus Protocol channel

− Configuring an Experion Analog Point

− Configuring an Experion Status Point

− Configuring RTU as Modbus Master

− Configuring RTU as Modbus slave

• Datalog configuration

− Configuring Host transfer

− Configuring Client transfer

− Configuring Datalog Server for specific stations

− Configuring Datalog Server for any station

− Copying datalog configuration

• Alarm configuration

− Adding discrete alarms

− Adding analog alarms

− Adding periodic alarms

− Adding recipient

2. RC-SCONTRL RTU configuration 2.2. Adding an RC-SCONTRL RTU


2.2 Adding an RC-SCONTRL RTU To add an RTU, you must create a configuration project in the Honeywell RC500 I/O Tool Kit. The file extension of the project is .6pj. It stores the configuration details of the RTUs and the I/O modules.

Perform the following steps to create a new project and to add an RC-SCONTRL RTU in the Honeywell RC500 I/O Tool Kit.

Step Action

1 Choose Start > Programs > Honeywell Tools > Honeywell Tool Kit.

The Honeywell RC500 I/O Tool Kit appears.

2 Choose File > New Project.

The Wizard Selection dialog box appears.

3 Click Add a new station to the project option and click OK.

The Select New Station Type dialog box appears.

If you want to add a station to an existing project, on the left-pane, in the Tree views right-click All Stations and choose New Station under By Type tab.

4 In the list, click RC500 RTU and click OK.

The Save As dialog box appears.

5 Enter a project name and click Save.

The RC500 RTU Station Configuration page appears.

6 Under Define General Properties, enter details in the Station Name box, the Station number box, and the Serial number box.

ATTENTION

• Station name should not exceed 20 characters, and in special characters, only the underscore is allowed.

• Value for the station number should be between 0 and 15999.

• The serial number can be found at the base of the RTU.

7 In the Station Type list, click RC-SCONTRL.

8 Click Configure Later.

A new station is added.

2. RC-SCONTRL RTU configuration 2.3. Configuring RC-SCONTRL RTU communication ports


2.3 Configuring RC-SCONTRL RTU communication ports Configure Ethernet ports

All RC-SCONTRL RTU models have two independent Ethernet ports. Each Ethernet port (Ethernet port 1 and Ethernet port 2) has its own MAC address.

The two Ethernet ports should be assigned IP addresses and subnet masks such that they operate on independent Ethernet networks. If the two Ethernet ports are configured to reside on the same Ethernet network, the RTU’s operating system may disable one of the two Ethernet ports and might result in undesired behavior.

The following table provides information about the protocols supported by the RTU.



Perform the following steps to configure Ethernet ports in the RTU.

Step Action

1 Right-click the station and choose Configure.

The RC500 RTU Station Configuration dialog box appears.

2 Click Ports tab.

3 Under Define Communication Port Properties, click Ethernet1, and then click Configure Selected Port.

The Ethernet Port Configuration dialog box appears.

Protocol Recommended port number

Use

RC500 UDP 1594 Used for communication between

• ISaGRAF and RTU

• Honeywell RC500 I/O Tool Kit and RTU

The communication port used is 1594.

RC500 UDP / TCP

1594 Used for communication between

• I/O module and RTU

• Peer-to-peer RTU

Modbus UDP / TCP Master


• RTU and I/O Modules

• RTU and third-party Modbus slave devices

The RTU acts as the Modbus Master.

Modbus UDP / TCP Slave


• RTU and SCADA

• RTU and third-party Modbus Masters

The RTU acts as Modbus Slave.

DNP3 UDP / TCP 20000 Used for communication between RTU and SCADA.



Step Action

4 Under IP address, click any one of the options provided.

• Automatically assign IP address based on station number Select this option to automatically assign IP address based on station number.In this case, if the station number is changed, the IP address also changes automatically.

• Use DHCP Select this option to allow DHCP server to assign the IP addresses to the stations.

• Manually assign IP address Select this option to assign IP address manually.

5 Click Advanced.

The Advanced Ethernet/IP Security dialog box appears.

6 In the Subnet mask box, enter the subnet mask of the network.

7 In the TCP/IP timeout list, either click an existing value or enter a value in seconds and click OK.

8 In the TCP/IP gateways box, enter the IP address.

ATTENTION

Subnet Mask

Assign an IP address for the subnet mask to associate the station to the required subnet.

TCP/IP Timeout

This setting determines the amount of time that a TCP/IP session can be inactive before it can be terminated by the station. An inactive TCP/IP session is terminated only if the station’s maximum allowable number of TCP/IP sessions is in use and a new TCP/IP session request is received from another Ethernet device.

TCP/IP gateway

This feature allows the station to communicate with devices on other networks. If you specify TCP/IP gateway address, then the TCP/IP gateway routes messages to the other networks.

9 Click Ethernet2 and then click Configure Selected Port.




Step Action

10 Perform the steps from step 4 to step 8.

11 In the Ethernet Port Configuration dialog box, click OK.

The Ethernet ports are configured. Configure serial ports

RC-SCONTRL RTU supports RS232 and RS485 serial ports. The following table provides information about various protocols supported by serial ports and their uses.

Protocol Use

RC500 Serial protocol Used for communication between

• RC500 and I/O module

• Peer-to-peer communication between RTUs

Modbus RTU Master protocol Used for communication between

• RC500 and I/O Modules

• RC500 and third-party Modbus slave devices

The RC500 acts as the Modbus Master.

Modbus ASCII Master protocol Used for communication between

• RC500 and third-party Modbus slave devices

The RC500 acts as the Modbus Master.

Modbus RTU Slave protocol Used for communication between

• RC500 and SCADA

• RC500 and third-party Modbus Masters.

The RC500 acts as the Modbus Slave.

DNP3 Serial protocol Used for communication between RTU and SCADA.

The RC500 acts as DNP3 Slave.

ATTENTION

RS232 A and RS232 B ports are not redundant.



Perform the following steps to configure serial ports in the RTU.

Step Action



2 Click the Ports tab.

3 Under Define Communication Port Properties, click a serial port and then click Configure Selected Port.

The Serial Port Configuration dialog box appears.

4 In Port protocol list, click the required communication protocol.

ATTENTION

RC500, Modbus RTU Master, Modbus ASCII Master, Modbus RTU Slave, Modbus ASCII Slave, and DNP V3.00 Slave are the protocols that are supported currently.

5 Select appropriate values in the Baud rate, Parity, Data bits, and Stop bits list.

6 In the Flow control list, click the required flow control method.

ATTENTION

For RS485 port, the only value available is 2-Wire Party Line.

7 In the Lead time box and in the Lag time box, enter appropriate values.

ATTENTION

The Lead time and Lag time boxes are enabled only if the Half Duplex Modem or the Full Duplex Modem is selected as flow control method.

8 In the Passthru to list, click the required COM port through which the data should be passed.

ATTENTION

The Passthru to list is enabled only for RC500 protocol.

2. RC-SCONTRL RTU configuration 2.4. Redundant RTUs


Step Action

9 If you want to connect a modem to the port, select Set modem check box, and enter the Modem Initialization string in the Set modem box.

Most RC500 RTUs can be configured to send an initialization string to a modem upon power-up. The string typically contains Hayes-compatible modem commands. A common use of this feature is to place the modem in auto-answer mode upon station power-up.

10 Click OK.

2.4 Redundant RTUs Overview

A redundant (secondary) RTU is configured along with the primary RTU as a backup option.

Using Honeywell RC500 I/O Tool Kit, you can automatically create and maintain the configuration of a second RC-SCONTRL RTU to ensure that redundant RTUs, used as a pair, would always have the same configuration loaded into them. When a configuration change is made to one RTU, the same changes are reflected in the secondary RTU as well. By default, configuration loaded into the primary RTU is simultaneously loaded into the secondary RTU.

The operation of redundant RTUs require Ethernet connectivity between the two RTUs, and Ethernet connectivity between the RTUs and the computer in which running Honeywell RC500 I/O Tool Kit.

Redundant RTU switch over conditions In redundant RTUs, there are two RTUs—A primary RTU and a secondary RTU. When the primary RTU fails, the secondary RTU takes over the place of the primary RTU and continues the operation.

Typically, the switch-over between RTUs take place under the following conditions.

• Software failure or program maintenance in RTU

• RTU hardware failure

• Power supply failure

• Ethernet connection failure



The RTUs use built-in redundancy features to identify the failure and to switch-over between the RTUs.

The conditions in which the redundancy are supported or not supported are provided in the following list.

Supported:

• Serial port redundancy is supported. Redundant RTUs communicates to third-party serial devices through Modbus. Here, the RTU acts as Modbus master. If there is RTU to third-party communication over serial, and if switch over happens, then the redundancy is achieved.

• RTU-SCADA redundancy over TCP/IP for single LAN (Ethernet) is supported. RTU redundancy to SCADA is achieved through Modbus and DNP3 protocols over TCP/IP. Here, RC500 acts as slave.

• I/O Module communication redundancy is achieved through ring configuration using the ring switches.

Not Supported:

• RTU-SCADA redundancy over serial is not supported. RTU redundancy to SCADA is not achieved through Modbus and DNP3 over serial, and over terminal server configurations. If the RTU communicates to SCADA over serial, and if there is a switch over, then the redundancy is not achieved.

• I/O Module redundancy is not supported.

Station Status Module variables

Each RTU has a set of key variables called Station Status Module variables. These variables are monitored by the redundancy code to ensure that the RTU’s determine which RTU is in control and whether the logic code is running. There are two types of variables—Self and Other. The RTU uses the Self as its own variables and the Other as the other RTU’s variables. The built-in redundancy configuration automatically sets a write transfer of the Self-bits to the other station’s Other-bits.



The following table provides more information about the Station Status Module variables.

Variable Description

Self_Heartbeat This bit is the Discrete Output variable that is toggled continuously by the ISaGRAF program. This variable is used by the built-in redundancy code to determine whether the station should be in Active mode or Back-up mode.

Self_Active This bit is the status-bit generated by the built-in redundancy feature. When the bit is ON, the RTU is in Active mode. The built-in redundancy sets this bit when all the active criteria are met.

Self_Backup This bit is the status-bit generated by the built-in redundancy feature. When this bit is ON, the station is in Back-up mode.

Other_Heartbeat This bit is the toggling heartbeat Discrete Output of the other station, which is generated by the ISaGRAF program of the other station.

Other_Active This bit is the Self_Active bit from the other station. This is used by the built-in redundancy feature to determine whether the RTU should be in Active mode or in Back-up mode.

Other_Status This bit is the Self_Back-up bit of the other station. It is used by the built-in redundancy feature to determine whether the station should be in Active mode or in Back-up mode.

Self_Status This bit is used to determine whether the station is in Active mode or Back-up mode.

The ON message indicates Active mode and the OFF message indicates Back-up mode.



Configure a redundant RTU When you need high-availability system, redundant RTUs can be configured.

Perform the following steps to configure the RTU with redundancy option.

Step Action

1 Choose Start > Programs > Honeywell Tools > Honeywell Tool Kit.


2 Choose File > New Project.

The Wizard Selection dialog box appears.

3 Click Add a new station to the project option and click OK.

The Select New Station Type dialog box appears.

ATTENTION

If you want to add a station to an existing project, right-click All Stations and choose New Station under By Type tab in the tree views.

4 In the list, click RC500 RTU and click OK.

The Save As dialog box appears.

5 Enter a project name and click Save.

The RC500 RTU Station Configuration page appears.

6 Under Define General Properties, enter details in the Station Name box, the Station number box, and the Serial number box.

7 In the Station Type list, select RC-SCONTRL.

8 Select Automatically configure a secondary controller check box.

The secondary station name is displayed.

9 Select Enable built-in redundancy check box.



Step Action

ATTENTION

If you want to enable the secondary RTU to an existing station, perform the following steps.

1. Right-click the station and choose Configure. The RC500 RTU Station Configuration dialog box appears.

2. In the General tab, select the Automatically configure a secondary controller check box and the Enable built-in redundancy check box.

10 Click Next.

The Ports page appears.

11 Perform the following steps to configure Ethernet ports.

a) Under Define Communication Port Properties, click Ethernet1 and then click Configure Selected Port.


b) Under IP address, click any one of the options given.

− Automatically assign IP address based on station number Select this option to automatically assign IP address based on station number. In this case, if the station number is changed, the IP address also changes automatically.

− Use DHCP Select this option to allow DHCP server to assign the IP addresses to the stations.

− Manually assign IP address Select this option to assign IP address manually.

c) Click OK.

d) Click Ethernet2 and then click Configure Selected Port.


e) Under IP address, click any one of the options given.

f) Click Advanced.


g) In the Advanced Ethernet tab, in Port list, click Ethernet2 and click OK.



Step Action

h) In the Ethernet Port Configuration dialog box, click OK.

ATTENTION

Subnet Mask

Assign an IP subnet mask for the RTU, if the RTU communicates through a TCP/IP gateway device (typically the computer) to a device on another network.

TCP/IP Timeout

This setting determines the period of time that a TCP/IP session can be inactive before it can be terminated by the station. An inactive TCP/IP session is terminated only if the station’s maximum allowable number of TCP/IP sessions is in use and a new TCP/IP session request has been received from another Ethernet device.

12 Click Next.

The I/O Modules page appears.

13 Click Next.

The Advanced page appears.

14 Click Next.

The I/O Transfers page appears.

15 Click Next.

The Redundant Controller Options page appears.

16 In the Serial number box, enter the serial number of the secondary RTU.

17 Under Station number options,

• If you want to use the same station number for the secondary RTU and the primary RTU, click Use the primary controller station number.

Or

• If you want to use different station numbers for secondary RTU station and primary RTU station, click Use a unique station number and enter a station number in the box.



Step Action

ATTENTION

• If the communication between SCADA and RTU is through Modbus, then use the same station number for the primary RTU and the secondary RTU.

• If the communication between SCADA and RTU is through DNP3, then you can either use same station number for both primary RTU and the secondary RTU or you can use unique station number for both RTUs.

18 In the IP Address box and in the 2nd IP Address box, enter the IP addresses for the secondary RTU.

ATTENTION

Ensure that both the IP addresses are in different subnet mask.

19 Under Built-in redundancy options, click the General tab.

20 Select Enable built-in redundancy and select Enable common IP.

The Common IP box and the Subnet mask box are available for editing.

ATTENTION

The Enable common IP option is enabled only if the Enable built-in redundancy check box is selected.

21 Enter an IP address in the Common IP box.

ATTENTION

Common IP address should be a unique IP address in LAN2. The Experion server uses this IP address to communicate with the RTU. The common IP address is bound to the RTU that is currently acting as primary.

For example, if the IP Address under Secondary controller options is 10.1.0.7, then the Common IP should be 10.1.0.x, where ‘x’ is a unique number in the network.

22 Click Heartbeat tab and enter time in seconds in Allowable loss period box. The default value is 5 seconds.



Step Action

ATTENTION

• If the primary RTU fails, then the secondary RTU waits for the allowable loss period and changes the status to primary.

• The default synchronization period is 50 ms. You can change the synchronization period by performing the following steps.

a) Click I/O Transfers tab.

b) Click _StaStatWire_ transfer and click Edit Selected Transfer. The I/O Transfer Configuration page appears.

c) Click Action Definition tab.

d) Under Scan time/ trigger,

− In the Scan option list, click Use the Specified Interval Time.

− In the Scan interval time list, click the period of your choice. This interval is the synchronization period.

e) To add an alert about the synchronization failure, in the Scan enable flag list, click Self_Active.

23 Click Virtual I/O Synch.

24 Enter the number of registers required in Num Regs and the starting register number in Start Addr for different I/O types.

These are used to create the range for all output types and to synchronize outputs between the two RTUs.

ATTENTION

• Do not change the Redundancy bits (Digital Output) starting address. The default starting address is zero.

• Do not synchronize the first seven Digital Output registers as they are used by the RTUs for redundancy operations.



Step Action

25 Click Finish.

ATTENTION

To enable redundancy, you have to create an ISaGRAF program and load it in the RTU. To know more about creating and loading ISaGRAF program, refer to Creating and loading ISaGRAF program for redundancy.

Create and load ISaGRAF program for redundancy

Perform the following steps to create and load the ISaGRAF program to RTU.

Step Action

1 Open the ISaGRAF tool.

2 Create a new ISaGRAF project.

3 Add a new program and add a functional block diagram to the program.

4 In the Honeywell RC500 I/O Tool Kit, choose File > Export > I/O Definitions to > ISaGRAF.

The ISaGRAF Export dialog box appears.

5 In the ISaGRAF version list, click the ISaGRAF version that is used and click Next.

The ISaGRAF version Export dialog box appears.

6 In the ISaGRAF project box, browse to the ISaGRAF project folder and select the project.

7 Click Next.

The ISaGRAF Export Tag Selection dialog appears.

8 Under Tags to export, click Tags from one station only and click the particular station in the list.

9 Click Next.

The ISaGRAF Export Summary dialog appears.

10 Click Finish.

The ISaGRAF Export Progress dialog box appears.



Step Action

11 Once the tags are exported, click Close.

12 Open the ISaGRAF tool and open the functional block diagram.

13 Create a functional block diagram for redundancy similar to the diagram shown below.

14 In the Honeywell RC500 I/O Tool Kit, load the ISaGRAF program to the RTU.

REFERENCE INTERNAL

For more information about loading an ISaGRAF program to the RTU, refer to Loading an ISaGRAF program to RTU.

Configure synchronization

While adding secondary RTU, it is essential to synchronize the output of the primary RTU with the secondary RTU.

ATTENTION

• Heart beat messages are exchanged through Ethernet1 port.

• Ethernet1 port of Primary RTU and Secondary RTU should be connected through a switch and should not be connected directly. If connected directly and if the cable between both the Ethernet1 ports fails, then both the RTUs go to backup state, which results in a single point failure.



Perform the following steps to synchronize outputs between the primary RTU and the secondary RTU.

Step Action

1 Right-click the station (primary RTU) and choose Configure.


2 Click I/O Modules tab and click Add Virtual I/O.

The Auto-Create Virtual Modules dialog box appears.

3 In Discrete Output row, click the cell under Starting Register Number and enter the value from which the register number must start.

4 Click the respective cell under Number of Registers and enter the number of registers required.

The maximum value allowed is 1024.

5 In Analog Output row, click the cell under Starting Register Number and enter the value from which the register number must start.

6 Click the respective cell under Number of Registers and enter the number of registers required.

Maximum value allowed is 1024.

ATTENTION

Only outputs can be synchronized.

7 Click Redundant Controller Options tab.

8 Under Built-in redundancy options, click Virtual I/O Synch tab.

9 In Discrete Output row, click the cell under Start Addr and enter the value from which the register number must start.

ATTENTION

Ensure to enter the same value entered for Starting Register Number in Auto-Create Virtual Modules dialog box.

10 In Discrete Output row, click the cell under Num Regs and enter the number of registers required.



Step Action

ATTENTION

Ensure to enter the same value entered for Number of Registers in Auto-Create Virtual Modules dialog box.

11 In Analog Output row, click the cell under Start Addr and enter the value from which the register number must start.

ATTENTION

Ensure to enter the same value entered for Starting Register Number in Auto-Create Virtual Modules dialog box.

12 In Analog Output row, click the cell under Num Regs and enter the number of registers required.

ATTENTION

Ensure to enter the same value entered for Number of Registers in Auto-Create Virtual Modules dialog box.

13 Click OK.



Add an I/O module to a redundant RTU Perform the following steps to add an I/O module to a redundant RTU.

Step Action

1 Right-click the station (primary RTU) and choose Configure.


2 Click Redundant Controller Options tab.

3 Under Built-in redundancy options, click I/O Transfers tab.

4 Click Add Remote I/O.

The Add Redundant Remote I/O Module dialog box appears.

5 In the Select a module type list, click the type of the I/O module that is added.

6 In the Module name box, enter a name for the I/O module.

7 In the Station number box, enter a station number for the I/O module.

8 In the IP Address box, enter the IP address of the I/O module.

9 Select Create a Remote I/O Link module and I/O Transfers check box.

10 Click OK.

2. RC-SCONTRL RTU configuration 2.5. Configuring peer-to-peer RTU communication


2.5 Configuring peer-to-peer RTU communication An I/O transfer is used to copy input or output values from one device to another. The RTU that is performing the transfer is called as the Local Station. I/O data can be transferred to/from an external device (I/O module or RTU) or within the local station itself. These transfers can be normal transfers or conditional transfers. A transfer made within the local station itself is referred to as Internal Block Move.

Configure I/O transfer Perform the following steps to configure I/O transfer.

Step Action


The I/O Module Configuration dialog box appears.

2 Click the I/O Transfers tab.

3 Click Wizard – Add New Transfer.

The Select Remote Station page appears.

4 If the remote station is part of the project file, then

a) Clear the Specify by station number check box.

b) In the Remote station name list, click the station to which you want transfer I/O.

c) Click Next. The Select Transfer Name page appears.

Or

If the remote station is not part of the project file or if it is a product of a different manufacturer (For example – serial device, PLC, and so on), then

a) Select the Specify by station number check box.

b) Enter the remote station number in the Remote station number box.


5 In the Name box, enter a name for the transfer.

The name should not exceed 40 characters.



Step Action

6 Click Next.

The Select Transfer Type page appears.

7 In the Transfer type list, click the type of I/O transfer.

• Select Read RC500 I/O to have this station read I/O in a Block I/O Move or from a remote station configured for RC500 protocol.

• Select Write RC500 I/O to have this station write I/O in a Block I/O Move or to a remote station configured for RC500 protocol.

• Select Read Modbus I/O to have this station read I/O from a remote Modbus device or a module configured for Modbus protocol.

• Select Write Modbus I/O to have this station write I/O to a remote Modbus device or a module configured for Modbus protocol.

ATTENTION

Using I/O transfers, you can either read data from the remote station or write data to the remote station.

8 Click Next.

The Select Port page appears.

9 In the Communications port list, click the port that is used for communication.

ATTENTION

Peer-to-peer communication is possible through the serial ports and the Ethernet ports.

10 Check the Current port settings.

Serial ports

a) Click Advanced.

b) In the Data format list, click either Binary or Hex, depending on the type of data transfer. Select Binary if 8-bit data format is required and select ASCII (Hex) if 7-bit data format is required.

c) In the Messaging sequence list, click either Rapid Fire or Wait for Reply.



Step Action Normally, whenever there is heavy network traffic, 'Wait for Reply' is used. Whenever there is high network bandwidth, 'Rapid fire' is used.

d) In the Message timeout box, enter the time in milliseconds. The default communication timeout is three seconds. This is displayed as a "3000" in the Message timeout box. Enter a longer timeout to compensate for transmission delays or data errors. Enter a shorter timeout to communicate over direct wiring and to perform quicker retries if there is any communication error.

e) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module. Whenever the network traffic is high, the number of message attempts is also high. Whenever the traffic is low, then the number of message attempts is also low.

f) Select Most significant word (MSW) first check box. Select this parameter only if the station communicates with a third-party Modbus slave device that swaps the word order when reading or writing 32-bit long integer values. By default, RC500 products that support Modbus communication do not swap the word order. If this parameter is selected, the master station reverses the order of the two analog registers in each 32-bit long integer value when sending or replying to third-party Modbus commands for long integer I/O. This parameter has no effect on floating point values or when using Daniel Extensions to read or write long integer values.

ATTENTION

If there is any mismatch between the Serial port type selected in the Current port settings, and the protocol type selected in the Ports tab, then a protocol error message appears.

If the error occurs, click Yes and update the port settings in Select Transfer Type page to match the protocol.

Ethernet ports

If the Destination IP address is same as the remote station’s IP address, then

a) Click Advanced.

b) In the Messaging sequence list, click either Rapid Fire or Wait for Reply.

c) In the Message timeout box, enter the time in milliseconds.



Step Action

d) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module.

e) Click Next. The Scan Options page appears.

Or

If the Destination Address is different from the remote station’s IP address, then

a) Select Use this destination IP address check box. The Use this destination IP address box is enabled for editing.

b) Enter the remote station’s IP address.

c) Click Advanced.

d) In the Messaging sequence list, click either Rapid Fire or Wait for Reply.

e) In the Message timeout box, enter the time in milliseconds.

f) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module.

g) Click Next. The Scan Options page appears

11 In the Update interval box, enter the I/O transfer interval of your choice and click Next.

The I/O options page appears.

12 a) In the I/O type list, click the type of the I/O to be transferred.

b) In the Register count box, enter the number of registers to be used.

c) Enter the details required in Local registers and Read from remote registers.

ATTENTION

Local registers - Virtual I/O module address of RTU that requests data.

Remote registers - Virtual I/O module address of RTU that provides data.



Step Action

13 Click Next.

The Complete! page appears.

14 Click Finish.

The summary of the I/O transfer appears and if you click any of the parameter, the corresponding configuration page of the I/O transfer appears.

Configure conditional transfer

While transferring data between RTUs, a certain condition can be set, depending on which the I/O transfers would take place. Generally, this condition would be the status of any particular discrete I/O tag or virtual I/O tag. Depending upon the status of the I/O tag, the I/O transfer is initiated.

Perform the following steps to configure conditional transfer.

Step Action



2 Add a Virtual I/O module.

For more information about how to add a virtual I/O module, refer to Adding Virtual I/O modules section.

3 Click the I/O Transfers tab.







Or

If the remote station is not part of the project file or if it is a product of a



Step Action different manufacturer, then


b) In the Remote station number box, enter the remote station number.




7 Click Next.


8 In the Transfer type list, click the type of I/O transfer.

• Select Read RC500 I/O to have this station read I/O in a Block I/O Move or from a remote station configured for RC500 protocol.

• Select Write RC500 I/O to have this station write I/O in a Block I/O Move or to a remote station configured for RC500 protocol.



ATTENTION


9 Click Next.


10 In the Communications port list, click the port that is used for communication.

ATTENTION

Peer-to-peer communication is possible through the serial ports and the Ethernet ports.

11 Check the Current port settings.



Step Action

Serial ports

a) Click Advanced.

b) In the Data format list, click either Binary or Hex, depending on the type of data transfer.

c) In the Messaging sequence list, click either Rapid Fire or Wait for Reply. Normally, whenever there is heavy network traffic, 'Wait for reply' is used. Whenever there is high network bandwidth, 'Rapid fire' is used.

d) In the Message timeout box, enter the time in milliseconds. The default communication timeout is three seconds. This is displayed as a "3000" in the Message timeout box. Enter a longer timeout to compensate for transmission delays or data errors. Enter a shorter timeout to communicate over direct wiring and to perform quicker retries if there is any communication error.

e) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module. Whenever the network traffic is high, the number of message attempts is also high. Whenever the traffic is low, then the number of message attempts is also low.

f) Select the Most significant word (MSW) first check box. Select this parameter only if the station communicates with a third-party Modbus slave device that swaps the word order when reading or writing 32-bit long integer values. By default, RC500 products that support Modbus communication do not swap the word order. If this parameter is selected, the master station reverses the order of the two analog registers in each 32-bit long integer value when sending or replying to third-party Modbus commands for long integer I/O. This parameter has no effect on floating point values or when using Daniel Extensions to read or write long integer values.

g) Click Next. The Scan Options page appears.

ATTENTION

If there is any mismatch between the Serial port type selected in the Current port settings, and the protocol type selected in the Ports tab, then a protocol error message appears.

If the error occurs, click Yes and update the port settings in Select Transfer Type page to match the protocol.



Step Action

Ethernet ports

If the Destination IP address is same as the remote station’s IP address, then

a) Click Advanced.

b) In the Messaging sequence list, click either Rapid Fire or Wait for Reply.

c) In the Message timeout box, enter the time in milliseconds.

d) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module.

e) Click Next. The Scan Options page appears.

Or

If the Destination Address is different from the remote station’s IP address, then

a) Select Use this destination IP address check box. The Use this destination IP address box is enabled for editing.

b) Enter the remote station’s IP address.

c) Click Advanced.

d) In the Messaging sequence list, click either Rapid Fire or Wait for Reply.

e) In the Message timeout box, enter the time in milliseconds.

f) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module.

g) Click Next. The Scan Options page appears.

12 In the Update interval list, click the I/O transfer interval of your choice.

13 Click Advanced.

• In Scan Enable Flag list, click the discrete tag name that would act as a conditional signal for I/O transfer.

Or



Step Action

• Select the Use a Trigger Name box and enter the trigger name that is assigned for this I/O transfer.

14 Click Next.


15 In the I/O type list, click the type of the I/O to be transferred.

16 In the Register count box, enter the number of registers to be used.

17 Enter the details required in Local registers and Read from remote registers.

18 Click Next.

The Complete! Page appears.

19 Click Finish.

2. RC-SCONTRL RTU configuration 2.6. Assigning I/O module to RTU


2.6 Assigning I/O module to RTU Once I/O modules are physically connected to the RTU, they have to be added and configured in the Honeywell RC500 I/O Tool Kit as well.

Perform the following steps to assign an I/O module to the station.

Step Action

1 Choose Configure > New I/O Module.

The Module Configuration dialog box appears.

2 In the Module type list, click Remote I/O Link.

3 In the Part number list, select an I/O module.

4 In the Module tag name box, enter a name for the module and click OK.

The General page appears.

5 Click Configure Later.

The I/O module is assigned to the RTU.

Add virtual I/O modules Virtual I/O modules are imaginary modules that can be added to the Honeywell RC500 I/O Tool Kit configuration. The registers in a virtual I/O module are separate from the registers associated with the physical I/O modules that are connected to the RTU.

By default, a RTU has many I/O registers of each type. The lowest numbered registers are assigned to the physical I/O connected to the RTU. The remaining registers can be read / written by Windows programs (Test I/O functionality of the Honeywell RC500 I/O Tool Kit) and by application programs running in the RTU itself.

Virtual I/O modules are commonly used for the following purposes.

• To pass setpoints and other data to an ISaGRAF program running in the RTU.

• To hold I/O data transferred from another station through an I/O transfer, by a Modbus I/O transfer (or) RC500 I/O Transfer.

• To monitor I/O module and/or remote station status from within Windows applications.



You can configure up to 1024 registers in each type of virtual I/O module. The following are the types of virtual I/O modules that can be added to the RTU.

• Discrete Inputs

• Discrete Outputs

• Analog Inputs

• Analog Outputs

• Floating Point Inputs

• Floating Point Outputs

• Long Integer Inputs

• Long Integer Outputs

Perform the following steps to add a virtual I/O module.

Step Action



2 Click I/O Modules tab and Click Add Virtual I/O.

The Auto-Create Virtual Modules dialog box appears.

3 Select Auto-create I/O tag names check box.

ATTENTION

The types of Input/Output available are given in a tabular format. By default, the value of the starting register number and the number of registers is set to None. You can change these values as per requirement.



Step Action

4 For a particular I/O type, click the respective cell under Starting Register Number.

5 Enter the value from which the particular I/O type register number must start.

6 For a particular I/O type, click the respective cell under Number of Registers and enter the number of registers required.

Maximum value allowed is 1024.

7 Click OK.

2. RC-SCONTRL RTU configuration 2.7. Configuring I/O modules


I/O tag names and restrictions I/O registers names can be automatically created or customized as per the requirement.

Perform the following steps to customize I/O tag names.

Step Action

1 Choose Operations > Advanced Operations > Tag Restrictions.

The I/O Tag Name Restrictions dialog box appears.

2 Under Restriction Types, click Custom Restrictions.

The choices under Restrictions are enabled.

ATTENTION

To follow IEC 1131-3 tag name standard, under Restriction Types, click IEC 1131-3 Tags.

3 Select the options given under Restrictions as per requirement.

Once you select the options, if any tag name does not follow the restriction, then in the Honeywell RC500 I/o Tool Kit the particular tag name is highlighted in yellow color.

The following list provides the options that are available for selection.

• Spaces Not Allowed in Tag Names

• Begin with an Alpha Character

• Upper/Lower Case are Equivalent

• Limit Tag Names to ____ Characters

• Limit Prefix Names to ____ Characters

• Limit Prefix+Tag Names to ____ Characters

4 Click Options.

The Error Checking Options dialog box appears.

5 Select the options given as per requirement.

These options are used to check the duplicate tag names, IP addresses, station numbers, and so on. Once you select the options, and if any duplicate item is found, then the Status field displays ‘ERROR’ message.

6 Click OK and again click OK.



2.7 Configuring I/O modules Perform the following steps to configure the I/O modules that are added to the station.

Step Action



2 Click I/O Modules tab.

3 Click the I/O module to be configured and click Configure Module.


4 Click Remote I/O Links Options tab.

5 Under Communication port, click a port in the Port list.

Note: The Current port settings vary depending on the port that is selected.

a) In the Data format list, click Binary or Hex, depending on the type of data transfer.

b) In the Messaging sequence list, click either Rapid Fire or Wait for Reply. Normally, whenever there is heavy network traffic, 'Wait for reply' is used and whenever high network bandwidth is used, 'Rapid fire' is used.

c) In the Message timeout box, enter the time in milliseconds. The default communication timeout is three seconds. This is displayed as a "3000" in the Message timeout box. Enter a longer timeout to compensate for transmission delays or data errors. Enter a shorter timeout to communicate over direct wiring and to perform quicker retries if there is any communication error.

d) In the Message attempts, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module. Whenever the traffic is high, then the number of message attempts is also high. Whenever the traffic is low, then the number of message attempts is also low.



Step Action

6 Under Scan time/trigger, perform the following tasks.

In the Scan option list,

a) Click Use a Trigger Name, and enter the name of the trigger in the Trigger name box.

b) Click Use a Default Scan Time and enter the time interval for scan in the Default time (for all actions) box.

c) Click Use the Specified Interval Time and enter the time interval for scan in Scan interval time box.

ATTENTION

To configure an I/O module for a redundant RTU, perform the following:

1. Under I/O scan options, select Use built-in redundancy options check box.

2. In the Read output enable list, click Self_Backup and select Read DO and Read AO check boxes. Selecting the Read DO and Read AO check boxes ensures that the outputs are read by the redundant RTU.

3. In the Write output enable list, click Self_Active and select Write DO and Write AO check boxes. Selecting the Write DO and Write AO check boxes ensures that the outputs are set by the primary RTU. Both the RTUs read the input parameters.

7 Click Discrete Options tab.

8 Under Discrete input options, enter a value in First DI register box.

ATTENTION

The I/O address of the Discrete input starts from the value entered in the First DI register box. For example, if you enter 2 in the First DI register box, the discrete input I/O address starts from X2.

9 Select Retain values on power loss check box.

The RTU retains the current values of the module if power is lost or cycled.

10 Click Discrete Tags tab.

2. RC-SCONTRL RTU configuration 2.8. Configuring DNP3 Slave driver in Honeywell RC500 I/O Tool Kit


Step Action

11 Perform the following steps in the Discrete Tags page.

a) In the I/O Tag Name column, enter the name for the particular I/O register.

b) In the OFF Message column, enter the message to be displayed if the specific register is in OFF state.

c) In the ON Message column, enter the message to be displayed if the specific register is in ON state.

12 Click Analog Options tab.

13 Under Analog input options, enter a value in First AI register box.

ATTENTION

The I/O address of the Analog input starts from the value entered in the First AI register box. For example, if you enter 2 in the First AI register box, the Analog Input I/O Address starts from AX2.

14 Select Retain values on power loss check box.

The RTU retains the current values of the module if power is lost or cycled.

15 Click Analog Tags tab.

16 In the I/O Tag Name column, enter the name for the particular I/O register.

17 Click OK.

ATTENTION

To know about the I/O module that a particular station is configured to, click Address Map in the I/O Modules tab and check the details in the Station I/O Address Map dialog box.



2.8 Configuring DNP3 Slave driver in Honeywell RC500 I/O Tool Kit

Experion uses DNP3 protocol to read/write data from/to RC500 RTUs. The DNP3 protocol allows data exchange between RTU and other controllers/systems, which supports DNP3 standards. RC500 is DNP3 Slave. DNP3 can store up to 50,000 events.

ATTENTION

• For redundant RTU Configuration, DNP3 Configuration must be performed in both the stations.

• Replicate the exact DNP3 configuration of the primary RTU to the secondary RTU as it involves manual configuration.

The DNP3 Slave Driver is an add-on option to the firmware that needs to be purchased separately and registered before it can run continuously.

If the DNP3 is not registered, the DNP3 Slave Driver executes in the demo mode. In this mode, the driver is fully functional, but operates as follows:

• The driver runs continuously for one hour, then the driver stops and does not process any DNP3 request from the master station.

• The DNP3 configuration needs to be reloaded before the driver works for another hour.

Configure DNP3 slave driver Perform the following steps to configure DNP3 Slave driver in Honeywell RC500 I/O Tool Kit.

Step Action

1 Choose Start > All Programs > Honeywell Tools > Honeywell Tool Kit.


2 Click .

The DNP3 Slave Driver Configuration dialog box appears.

3 Under Stations, the list of configured station is displayed. Select the station to be configured for DNP3.

4 Click Configure Selected Station.



Step Action

The Station dialog box appears.

Defining general properties

5 In General tab, under Compatibility Mode, click Level 2+ option button.

It supports binary, analog, and binary-counter DNP points.

ATTENTION

• If you click Level 2 option button, it does not support frozen analog input, frozen analog event, and frozen counter change.

• If you select Enable Unsolicited Responses, then the RTU sends event data to SCADA without any request from SCADA.

6 Under On new event when Event Queue is full,

• Click Discard Newest Event, if you want to remove the new event.

or

• Click Discard Oldest Event, if you want to remove the oldest event.

Defining physical link layer properties

7 In Physical Link Layer tab, under Mode of Operation, click the necessary option.

• If you want to establish serial communication, click Serial option and perform the following under Serial.

a) Select the port from the Serial Port drop-down list. By default, Port A is selected.

b) Select Enable Collision Avoidance to prevent any data collision on the link.

c) Type any value in the Max. Random Delay box. Maximum allowed value is 5000 ms.



Step Action

ATTENTION

SCADA Master monitors the data from many DNP3 Slaves through RS-485 network (multi-drop links). However, RS-485 network supports only simplex (one-way communication at a time) and if unsolicited response is enabled, then multiple RTUs try to transmit data at the same time. In this scenario, RTU supports a collision avoidance algorithm.

or

• If you want to establish Ethernet TCP communication from RTU based controllers, click TCP option button and perform the following under TCP/UDP.

a) Click Client and type the IP address of the host (server).

b) Type the value in TCP/UDP Port box that is used in TCP/UDP communication. or

a) Click Server.

b) Type the value in TCP/UDP Port box that is used in TCP/UDP communication.

or

• If you want to establish Ethernet UDP communication from RTU based controllers, click UDP option and type the value in TCP/UDP Port box.

ATTENTION

TCP server configuration is common.

Defining data link layer properties

8 In the Data Link Layer tab, if Same as IPm Station Number is not selected, then type the DNP address of the selected controller in This Station DNP Address box.

ATTENTION

If Same as IPm Station Number is selected, then the DNP address is same as the station number.



Step Action

9 Type the time delay before sending the response from the slave in Min Response Delay box.

Maximum allowed value is 65535 ms.

10 Select Enable Data Link Confirmations to configure retry and timeout for the data link frames that are not confirmed.

ATTENTION

• Enable Data Link Confirmations is not selected by default.

• Care must be taken to set the Data Link Timeout and Retries as it might load the network.

11 Type the value in Data Link Retries and Retry Timeout boxes.

Maximum allowed value for retries is 255.

Maximum allowed value for retry timeout is 3600000 ms.

12 Select Enable Self Address checkbox.

The DNP3 Slave Driver can be configured to send its own DNP Address when a DNP Master requests for it. When Enable Self Address is selected, if a message is sent with the "Self Address" (65532) in the destination address field, RC500 responds with its unique individual address. This feature simplifies the commissioning, troubleshooting, and maintenance of devices with an unknown address. If this feature is not enabled, the station ignores the messages sent to the "Self Address.”

Defining application layer properties

13 In the Application Layer tab, select Enable Application Layer Confirm to retry the application fragments that are not confirmed.

14 Type the value in Retries and TimeOut boxes.

Maximum allowed value for retries is 127.

Maximum allowed value for timeout is 7200000 ms.



Step Action

Defining DNP objects mapping

In the Object Mapping tab, you can map the RC500 I/O as DNP points. It displays a list with all existing I/O types.

15 Double-click the required I/O type or select the I/O type and click Map I/O.

The Station dialog box appears.

16 In the General tab, clear Auto Detect and then type the register address in the Highest Register Address box.

ATTENTION

• If Auto Detect is selected, the detected last register address shows in the Highest Register Address box automatically and No DNP Points is unavailable.

• If you do not want to map the RC500 I/O points to DNP3 points, select No DNP Points.

In the Object 1-Binary Inputs tab, you can map each of the Binary inputs configured in the station to a respective DNP Point.

Similarly, you can also map the following I/O types that are configured in the station to a respective DNP Point.

• Binary Outputs

• Analog Inputs

• Analog Outputs

• Floating Point Inputs

• Floating Point Outputs

• Long Inputs

• Long Outputs

• Binary Counters

For more information about how to map all I/O types to DNP points, refer to section Mapping I/O types to DNP points.



Step Action

Defining default variation configuration

Under Default Variation tab, you can configure default variation for each type of DNP point. Default variation defines the data format that is used by the RC500 to send data to DNP3 Master, when the Master does not specifically ask for a specific data variation.

17 Default values are selected for each DNP point. If you want to change the value, select the required value from the drop-down list for each DNP point.

18 Click OK.

The DNP3 Slave Driver Configuration dialog box appears.

19 Click Add to Files to Load and close the dialog box.

The DNP3 slave configuration is completed.

ATTENTION

The Delete Selected Configuration option is used for deleting the DNP3 configuration. Hence, the selected station does not act as a DNP3 slave.



Map I/O types to DNP points

Mapping binary inputs to DNP point

Perform the following steps to map the binary inputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Binary Inputs (D IN (X)) or select the I/O type and click Map I/O.

The Define Highest Register Address page appears.


3 Click Object 1 – Binary Inputs tab.

The confirmation message appears displaying DNP points are more than I/O tags.

4 Click OK.

It displays all DNP points that are mapped to binary inputs.

5 Under Class Assignments column, for all DNP points, class is None by default. To generate an event, you need to assign a class to DNP point.

6 To assign classes to all DNP points at a time,

click .

The Binary Input Change dialog box appears.

7 You can assign all DNP points to Class 1, Class 2, Class 3, or None and click Assign All.

ATTENTION

Assigning classes to DNP points varies based on the compatibility mode selection in General tab and I/O type selection in Object Mapping tab.

8 If you want to assign a class to required DNP point, select the DNP point and assign a class from the Object 2 – Binary Change Event drop-down list.

9 Click OK.



Mapping binary outputs to DNP point

Perform the following steps to map the binary outputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Binary Outputs (D OUT (Y)) or select the I/O type and click Map I/O.



3 Click Object 10 – Binary Outputs tab.


4 Click OK.

It displays all DNP points that are mapped to binary outputs.



Mapping analog inputs to DNP point

Perform the following steps to map the binary inputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Analog Inputs (A IN (AX)) or select the I/O type and click Map I/O.



3 Click Object 30 – Analog Inputs tab.


4 Click OK.

It displays all DNP points that are mapped to analog inputs.

5 Select DeadBand drop-down list to enter deadband value to all I/O types at a time.

The Assign Deadbands dialog box appears.

ATTENTION

The events are generated only if you enter the deadband value greater than the DNP point value.

6 Enter the deadband value and then click Assign All.

If you want to enter the deadband value to required I/O type, type the deadband value.



Step Action

7 If the Compatibility Mode is Level 2+, then Object 31 Frozen Analog Input and Object 33 Frozen Change Event columns are also enabled along with Object 32 Analog Change Event.

• If a DNP point generates Frozen (Object 31 Frozen Analog Input) event, then assign DNP points to Class 0 or None.

To assign all DNP points, click and then click Assign All.

• If a DNP point generates Object 32 Analog Change Event or Object 33 Frozen Change Event, then assign DNP points to Class1, Class2, or Class 3.

ATTENTION

A DNP point does not generate Object 33 Frozen Change Event that has a value of None in Object 31 Frozen Analog Input.

8 Click OK.

Mapping analog outputs to DNP point

Perform the following steps to map the analog outputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Analog Outputs (A OUT (AY)) or select the I/O type and click Map I/O.



3 Click Object 40 – Analog Outputs tab.


4 Click OK.

It displays all DNP points that are mapped to analog outputs.



Mapping floating inputs to DNP point

Perform the following steps to map the floating inputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Floating Point Inputs (F IN (FX)) or select the I/O type and click Map I/O.



3 Click Object 30 – Floating Inputs tab.


4 Click OK.

It displays all DNP points that are mapped to floating inputs.



ATTENTION







If a DNP point generates Object 32 Analog Change Event or Object 33 Frozen Change Event, then assign DNP points to Class1, Class2, or Class 3.



Step Action

ATTENTION


8 Click OK.

Mapping floating outputs to DNP point Perform the following steps to map the floating outputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Floating Point Outputs (F OUT (FY)) or select the I/O type and click Map I/O.



3 Click Object 40 – Floating Outputs tab.


4 Click OK.

It displays all DNP points that are mapped to floating outputs.

Mapping long inputs to DNP point

Perform the following steps to map the long inputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Long Inputs (L IN (LX)) or select the I/O type and click Map I/O.





Step Action

ATTENTION

The highest register address must be greater than LX512.

3 Click Object 30 – Long Inputs tab.

It displays all DNP points that are mapped to long inputs.



ATTENTION







• If a DNP point generates Object 32 Analog Change Event or Object 33 Frozen Change Event, then assign DNP points to Class1, Class2, or Class 3.

ATTENTION


7 Click OK.



Mapping long outputs to DNP point

Perform the following steps to map the long outputs to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Long Outputs (L OUT (LY)) or select the I/O type and click Map I/O.



3 Click Object 40 – Long Outputs tab.


4 Click OK.

It displays all DNP points that are mapped to long outputs.

Mapping binary counters to DNP point Perform the following steps to map the binary counters to DNP point.

Step Action

1 In the Station dialog box, under Object Mapping tab, double-click the Binary Counters (COUNTERS (LX)) or select the I/O type and click Map I/O.



3 Click Object 20 – Binary Counters tab.


4 Click OK.

It displays all DNP points that are mapped to binary counters.

5 Under DeadBand column, type the deadband value for the required I/O type.

2. RC-SCONTRL RTU configuration 2.9. Establishing communication between Experion and RTU using DNP3


Step Action

6 If the Compatibility Mode is Level 2+, then Object 23 Frozen Change Event column is also enabled along with Object 21 Frozen Counter and Object 22 Counters Change Event.

• If a DNP point generates Object 21 Frozen Counter event, then assign DNP points to Class 0 or None.


• If a DNP point generates Object 22 Counters Change Event or Object 23 Frozen Change Event, then assign DNP points to Class1, Class2, or Class 3.

ATTENTION

A DNP point does not generate Object 23 Frozen Change Event that has a value of None in Object 21 Frozen Counter.

7 Click OK.



2.9 Establishing communication between Experion and RTU using DNP3

To establish communication between Experion and RTU using DNP3, you need to perform the following tasks.

• Enabling components in Quick Builder

• Adding a DNP3 Protocol channel

• Adding a DNP3 Protocol controller

• Configuring an Experion Analog Point

• Configuring an Experion Status Point

Prerequisite The following prerequisite required to establish the communication between Experion and RTU using DNP3.

• Apply the Experion license, which has DNP3 and DNP3 history backfill feature. The general license contains only the basic DNP3 protocol and does not have History Backfill feature.

Before you establish the communication between Experion and RTU using DNP3, perform the following steps in Experion Server for enabling History Backfill feature.

Step Action

1 Apply the Experion license, which has DNP3 and DNP3 history backfill feature. The general license contains only the basic DNP3 protocol and does not have History Backfill feature.

2 Choose Start > Programs > Accessories > Command Prompt.

The Command Prompt window appears.

3 Type liclist and press ENTER to verify the availability of DNP3 History Backfill feature license.

4 Type fileio.and press ENTER. It prompts you to enter the file number and then record number.

5 Type the File number 8 and press ENTER.

6 Type the Record Number as 1 and press ENTER.



Step Action It prompts you to enter the Word offset.

7 Type the Word offset as 26 and press ENTER. It displays the list of parameters and prompts you to select the parameter that has to be altered.

8 Type 1 to select Integer option and press ENTER. The default integer value is 0.

9 Type the new value as 100 and press ENTER. The systems history initialization percent is set to 100% and then save the setting.

10 Type the Word offset as 470 and press ENTER. It displays the list of parameters.

11 Type 1 and press ENTER to select the Integer option. The default integer value is 0.

12 Type the new value 1 and press ENTER. The value entered should not be greater than the number of days of standard history snapshots that is configured for the system. This value entered is the maximum number of days that can be backfilled into the system.

13 Save the setting and then type the Word offset as 494. It displays the list of options for all parameters.

14 Type 1 and press ENTER to select the Integer option. The default value is 0.

15 Type any value between 1 and 3 and press ENTER. This sets the priority of the alarm due to an overflow in the controller's event buffer or an overload of the history backfill task. A journal, low, high, or urgent priority alarm is raised in the System Alarm Summary page on entering 0, 1, 2, or 3 values respectively.

ATTENTION

The hstbck.exe is available in the Task Manager only after downloading at least one DNP3 channel to Experion Server.



Enable components in Quick Builder To enable DNP3 protocol, Analog Points, and Status Points in Quick Builder, the Quick Builder component manager must be configured.

Perform the following steps to configure the Quick Builder component manager.

Step Action

1 Create a new project in Quick Builder.

The Enable Components dialog box is displayed.

2 Select Experion server from Server list.

3 Click Enable Components tab.

ATTENTION

For an existing project, perform the following steps.

4. Open the project in Quick Builder.

5. Choose Tools > Component Manager. Modify Project dialog box appears.

4 Select DNP3 Protocol from Device.



Step Action

5 Select Analog Point and Status Point from Point components.

6 Click OK.

REFERENCE - EXTERNAL

For more details about Experion Quick Builder tool, refer to Quick Builder Guide in Knowledge Builder.

Add a DNP3 Protocol channel

You need to define a channel for the connection, which the server would use to communicate with DNP3 Protocol controllers.

Perform the following steps to add a DNP3 Protocol channel.

Step Action

1 Click .

The Add Items dialog box appears.

2 Select Channel from Add Items.

3 Select DNP3 Protocol from Type.

4 Enter the property values in the Main tab.



Step Action

5 Click the Port tab, and in the Port Type list, click one of the following:

• LANVendor (if an Ethernet channel is required)

• Serial

• Terminal Server

6 Specify the Redundant Port properties, if any.


For more details about DNP3 Protocol channel Main properties, DNP3 Protocol Port properties, and Redundant port properties, refer to DNP3 Protocol Interface Reference in Experion Knowledge Builder.

Add a DNP3 Protocol controller You need to define a controller to describe each DNP3 Protocol on a channel.

Perform the following steps to add a DNP3 Protocol controller.

Step Action

1 Click .


2 Select Controller from Add Items.

3 Select DNP3 Protocol from Type.

4 Enter the property values in the Main tab.

5 Enter the property values in the DNP3 Protocol tab.


For more details about DNP3 Protocol controller Main properties and DNP3 Protocol controller protocol specific properties, refer to DNP3 Protocol Interface Reference in Experion Knowledge Builder.



Configure Experion Points In DNP3 Protocol controller, you can add two types of points. They are Analog points and Status points. Analog points are used to exchange continuous data and Status points are used to exchange discrete data.

Configure an Experion Analog Point Perform the following steps to configure the Experion Analog Point.

Step Action


2 Add a DNP3 Protocol Channel and one (or more) DNP3 Protocol Controller(s).

REFERENCE – INTERNAL

For more details about adding DNP3 Channel and DNP3 Controller, see Adding a DNP3 Protocol channel and Adding a DNP3 Protocol controller.

3 Right-click the Point icon from the right-pane of the Quick Builder window and select Add Item.

The Add Item(s) dialog box appears.

4 In Add Items list, click Point and in Type list, click Analog Point.

5 Select the Points icon from the left-pane of the Quick Builder window. From the right pane, select the point that you want to configure.

6 In the Main tab, enter the Parent Asset for the point. All Alarms/Events raised by Experion are in this asset.

ATTENTION

Honeywell recommends that the Parent Asset configured here must be the same as the Experion Asset Name.

7 In the Main tab, click next to PV Source Address.

The Address Builder dialog box appears.

8 Select Controller from the Address Type list and appropriate controller name from the Controller list.

9 Enter the Point name in the Location box.



Step Action


For details about defining a DNP3 Protocol address for a point parameter value, refer to DNP3 Protocol Interface Reference in Experion Knowledge Builder.

Configure an Experion Status Point

Perform the following steps to configure an Experion Status Point.

Step Action


2 Add a DNP3 Protocol Channel and one (or more) DNP3 Protocol Controller(s)


For more details about adding DNP3 Channel and DNP3 Controller, see Adding a DNP3 Protocol channel and Adding a DNP3 Protocol controller.



4 In Add Items list, click Point and in Type list, click Status Point.

5 Select the Points icon from the left-pane of the Quick Builder window. From the right pane, select the point that you want to configure.

6 In the Main tab, enter the Parent Asset for the point. All Alarms/Events raised by Experion are in this Asset.

ATTENTION

Honeywell recommends that the Parent Asset configured here must be the same as the EXPERION Asset Name.



2. RC-SCONTRL RTU configuration 2.10. Establishing communication between Experion and RTU using Modbus


Step Action

8 Select Controller from the Address Type list and appropriate Controller name from the Controller list.

9 Enter the Point name in the Location box.


For details about defining a DNP3 Protocol address for a point parameter value, refer to DNP3 Protocol Interface Reference in Experion Knowledge Builder.

2.10 Establishing communication between Experion and RTU using Modbus

To establish communication between Experion and RTU using Modbus, you need to perform the following tasks.

• Enabling components in Quick Builder

• Adding a Modbus Protocol channel

• Adding a Modbus Protocol controller

• Configuring an Experion Analog Point

• Configuring an Experion Status Point

Enable components in Quick Builder To enable Modbus protocol, Analog and Status Points in Quick Builder, the Quick Builder component manager must be configured.

Perform the following steps to configure the Quick Builder component manager.

Step Action


The Enable Components dialog box appears.

2 Select Experion server from Server list.

3 Click Enable Components tab.



Step Action

ATTENTION

For an existing project, perform the following steps.

1. Open the project in Quick Builder.

2. Choose Tools > Component Manager. Modify Project dialog box opens.

4 Select Modbus Protocol from Devices.

5 Select Analog Point and Status Point from Point components.

6 Click OK.


For more details about Experion Quick Builder tool, refer to Quick Builder Guide in Knowledge Builder.



Add a Modbus Protocol channel You need to define a channel for the connection, which the server uses to communicate with Modbus Protocol controllers.

Perform the following steps to add a Modbus Protocol channel.

Step Action

1 Click .


2 Select Channel from Add Items.

3 Select Modbus Protocol from Type.

4 Enter the property values for Main tab.

5 Click the Port tab, and in the Port Type list, click one of the following:

• LANVendor (if an Ethernet channel is required)

• Serial

• Terminal Server

6 Specify the Redundant Port properties, if any.


For more details on Modbus Protocol channel Main properties, Modbus Protocol Port properties, and Redundant port properties, refer to Modbus Protocol Interface Reference in Experion Knowledge Builder.



Add a Modbus Protocol controller You need to define a controller to describe each Modbus Protocol on a channel.

Perform the following steps to add a Modbus Protocol controller.

Step Action

1 Click .


2 Select Controller from Add Items.

3 Select Modbus Protocol from Type.

4 Enter the property values for Main tab.


For more details about Modbus Protocol controller Main properties and Modbus Protocol controller protocol specific properties, refer to Modbus Protocol Interface Reference in Experion Knowledge Builder.

Configure Experion Points

In the Modbus Protocol controller, you can add two types of points. They are Analog points and Status points. Analog points are used to exchange continuous data and Status points are used to exchange discrete data.

Configure an Experion Analog Point

Perform the following steps to configure the Experion Analog Point.

Step Action


2 Add a Modbus Protocol Channel and one (or more) Modbus Protocol Controller(s).


For more details about adding Modbus Channel and Modbus Controller, see Adding a Modbus Protocol channel and Adding a Modbus Protocol controller.



Step Action

3 Right-click the Point icon on the right-pane of the Quick Builder window and select Add Item.


4 In Add Items list, click Point and in Type list, click Analog Point.

5 Select the Points icon on the left-pane of the Quick Builder window. On the right-pane, select the point that you want to configure.


ATTENTION




8 Select Controller from the Address Type list and appropriate Controller name from the Controller.

9 Enter the name in the Point Location box.


For details about defining a Modbus address for a point parameter value, refer to Modbus Interface Reference in Experion Knowledge Builder.

2. RC-SCONTRL RTU configuration 2.11. Configuring RTU as Modbus Master


Configure an Experion Status Point Perform the following steps to configure an Experion Status Point.

Step Action


2 Add a Modbus Protocol Channel and one (or more) Modbus Protocol Controller (s).


For more details on adding Modbus Channel and Modbus Controller, see Adding a Modbus Protocol channel and Adding a Modbus Protocol controller.



4 In Add Items list, click Point and in Type list, click Status Point.

5 Select the Points icon on the left-pane of the Quick Builder window. On the right-pane, select the point that you want to configure.


ATTENTION




8 Select Controller from the Address Type list and appropriate Controller name from the Controller list.

9 Enter the name in the Point Location box.


For details about defining a Modbus address for a point parameter value, refer to Modbus Interface Reference in Experion Knowledge Builder.



2.11 Configuring RTU as Modbus Master Perform the following steps to configure RTU as a Modbus master.

Step Action



2 Click Ports tab.

3 Select the serial port used for communication and click Configure Selected Port.


ATTENTION

The RTU as Modbus Master over Ethernet is supported by default.

4 In the Port protocol list, click either Modbus ASCII Master or Modbus RTU Master.

5 Click appropriate values in Baud rate, Parity, Data bits, Stop bits, and Flow control list.

6 Select First register low in 32 bit integer types (Modbus) check box if the RTU communicates with Modbus master or slave device that swaps the word order when reading or writing 32-bit long integer values.

7 Select First register low in 32 bit float types (Modbus) check box if the RTU communicates with Modbus master or slave device that swaps the word order when reading or writing 32-bit floating point values.

8 Click OK.

9 Click I/O Transfers tab.






c) Click Next.



Step Action

The Select Transfer Name page appears.

Or

If the remote station is not part of the project file or if it is a product of a different manufacturer (For example – serial device, PLC, and so on), then


b) Enter the remote station number in the Remote station number box.

c) Click Next.

The Select Transfer Name page appears.



13 Click Next.


14 In the Transfer type list, click any one of the following type of I/O transfer.



ATTENTION


15 Click Next.


16 In the Communications port list, click the serial port that was configured to use Modbus Master.

17 Click Advanced.

a) In the Message timeout box, enter the time in milliseconds. The default communication timeout is three seconds. This is displayed as a "3000" in the Message timeout box. Enter a longer timeout to

2. RC-SCONTRL RTU configuration 2.12. Configuring RTU as Modbus Slave


Step Action compensate for transmission delays or data errors. Enter a shorter timeout if you are communicating over direct wiring and require quicker retries if there is any communication error.

b) In the Message attempts box, enter the number of times the station would send messages to remote station or I/O module before moving to the next station or I/O module. Whenever the network traffic is high, the number of message attempts is also high. Whenever the network traffic is low, the number of message attempts is also low.

18 Click Next.

The Scan Options page appears.

19 In the Update interval box, enter the I/O transfer interval of your choice.

ATTENTION

To enable secondary RTU to act as Modbus Master, perform the following steps.

1. In the Scan Options page, click Advanced.

2. In the Scan enable flag list, click Self_Active.

20 Click Next.


21 In the I/O type list, click the type of the I/O to be transferred.

22 In the Register count box, enter the number of registers to be used.

23 Enter the details required in Local registers and Read from remote registers.

24 Click Next.

The Complete! Page appears.

25 Click Finish.

The summary of the I/O transfer appears and if you click on any of the parameter, the corresponding configuration page of the I/O transfer appears.

2. RC-SCONTRL RTU configuration 2.12. Configuring RTU as Modbus Slave


2.12 Configuring RTU as Modbus Slave Perform the following steps to configure the RTU as Modbus Slave.

Step Action



2 Click Ports tab.

3 Select the serial port used for communication and click Configure Selected Port.


ATTENTION

RTU as Modbus Slave over Ethernet is supported by default.

4 In the Port protocol list, click either Modbus ASCII Slave or Modbus RTU Slave.

5 Click appropriate values in Baud rate, Parity, Data bits, Stop bits, and Flow control list.

6 Select First register low in 32 bit integer types (Modbus) if the RTU communicates with Modbus master or slave device that swaps the word order when reading or writing 32-bit long integer values.

7 Select First register low in 32 bit float types (Modbus) if the RTU communicates with Modbus master or slave device that swaps the word order when reading or writing 32-bit floating point values.

8 Click OK.

9 Click Advanced tab in RC500 RTU Station Configuration dialog box.

10 Check the Modbus Starting Addresses. The addressing range for Modbus in RC500 RTU is given below.

I/O Type Address range

Long IN (Register pair) 3:5001 to 3:6999

Long OUT (Register pair) 4:5001 to 4:6999

Float IN (Register pair) 3:7001 to 3:16999

2. RC-SCONTRL RTU configuration 2.13. Configuring datalogging


Step Action

Float OUT (Register pair) 4:7001 to 4:16999


For more details about Modbus addressing, refer to Modbus Interface Reference in Experion Knowledge Builder.

11 Click OK.

The RTU is configured as Modbus slave.

2.13 Configuring datalogging I/O values can be stored in RTUs for later reference. However, as the memory of the RTUs is limited, data cannot be stored for a very long time. In such situation, the data can be transferred to a computer and stored in .csv files.

The RTUs are capable of logging data, time stamping it, and storing it in data files. The station’s datalog files should be transferred to a central computer where they can be archived and viewed.

There are two methods for accomplishing this data transfer:

Host Transfer - The central computer can poll the RTU for the logged data. In this scenario, each RTU is a slave, responding to external requests for the logged data.

Client Initiated Data Transfer- Some RTUs can act as masters or clients, sending their logged data to the computer automatically. A driver such as the RC500 Datalog Server runs on the computer, which accepts data, and creates data files on the computer’s hard drive.

The Datalog Server can accept data from multiple serial ports, Ethernet UDP port (number 1658, by default), and Ethernet TCP port simultaneously and is suitable even for large systems with many stations.

Configure Host transfer In this method, the data logged in the RTU is transferred to the computer when the transfer is initiated from the computer. You can use Honeywell RC500 I/O Tool Kit to initiate the transfer.



Datalogging is used to record I/O values and log them into data files in the RTU. These data files are later retrieved and displayed by the Windows system.

Perform the following steps to perform Host transfer.

Step Action

1 In the Tree Views, click RC500 DataLog tab.

2 Click the station to which you want to configure datalogging.

3 Choose Configure > Datalogging > New Datalog Configuration.

The Datalog Configuration page appears.

4 In the Datalog configuration name box, enter a name for the datalog.

ATTENTION

Use only lowercase letters and numbers for naming datalog.

5 In the Timestamp format, click the relevant time format and click Next.

The Capture Parameters page appears.

6 Enter the following details:

a) In the Number of records box, enter the number of the datalogs to be recorded.

b) Under Record capture control, select the Define fixed log rate check box.

c) In the Timed log rate box, enter the interval at which the data should be recorded.

7 In the Action when full group box, select the appropriate action to be taken when the datalogging buffer (memory) becomes full.

• If you want the oldest data to be overwritten by the new data, then click Cyclic buffer.

Or

• If you want the datalogging to be stopped until the previous records are retrieved and the buffer is cleared, then click Save until cleared.

8 Click Next.

The Record Content page appears.

9 Under Select I/O points to be logged, click the I/O point row, and click Add.



Step Action

ATTENTION

You can also select multiple I/O points at one time and then click Add. Ensure that the I/O points have tag names.

10 In the Additional variables list, click the variables that you want to be logged in the record and click Add.

The following list explains the options available in the list.

• Time - Standard time in the format you chose from the Timestamp Format field of the General view.

• Elapsed_mS - Number of milliseconds elapsed since the last power up of the station.

• Modulo_mS - To obtain timestamp precision better than one second, add a Modulo_mS entry. The Time and Modulo_mS values in each data record may be added together in a spreadsheet or other application to provide timestamp resolution to one millisecond.

11 Click Next.

The Host Transfers page appears.

12 Click Create New Transfer.

The Choose Host Transfer Name appears.

13 Enter the following details:

a) Enter a name for the transfer in the box and click OK.

b) Click that is next to the PC file name box.

The Select Data File dialog box appears.

c) In File name box, enter a name for the .csv file and click Open. If the file does not exist, a message would appear whether to create a new file. Click Yes.



Step Action

14 Under Transfer action, click one of the following actions to be taken while transferring the data.

Append – To add new data to the specified file.

Append and erase data older than ___ Hours – To add new data and remove old data from the specified file.

Erase and store new – To remove the old data completely and add new data.

Sequential filename – To create files in a sequential order for each transfer.

ATTENTION

• If you select Append and erase data older than ___ Hours, ensure that you enter a value in hours in the box.

• If you select Sequential file name, ensure that you enter a number in the Next number box.

15 Click Next.

The Client Transfer page appears.

16 Click Finish. Execute Host transfer

Once the host transfer is configured, you have to execute the transfer from the Honeywell RC500 I/O Tool Kit.

Perform the following steps to initiate the data transfer from the RTU to the computer.

Step Action

1 In the Tree views, click RC500 DataLog tab.

2 Click the station in which host transfer is configured, and browse to the particular host transfer.

3 Right-click the host transfer and choose Execute this Host Transfer.

The Host Transfer Command Options dialog box appears.

4 Click OK.

The data is transferred and saved in the .csv file provided in the Host Transfer configuration.



Configure Client transfer

Datalogging is used to record I/O values and log them into data files in the RTU. These data files are later retrieved and displayed by the Windows system.

Perform the following steps to configure client transfer datalogging.

Step Action

1 In the Tree Views, click RC500 DataLog tab.

2 Click the station in which you want to configure datalog.

3 Choose Configure > Datalogging > New Datalog Configuration.

The Datalog Configuration page appears.

4 In the Datalog configuration name box, enter a name for the datalog.

ATTENTION

Use only lowercase letters and numbers for naming the datalog.

5 In the Timestamp format, click the relevant time format and click Next.

The Capture Parameters page appears.

6 Enter the following details.

a) In the Number of records box, enter the number of the datalogs to be recorded.

b) Under Record capture control, select the Define fixed log rate check box.

c) In the Timed log rate box, enter the interval at which the data should be recorded

7 In the Action when full group box, select the appropriate action to be taken when the datalogging buffer (memory) becomes full.

If you want the oldest data to be overwritten by the new data, then click Cyclic buffer.

Or

If you want the datalogging to be stopped until the previous records are retrieved and buffer is cleared, then click Save until cleared.

8 Click Next.



Step Action

The Record Content page appears.

9 Under Select I/O points to be logged, click the I/O point row, and click Add.

ATTENTION

You can also select multiple I/O points at one time and then click Add. Ensure that the I/O points have tag names.

10 In the Additional variables list, click the variables that you want to be logged in the record and click Add.

The following list explains the options available in the list.

• Time - Standard time in the format you chose from the Timestamp Format field of the General view.

• Elapsed_mS - Number of milliseconds elapsed since the last power up of the station.

• Modulo_mS - To obtain timestamp precision better than one second, add a Modulo_mS entry. The Time and Modulo_mS values in each data record may be added together in a spreadsheet or other application to provide timestamp resolution to one millisecond.

11 Click Next.

The Host Transfers page appears.

12 Click Next.

The Client Transfer page appears.

13 By default, ClientXfer1 is displayed in Select Client Transfer list.

To create a new transfer, click Create New.

The Client Transfer Name dialog box appears.

14 In the box, enter a name for that particular client transfer and click OK.



Step Action

15 Under What to Send, perform one of the following actions.

• If you want all the records since previous transfer to be transferred, then click All records since last transfer.

• If you want the recent particular number of records to be transferred, click Most recent ____ records and enter the number of records in the box.

• If you want all the new records logged in the past specific number of minutes, click All records for the past _____ minutes and enter the number of minutes in the box.

16 Under When to Send, perform the following actions based on requirement.

• To transfer data in fixed intervals, select Define fixed transfer rate and enter the time interval in seconds.

• To transfer data based on data transfer from a particular discrete I/O, select Start/Stop control, and click a discrete tag in the list.

• To indicate that the transfer is complete, select Set transfer complete tag and click a discrete tag from the list.

17 Enter the following details under Communications.

a) In the Port list, select the communication port to be used for transfer.

b) If IP (Ethernet and PPP) is selected as port, then in the Protocol list select the protocol to be used.

c) In the Retry count box, enter the number of times to retry incase of transfer failure.

d) In the Timeout box, enter a timeout period for data transmission.

e) In the Station Identifier list, click Use Station Number if only one client transfer is configured in the station.

f) Click Use a Specific Value, if multiple client transfers are configured in the station, and assign a unique value for each client transfer configuration.

g) If IP (Ethernet and PPP) is selected as port, then enter the Datalog Server’s IP address in the Destination IP box, and the port number in the IP port box.

18 Click Finish.



Configure Datalog Server for specific stations Datalog server accepts client initiated datalog messages and stores the data in universal ASCII (.csv) data files. These data files can be organized in a daily, weekly, or monthly format.

Perform the following steps to configure datalog server for specific stations.

Step Action

1 Choose Configure > Datalogging > Configure Datalog Server.

The Configure Datalog Server dialog box appears.

2 In the General tab, under Client connection mode, click Only allow specified stations to log data.

3 Click Client Transfers tab and click Add From File.

The Select Project File dialog box appears.

4 Click the project file in which the client transfer is configured and click Open.

The Add From File dialog box appears.

5 In the Station name list, click the station name from which data would be logged.

6 In the Datalog Configuration list, click the datalog configuration name.

7 In the Client Transfer Name list, click the required client transfer configuration.

8 Click Edit.

The Record Storage Options dialog box appears.

9 Click Browse.

The Store Records in dialog box appears.

10 Click the required file and click Open.

ATTENTION

To create a new file, enter the file name in File name box and click Open.

11 Click OK in Record Storage Options dialog box, and again click OK in Add From File dialog box.

12 Click UDP/TCP Ports tab.



Step Action

13 Click Add.

The UDP/TCP Port Configuration dialog box appears.

14 In the Type list, click either TCP or UDP, depending on the port type configured in the client transfer.

15 In the Port number box, enter the port number that is configured in the client transfer and click OK.

16 Click COM Ports tab.

17 If you have configured any COM port in the client transfer,

a) Click Add. The COM Port Configuration dialog box appears.

b) In the Port number box, type or select the port number that is configured in the client transfer.

c) Click OK.

Or

• Click OK

18 In the Configure Datalog Server dialog box, click OK.

Configure Datalog Server for any station Perform the following steps to configure datalog server for any station.

Step Action

1 Choose Configure > Datalogging > Configure Datalog Server.

The Configure Datalog Server dialog box appears.

2 In the General tab, under Client connection mode, click Allow new clients to automatically connect/log data.

3 In Create new files list, click any one of the methods to create the data file.

4 Under Data file location, in Directory box, click and browse to the folder in which you want to save the data file.



Step Action

5 In the Data file base name list, click any one of the naming method to name the data file.

• Station Name

• Station Number

• Datalog Cfg Name

• Station Name_Datalog Cfg Name

• Datalog Cfg Name_Station Number

• Datalog Cfg Name_Station ID

Depending upon the naming method that you select, the file name also changes. A sample of the file name is displayed accordingly below the Data file base name list.

6 Click UDP/TCP Ports tab and click Add.

The UDP/TCP Port Configuration dialog box appears.

7 In the Type list, click either TCP or UDP, depending on the port type configured in the client transfer.

8 In the Port number box, enter the port number that is configured in the client transfer and click OK.

9 Click COM Ports tab.

10 If you have configured any COM port in the client transfer,

a) Click Add. The COM Port Configuration dialog box appears.

b) In the Port number box, type or select the port number that is configured in the client transfer.

c) Click OK.

Or

• Click OK

11 In the Configure Datalog Server dialog box, click OK.



Copy datalog configuration You can copy the existing datalog configuration of a station to other stations as well.

Perform the following steps to copy the datalog configuration from one RTU to another RTU.

Step Action

1 In Tree Views, click RC500 DataLog tab.

2 Choose Configure > Datalogging > Copy RC500 Datalog Configuration.

The Copy Datalog Configurations dialog box appears.

3 In Select the datalog configuration to be copied list, click the datalog that you want to copy.

4 In the Destination project file box, click .

The Destination Project dialog box appears.

5 Select the project that you want to copy the datalog configuration to, and click Open.

6 In Destination station list, click the station to which you want to copy the datalog configuration.

7 In the New datalog configuration name box, enter a name for the datalog configuration. This name would be the name of the datalog configuration in the destination station.

ATTENTION

To overwrite the datalog configuration of any existing datalog in the destination station, select Overwrite configuration check box and click the datalog to be overwritten in the list.

8 Click Copy Now.

The datalog configuration is copied to the destination station.

2. RC-SCONTRL RTU configuration 2.14. Configuring alarms in RTU


2.14 Configuring alarms in RTU When the I/Os are not within the defined value, an alarm is generated. Depending on whether the monitored I/O is analog type or discrete type, the type of alarm also varies.

Add discrete alarms Perform the following steps to add a discrete alarm.

Step Action



2 In the General tab, click Configure Alarms.

The Alarms dialog box appears.

3 Click Add Alarm.

The General dialog box appears.

4 Enter the following details.

a) Enter a name for the alarm in the Name box.

b) Click any one of the following type of the Alarm in the Type list.

• Discrete set - monitors a discrete (DI or DO) for a TRUE or ‘1’ state.

• Discrete clear – monitors a discrete for a FALSE or ‘0’ state.

c) In the Delay box, enter the number of seconds after which the alarm should be executed.

5 Click Next.

The Recipient dialog box appears.

6 Enter a name in the Recipient name list, or click a name of the recipient in the Recipient name list.



Step Action

7 Click a channel in Channel list.

A channel identifies the type of action to be taken upon an alarm.

• sxtrig channels activate a trigger.

• sxio channels turn on a discrete I/O point.

8 Click a destination in the Destination list.

9 Click Finish.

Add analog alarms Perform the following steps to add analog alarms.

Step Action





3 Click Add Alarm.


4 Enter a name for the alarm in the Name box.

5 Click any one of the following type of the Alarm in the Type list.

• Analog low limit – monitors an analog (any non-discrete) for a value below the ‘Limit’.

• Analog high limit – monitors an analog for a value above the ‘Limit’.

6 In the Tag/Register Address list, click the I/O tag.

This field indicates which I/O point to monitor. I/O is listed in the list for virtual or physical points defined in the station’s configuration.

7 In the Delay box, enter the number of seconds after which the alarm should be executed.



Step Action

8 Click Next.

The Analog Settings dialog box appears.

9 Enter values in the Alarm limit box and Deadband box.

Alarm limit: For ‘Analog high limit’ types, this is the value that the monitored point must be equal or more before an alarm is initiated. For ‘Analog low limit’ types, the monitored I/O must be equal to or lesser than this value before an alarm is initiated.

Deadband: Deadband value indicates the value that the monitored I/O point can fluctuate before it is considered to be in the ‘cleared’ state. For ‘Analog high limit’ types, the monitored point can decrease by this value below the ‘Limit’ before the alarm state changes. For ‘Analog low limit’ types, the monitored point can increase by this value above the ‘Limit’ before the alarm state changes.

10 Click Next.


11 Enter a name in the Recipient name list, or click a name of the recipient in the Recipient name list.

12 In the Channel list, click a channel.

A channel identifies the type of action to be taken upon an alarm.

• sxtrig channels activate a trigger.

• sxio channels turn on a discrete I/O point.

13 In the Destination list, click a destination.

14 Click Finish.



Add periodic alarms Perform the following steps to add a periodic alarm.

Step Action





3 Click Add Alarm.


4 In the Name box, enter a name for the alarm.

5 In the Type list, click Periodic.

6 In the Delay box, enter the number of seconds after which the alarm should be executed

7 Click Next.


8 In the Recipient name list, enter a name, or click a name of the recipient.

9 Under Recipient Properties, in the Channel list click sxtrig.

ATTENTION

Periodic alarms cannot use sxio as channel type.

10 In the Destination list, enter a trigger name.

11 Click Finish.



Add a recipient Perform the following steps to add a recipient.

Step Action





3 Click Add Recipient.

The Alarm Recipient dialog box appears.

4 In the Recipient name box, enter a name.

5 In Channel list, click a channel.

6 In the Destination list, click a destination.

7 Click OK.




3. Load RC-SCONTRL RTU configuration

3.1 Overview Honeywell RC500 I/O Tool Kit is used to configure the stations for RTUs and I/O modules. This configuration needs to be downloaded to the RTU’s memory. To download this configuration to the RTU, the Load option is used.

Depending upon the requirement, various types of configuration can be loaded to the RTU.

3.2 Startup operations Start an RTU

Perform the following steps to start an RTU.

Step Action

1 Connect the power cables to the RTU.

ATTENTION

Check the power rating of the RTU before connecting the power supply to it. As the RTU supports power supply redundancy, ensure that the +ve terminal, the -ve terminal, and the ground terminal of both the power supplies are wired to the RTU.

2 Supply power to the RTU and check the P1 and P2 status LEDs in the RTU. If the LEDs are ON, then the power supplies to the RTU are functioning normally.

3 Check the Status LED in the RTU. If it glows steadily, then the RTU is functioning properly.

ATTENTION

If the LEDs are blinking or not glowing continuously, then refer to section Maintenance and troubleshooting.

3. Load RC-SCONTRL RTU configuration 3.2. Startup operations


Establish communication between Honeywell RC500 I/O Tool Kit and RTU Once the RTU is started, you need to establish communication between the computer on which the Honeywell RC500 I/O Tool Kit runs and the RTU.

Perform the following steps to establish communication between the Honeywell RC500 I/O Tool Kit and the RTU.

Step Action

1 Choose Device > Select.

The Select Communication Device dialog box appears.

2 If you are using Ethernet port to establish communication, click Use Ethernet.

The options related to Ethernet port are enabled.

Under Use Ethernet,

a) To use the IP address assigned to the station/module for communication, click Use Station’s IP Address.

b) To use an alternate IP address to communicate with the station/module, click Specify an IP Address, and enter the IP address.

c) In the Timeout box, enter the timeout value in milliseconds. The default timeout of 3 seconds (3000 milliseconds).

d) Under Connection, click Single station.

3 If you are using Serial port to establish communication, click Use com port and perform the following steps.

a) In the Com port list, select the port used for communication.

b) Select appropriate values in Parity, Data bits, Stop bits, and Flow control list.

c) In the Timeout box, enter the timeout interval in seconds. The default value is 3 seconds (3000 milliseconds).

d) In the Test I/O default protocol list, click the protocol to display in the Test I/O window when testing the I/O using a serial port.

4 Click OK.

3. Load RC-SCONTRL RTU configuration 3.3. Load options


3.3 Load options While loading the configurations into RTU, you can save and archive the configuration.

Perform the following steps to configure the load options.

Step Action

1 Choose Operations > Load > Load Now (Basic Parameters Only).

The Loading station configuration dialog box appears.

2 Select Archive the station information with every load check box.

Station information is stored in the non-volatile memory. The archived station data is retrieved by using the ReadBack option from the Operations menu.

3 Select Set the station’s clock check box.

Each time the station configuration is loaded, the real-time clock in the stations is set to the computer's clock time or to GMT time. For more information about how to Set the station’s real-time clock, refer to

Set the real-time clock for an RTU section.

4 Click OK.

3.4 Loading basic configuration to RTU Use this option to load just the basic I/O Tool Kit configuration data into the highlighted station.

Perform the following steps to load the configuration into the RTU.

Step Action

1 Click the station to which the configuration needs to be loaded.

2 Choose Operations > Load > Load Now (Basic Parameters Only).

The Loading station configuration dialog box appears

3. Load RC-SCONTRL RTU configuration 3.5. Loading DNP3 protocol configuration to RTU


Step Action

3 The following parameters are loaded.

• Load module EEROMs

• Load scan list

• Load special features

• Load general settings

• Load ring monitoring

• Load I/o transfers

• Load registration data

• Load IP security

• Load SNMP configuration

• Load port settings

• Load project archive

• Set clock

ATTENTION

• The progress bar closes once the files are loaded to the RTU. The status of the files loaded is displayed in the Report Views.

• To enable Report Views, choose View > Report Views.

3. Load RC-SCONTRL RTU configuration 3.5. Loading DNP3 protocol configuration to RTU


3.5 Loading DNP3 protocol configuration to RTU You can configure DNP3 protocol to establish communication between RTUs and Experion. Once the protocol is configured, the protocol configuration should be loaded to the RTU.

Perform the following steps to load the protocol configuration into RTU.

Step Action


2 Choose Operations > Load > Load Advanced (Select Files).

The Load Selected Features/Files dialog box appears.

3 Under User Files, select the DNP3 protocol configuration file.

4 Click Load.

ATTENTION

The progress bar closes once the files are loaded. The status of the files loaded is displayed in the Report Views.

Load DNP3 protocol configuration to secondary RTU

While loading DNP3 protocol configuration to a secondary RTU, you need to download the same configuration file to the primary RTU and the secondary RTU.

Perform the following steps to load the DNP3 protocol configuration to secondary RTU.

Step Action



The Select station dialog box appears.

3 To load the DNP3 configuration file in both the primary RTU and the secondary RTU, select Primary station check box and Backup station check box.

3. Load RC-SCONTRL RTU configuration 3.6. Loading all configuration files


Step Action

ATTENTION

Load the files through Ethernet port . The Primary station and the Backup station options are available only when the files are loaded through Ethernet port.

4 Click OK.


5 Under User Files, select the DNP3 protocol configuration file.

6 Click Load.

ATTENTION


3.6 Loading all configuration files You can load multiple files into the RTU at one time. However, using this method would erase all the existing ISaGRAF files, datalogs, and other files in the RTU.

Perform the following steps to load all the configuration files into the RTU.

Step Action


2 Choose Operations > Load > Load All Now (Predefined Files).

A warning message appears.

3 Read the warning message and click Yes if you want to continue.

The Loading station configuration dialog box appears and the files are loaded.

ATTENTION


3. Load RC-SCONTRL RTU configuration 3.7. Loading an ISaGRAF program to RTU


3.7 Loading an ISaGRAF program to RTU Perform the following steps to associate an ISaGRAF program to an RTU and to load it to the RTU.

Step Action



2 Click Files to Load tab and click ISaGRAF tab.

3 Select Load an ISaGRAF program check box.

4 In the Run time version list, click RTU.

5 Click Project.

The Select ISaGRAF Executable dialog box appears.

6 Click the ISaGRAF Executable program to load and click Open.

7 Click OK.



9 Click ISaGRAF Project and click Load.

The ISaGRAF project is loaded in to the RTU.

3. Load RC-SCONTRL RTU configuration 3.7. Loading an ISaGRAF program to RTU



4. RC-SCONTRL RTU operations

4.1 Overview Once the configuration is loaded into the RTU, you can perform various operations like verifying the configuration, reading the configuration from the RTU, monitoring the RTU, and so on.

4.2 Replacing/upgrading redundant RTUs In the instances where you need to perform firmware upgrade or load new project configuration in the redundant RTUs, you need to physically remove the RTUs and do the upgrades or replace the RTUs.

Perform the following steps to replace a secondary RTU.

Step Action

1 Remove the primary RTU from the network.

The secondary RTU becomes the primary RTU.

2 Perform the firmware upgrade to the RTU that is removed from the network.

3 Load the required project configuration to the removed RTU.

4 Reconnect the RTU to the network. It becomes the primary RTU.

5 Remove the secondary RTU from the network and perform step 2 and step 3.

6 Reconnect the secondary RTU to the network.

4. RC-SCONTRL RTU operations 4.3. Verifying the loaded configuration data


4.3 Verifying the loaded configuration data If you want to check whether there are any mismatches between the configuration of the RTU and the configuration in the project file, then you can use the verify option provided in the operations menu.

Ensure that you selected Serial or Ethernet communication port before verifying the loaded configuration data.

Perform the following steps to verify the configuration loaded in the RTU.

Step Action

1 Click the station to which the configuration needs to be verified.

2 Choose Operations > Verify.

The Verifying station configuration dialog box appears and the station configuration is verified.

ATTENTION

• The progress bar closes once the files are verified. The status of the files verified is displayed in the Report Views.


4.4 Retrieving the configuration data Ensure that you selected Serial or Ethernet communication port before retrieving the loaded configuration data.

Perform the following steps to read/retrieve configuration data from the RTU.

Step Action

1 Click the station to which the configuration needs to be verified.

2 Choose Operations > Read Back.

ATTENTION

• The status of the files read is displayed in the Report Views.


4. RC-SCONTRL RTU operations 4.5. Monitoring RC-SCONTRL RTU


4.5 Monitoring RC-SCONTRL RTU Honeywell RC500 stations and I/O modules have a number of built-in watchdogs. These watchdogs can be used to automatically turn off discrete outputs and/or analog outputs or hold them in their last known states if an undesirable condition occurs, such as communication loss or heartbeat loss. Watchdog options are also used to monitor and take action if there is communication loss in the SCADA points.

Monitor I/O modules Using the Test I/O utility, you can monitor the input and output values of virtual I/O modules and physical I/O modules.

Perform the following steps to monitor the outputs.

Step Action

1 Right-click the I/O module and choose Test I/O.

The Test I/O screen appears.

2 To monitor the analog input values, click A IN tab.

The I/O value column displays the analog input values of each I/O.

3 To monitor the analog output values, click A OUT tab.

The I/O value column displays the analog output values of each I/O.

4 To monitor the discrete input values, click D IN tab.

The I/O value column displays the discrete input values of each I/O.

5 To monitor the discrete output values, click D OUT tab.

The I/O value column displays the discrete output values of each I/O.



Change I/O values using Test I/O While monitoring the I/O values, you can also change the output values in physical I/O modules, and you can change both input and output values in virtual I/O modules.

Perform the following steps to change the I/O values.

Step Action

1 Right-click the I/O module and choose Test I/O.

The Test I/O screen appears.

2 In the Test I/O screen, click A IN tab or A OUT tab and click I/O Value row of the particular I/O register.

3 In the tool bar click any one of the following buttons to change values.

- Changes the value of the I/O to minimum value.

- Changes the value of the I/O to zero.

- Changes the value of the I/O to maximum value.

- Increases the value of the I/O by one percent.

- Increases the value of the I/O by 10 percent.

- Decreases the value of the I/O by one percent.

- Decreases the value of the I/O by 10 percent.

4 Click to change the status of the digital I/O to ON and click to change the status of the digital I/O to OFF.



Monitor the communication between I/O modules and RTU To monitor communication between the I/O modules and the RTUs, we can configure watchdog options using Honeywell RC500 I/O Tool Kit.

ATTENTION

Ensure that while adding an I/O module to the RTU, Assign watchdog output to first channel is selected in Discrete/Analog output options.

Perform the following steps to monitor the communication between RTU and the I/O module.

Step Action

1 Choose Configure > Configure Station/Module.


2 Click Advanced tab.

3 Under Watchdog Options, in the Allowable loss period (sec) box, enter the timeout period in seconds.

4 Under Output Control, select Communication loss check box.

5 Under Actions taken on timeout, select Freeze/Drop outputs per module cfg.

6 Click OK. Monitor the heartbeat register

The watchdog monitors a heartbeat register (toggling physical or virtual discrete output) and if the heartbeat stops changing state for more than the specified timeout period, it either freezes the outputs or turns off the outputs.

To use this heartbeat loss feature, program your application to toggle a discrete output (Y register) on and off at a rate faster than the desired watchdog timer period. The output you select can be a physical register (controlling an unused discrete output in your system) or a virtual register (scanned but not associated with any outputs in your system). The default register is Y0.



Perform the following steps to monitor heartbeat register.

Step Action

1 In the Tree View, click the station to be monitored.



3 Click Advanced tab.

4 Under Watchdog Options, in the Allowable loss period (sec) box, enter the timeout period in seconds.

5 Select Monitor for heartbeat check box.

6 In the Heartbeat output register Y: box, enter the output register number for which the status should be monitored.

7 Click OK.

8 Choose Operations > Test I/O.

The Test I/O page appears.

9 Click D OUT tab, and check the status of the discrete output that is configured for monitoring.

Monitor redundancy

The secondry RTU status is observed by the Test I/O window. The Self_Heartbeat provides the status of the primary RTU and the Other_heartbeat provides the status of the secondary RTU.

Perform the following steps to monitor the redundant RTU status.

Step Action

1 In the Tree Views, select the station.



3 Click D OUT tab.

4 Check the status of Self_Heartbeat and Other_Heartbeat I/O values.

The heartbeats should toggle between systole and diastole.

4. RC-SCONTRL RTU operations 4.6. Monitoring the ring switch status


Step Action

5 Check the status of the Self_Active.

If the status is ‘Running’, then the primary RTU is functioning normally.

If the status is ‘Idle’, then the primary RTU is not functioning as primary RTU.

6 Check the status of the Other_Active.

If the status is ‘Running’, then the secondary RTU is healthy and connected.

If the status is ‘Idle’, then the secondary RTU is not healthy or disconnected from primary RTU and hence need to check the secondary RTU and bring it to running status.

4.6 Monitoring the ring switch status Ethernet ring switches provides quick, fault-tolerant network redundancy and prioritized message delivery that is required in critical real-time systems. These switches are self-configure, and run without the complex configuration steps.

Monitor the ring switch status using RTUs

The RC500 Real-time Ring™ Switch has 32 discrete input registers that are updated with various types of status information.

The RTU polls the ring switches using "raw Ethernet packets”. This technique enhances the network performance and eliminates the need to configure an IP address in each Ring switch.

The following table provides configuration details of the DI registers.

DI register address

Status

0 Link status for port 1. ON if the port is linked.

1 Link status for port 2. ON if the port is linked







DI register address

Status




9 Reserved for future use.







16 Ring 1 status. ON if the ring is complete, OFF if the ring is broken.

17 Ring 1 first port. ON if passing messages, OFF if blocking messages or adjacent switch is not responding.

18 Ring 1 second port. ON if passing messages, OFF if blocking messages or adjacent switch is not responding.

19 Ring 2 status. ON if the ring is complete, OFF if the ring is broken.

20 Ring 2 first port. ON if passing messages, OFF if blocking messages or adjacent switch is not responding.

21 Ring 2 second port. ON if passing messages, OFF if blocking messages or adjacent switch is not responding.








DI register address

Status


28 Ring Switch Online Reporting. ON when communication to the Ring switch is good.

29 OK output. Will be ON if both P1 and P2 power inputs are powered and all configured rings have continuous ring integrity. Will be OFF if either P1 or P2 is not powered, or if any one of the active rings (for which this switch is a member of) encounters a segment failure.

30 First power input. ON when power is present.

31 Second power input. ON when power is present.

Perform the following steps to monitor the ring switch status using the RTU.

Step Action



2 Click Ports tab and double-click Ethernet1.


3 Click Advanced.


4 Click Ring Switch Monitoring tab and select Enable Ring Switch monitoring check box.

5 Click Add.

The Add Ring Switch Monitor dialog box appears.

ATTENTION

The MAC address field is located at the right-hand side of the ring switch.



Step Action

6 In the Select or enter the switch to be monitored list, enter the MAC address of the ring switch and click OK.

The ring switch is added to the Ring Switches to monitor list and a virtual Discrete Input module is automatically added.

ATTENTION

When you add a ring switch, a virtual discrete input I/O module is automatically added. The I/O module name is same as the MAC address entered. You can change the module name by entering a different name in the Module name box.

7 In the Advanced Ethernet/IP Security dialog box, click OK.

8 In the Ethernet Port Configuration dialog box, click OK.


You can see that a virtual DI module is added.

10 Click the virtual DI that is added and click Configure Module.

The Module configuration dialog box appears.

11 Click Discrete Tags tab.

12 Enter the names for the DIs under I/O Tag Name column and click OK.

13 In the RC500 RTU Station Configuration dialog box, click OK.



15 Click D IN tab and check the status of the ring switch port that was configured earlier.

4. RC-SCONTRL RTU operations 4.7. Resetting the RTU


Monitor RTU Status You can monitor the status of the RTUs and I/O modules by mapping them to a particular discrete input in the Station Status Module.

Perform the following steps to monitor the status of the RTU.

Step Action




3 Click Add New Module tab.


4 In the Module type list, click Virtual Module.

5 In the Part number list, click Station Status Module.

6 In the Module tag name box, enter a name for the module and click OK.


7 Click Next.

8 Enter data in First DI register box and Num. registers box.

9 Click Next.

The Discrete Tags dialog box appears.

10 In the Feature column, click the station that you want to monitor against a particular I/O register.

11 Click Finish.



13 Click D IN tab and in the I/O Value column, check the status of the I/O register configured earlier.

If the RTU is ON, the message would be ‘On_line’ and if the RTU is OFF, the message would be ‘Off_line’.

4. RC-SCONTRL RTU operations 4.7. Resetting the RTU


4.7 Resetting the RTU Resetting the RTU has the same effect as cycling power to the RTU.

Perform the following steps to rest the RTU.

Step Action

1 Click the station that needs to be reset.

2 Choose Operations > Advanced Operations > Perform Hard Reset.

The RTU takes about 30 seconds to reset. Set the real-time clock for an RTU

Perform the following steps to set the real-time clock for the RTU based station.

Step Action

1 Select the RTU and then Choose Operations > Set the Clock.

The Set Clock dialog box appears.

2 From the Method list, select any one method of time.

• Use Computer’s GMT: To set your computer’s GMT (Greenwich Mean Time) time and date. Or

• Use User Set Time: To set your own time and date.

ATTENTION

You can also set the real-time clock to Computer's GMT time automatically in the Load Options dialog box before you load configurations into RTU.

3 If you select Use User Set Time, the New time to set in station is enabled, then set your own date and time.

4 Click Apply.

The date and time are synched with the RTU and the updated date and time appears under the Current station date/time.

5 Click Close.


5. Maintenance and troubleshooting

5.1 Upgrading firmware The Firmware Loader is used for upgrading or reloading the firmware in RTU-based station. You can also read the firmware version of RTU in Honeywell RC500 I/O Toolkit using Operations > Advanced Operations > Read Firmware Version.

Considerations • To load the firmware, establish the Ethernet connection from the computer to the

station’s primary Ethernet port (use "Ethernet 1" only, on RC500 RTU models).

• To upgrade the firmware, establish the connection from serial port to primary RS232 Port B.

• The Ethernet port of the computer should be assigned a fixed IP address that is on the same subnet as the IP address you assigned to RTU.

Perform the following steps to upgrade firmware.

Step Action

1 Select RTU and then click Operations > Advanced Operations>Upgrade Firmware.

The Firmware Loader dialog box appears.

ATTENTION

• You cannot stop loading the firmware once it starts.

• You cannot load firmware for ring switches.

• Ensure port 69 is open for a connection from the device that you are loading to the computer.

2 Click Next.

The Select Product and Version dialog box appears.

3 Under Product selection,

a) Select the type of product as Industrial Controller/RTU.

b) Select project file and station name.

5. Maintenance and troubleshooting 5.1. Upgrading firmware


Step Action

ATTENTION

The Station name list shows all RTU stations configured in that project. Ensure that the required RTU is selected.

4 Under Firmware Selection,

c) Click to browse the firmware file. The Browse for Folder dialog box appears and select the latest firmware file. The firmware version is selected automatically in the Select firmware version list.

d) Click Options. The Search Options dialog box appears. Analyze and select all the archive types (.zip, .tar, .tgz, and .gz) provided for firmware files and then click OK.

ATTENION

By default, firmware is available in C:\Program Files\Honeywell Tools\Programs\Firmware.

5 Click Next.

The Connection dialog box appears.

6 Select the type of connection as Use Ethernet and serial communications and select the communication port from the Port list.

ATTENTION

Select the type of connection as Use Ethernet only (no serial port connection) if station supports Ethernet-only loading.

7 Click Next.

The IP Settings dialog box appears. The IP address of computer and RTU are selected by default from the project files. Enter the IP address and/or subnet mask of your station if the value is different from the default values saved in the project file.

5. Maintenance and troubleshooting 5.1. Upgrading firmware


Step Action

ATTENTION

If the IP address of computer and station are on a compatible subnet and the Ethernet communication to the station is proper, then you need not enter Gateway IP address. However, if you need to route messages through an IP gateway, enter the Gateway IP address.

8 Click Next.

The Begin Load dialog box appears.

9 Click Load Now.

The Turn Power OFF message box appears.

10 Turn off the power of RTU and then click OK.

The Cycle Power message box appears. Turn on the power of RTU.

The firmware starts loading and the confirmation message appears after the completion of firmware load.

11 Click OK in the confirmation message box.

The Configuration Load Options dialog box appears.

The .Load station configuration on exit is selected by default and this option allows the station to be loaded with current settings in the previously selected project file. Ensure that all configurations are loaded in status monitoring of Honeywell RC500 I/O Tool Kit.

12 Click Finish.

5. Maintenance and troubleshooting 5.2. Resetting System Com Port


5.2 Resetting System Com Port The Reset System Com Port option is used for resetting the system port of the RTU back to its default communication settings. The system port of the RTU has default communication settings of 9600 baud, 8 data bits, 1 stop bit and no priority. The applicable serial ports are, RS232 and RS485.

You can reset the serial port of an RS485 RTU through the RS485 connections or RS232 connections on the module. The module base has a jumper that activates either the RS232 or the RS485 connections. If this operation has to be performed on an RS485 network with more than one RS485 RTU, then it is recommended that all RS485 RTU logic modules are to be unplugged except for the module that has to be reset. Otherwise, all RS485 RTU modules that are active on the RS485 network are to be reset.

ATTENTION

The Reset System Com Port option is not available for configured Ethernet I/O-2.

Perform the following steps to reset the Com port.

Step Action

1 Select the station and then click Operations>Advanced Operations>Reset System Com Port.

The warning message appears.

2 Click Yes to reset the station.

The Select Com Port dialog box appears.

3 Select a system port for which you want to reset the RTU and then click OK.

4 Restart RTU by switching off and switching on the RTU.

The following message box appears.

5 Click OK.

5. Maintenance and troubleshooting 5.3. Formatting Battery Backed RAM


5.3 Formatting Battery Backed RAM The Format Battery Backed RAM option is used for deleting and/or replacing NVRAM (battery backed RAM) data as appropriate by the loading and reloading operations in the Honeywell RC500 I/O Tool Kit. This operation should be performed only if the NVRAM is corrupted.

ATTENTION

The Format Battery Backed RAM option is not available for configured Ethernet I/O-2.

To use this option, connect a serial port of your computer to port B of your RTU station. The NVRAM reformatting takes approximately 30 seconds to complete. After completion of the reformatting, you must reload the following:

• Datalog configuration, if any

• The Honeywell RC500 I/O Tool Kit configuration

• User files (if any) that were loaded into the /nvram folder of the station

Perform the following steps to format the battery backed RAM.

Step Action

1 Select the RTU and then click Operations > Advanced Operations > Format Battery Backed RAM.

The Format Battery Backed RAM dialog box appears.

2 From the Port box, select the communication port and then click Format Now.

The data deleted from the selected port. There are two LEDs are available in Format Battery Backed RAM dialog box.

- Transmit LED

- Receive LED

If both the LEDs are blinking, it indicates that RTU and computer are communicating with each other.

5. Maintenance and troubleshooting 5.4. LED Status


5.4 LED Status Local diagnostics can be performed using the status of the LEDs that are available on the RTUs. Diagnostic software, such as, the Honeywell RC500 I/O Tool Kit, can also be used to display the status of the I/O registers.

The LEDs display the status of the RTU operation. The following figure shows the LEDs on RC-SCONTRL RTU.

The following table describes the LEDs on the RTU.

LED Description

Status The LED is in ON status, when the RTU is functioning properly.

ACT/LNK The LED is in ON status, whenever a link is established.

100 The LED will be in ON status whenever a 100 megabits/second connection to another Ethernet device is established. The LED will be in OFF status, whenever the connection is at 10 megabits/second.

PWR P1/P2 Indicates whether the power supply is connected to the particular screw terminal.

TD Transmit Data – The LED will be in ON status if the port is transmitting data.

RD Receive Data – The LED will be in ON status if the port is receiving data.

5. Maintenance and troubleshooting 5.5. Diagnostics and troubleshooting


5.5 Diagnostics and troubleshooting Local diagnostics can be performed through any available port while the RTU is responds to messages from the other port. Diagnostic software, such as, the Honeywell RC500 I/O Tool Kit, can also be used to display the status of the I/O registers.

The following table displays the status of LED and the description of the issue.

LED Status Resolution/Workaround

The LED status blinks fast (blinking about 10 times a second).

Possible cause

This error could occur when the RTU is being reset, or if the firmware is to be downloaded from the Honeywell RC500 I/O Toolkit.

Resolution

a) Apply power to the RTU.

b) Load firmware through serial and Ethernet ports. To load the firmware, go to Operations > Advanced Operations > Upgrade Firmware

The LED status is a slow or periodic blink.

Possible cause

This indicates that the internal Watchdog has detected a problem.

Resolution

a) Perform a project load from Honeywell RC500 I/O Tool Kit.

b) Clear the station memory. Go to Operations > Advanced Operations > Clear Configuration.

The LED status is Full OFF.

Possible cause

There is no power provided to the RTU.

Resolution

a) Verify power connections are adequate and 10 -30 Vdc is present on the power terminals.

b) Contact Honeywell TAC.




The RTU does not respond to the communication request over Ethernet or serial port.

Possible cause

The module is not configured with the appropriate communication parameters. By default, the RTU has the IP address as 10.1.0.1.

Resolution

a) Verify the IP address or serial communication parameters in the Honeywell RC500 I/O Tool Kit are compatible with IP address/communication parameters in engineering workstation through Device > Select menu.

b) Load the configuration using the single station mode in the Device > Select menu window and connect directly to the RC500 RTU’s Ethernet port.

c) Load the IP address through the RS232 port B in the RTU.

Failure in Read Back operation.

Possible Cause

Archive option is not selected during the initial configuration.

Resolution/Workaround

a) Choose Operations > Load > Load Options.

b) Select Archive the station with every load check box and click OK.

− Ensure that the RTU is loaded at least once after selecting this option.

• Ensure communication between the RTU and Engineering Station.




During Firmware download, the Status LED shows as “Continuous Blink.” In such a situation, the RTU goes to Boot mode state and does not come back to the normal state.

Possible Cause

RTU goes to Boot mode if it encounters problem while loading RTU firmware upgrade.


• Switch off and switch on the RTU and ensure that the Status LED is constant.

• Reload the Firmware and check the Status LED.

The RTU does not respond quickly to the SCADA communication and to the internal operation.

Possible Cause

• There could be a problem with the memory available in the RTU.

• If RTU is loaded with more than 5000 data points, then the communication between RTU and SCADA gets affected.


• Memory can be analyzed through Telnet using ‘free’ command. The analysis provides information about total memory, memory used, and memory free.

• Reduce the load on RTU by reducing Virtual I/O that are not used and are reserved.

Failure in upgrading the RTU Firmware

Possible Cause

While loading RTU firmware, if firmware upgrade encounters any issue, then RTU goes into Boot mode state.


• Switch off the RTU and then start the firmware upgrade. Repeat the operation, if the firmware upgrade fails

• The Honeywell RC500 I/O Tool Kit communicates with the station, when the Upgrade Firmware command is selected. Even if this initial communication fails, proceed with the "Upgrade Firmware and OS" and follow the instructions.

• Check the communication path to the station and




check whether the Ethernet communication to the station is good.

• If you are running an Ethernet-only firmware upgrade and if you are unable to reload the firmware, then re-run the Upgrade Firmware command and choose "Use Ethernet and serial communication.” If serial connection is not available, add a serial connection to the primary RS232 port.

• An unsuccessful or partial firmware load is recoverable.

The values coming from the RTU are not updated in the station while the values in the RTU are updated.

Possible Cause

Mismatch in RTU Configuration and Experion Quick Builder configuration.


Check the following causes in Qucik Builder:

a) Check whether the Class Polling (1, 2, and 3) is defined in the Controller Configuration.

b) Check whether “Accept Unsol, Enable Unsolicited message control” is enabled in the Controller definition.

c) Check whether the Dead band is defined in the DNP3 driver.

Check the following causes in RTU configuration:

a) Check whether the Object variation 2 and 30 (Binary/Analog input change event) are set for “16/32 bit - with Time.”

b) Check whether the Time synch checkbox is selected for exact time/date stamp.

Refer to QB help file for complete information.




While loading datalog configuration to the RTU, the error ‘Invalid Record size’ id displayed and the datalog configuration is not loaded in the RTU.


• Ensure that datalog records are not defined more than 230 bytes. If the record size is defined as more than 230 bytes, correct it and reload the configuration again.

• If any clear the datalog configuration from the RTU.

• Perform Format Battery Back RAM.

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