TABLE OF CONTENT

01_4551_I_1 Safety Instrumented Systems Overview.ppt, 22 Slides

02_4551_I_1 Safety Concepts.ppt, 24 Slides

03_4551_I_1 Architectures.ppt, 38 Slides

04_4551_I_1 Network Configurator.ppt, 92 Slides

04_4551_I_2 Network Configurator.doc, 34 Pages

05_4551_I_1 Hardware Configurator.ppt, 98 Slides

05_4551_I_2 Hardware Configurator.doc, 18 Pages

06_4551_I_1 Point Configurator.ppt, 62 Slides

06_4551_I_2 Point Configurator.doc, 26 Pages

07_4551_I_1 Application Editor.ppt, 58 Slides

07_4551_I_2 Application Editor.doc, 56 Pages

08_4551_I_1 On-line Environment.ppt, 80 Slides

08_4551_I_2 On-line Environment.doc, 24 Pages

09_4551_I_1 Diagnostics.ppt, 82 Slides

09_4551_I_2 Diagnostics.doc, 14 Pages

10_4551_I_1 On-line modification.ppt, 50 Slides

10_4551_I_2 On-line modification.doc, 12 Pages

11_4551_I_1 Communication Overview.ppt, 62 Slides

11_4551_I_2 Communication Overview.doc, 24 Pages

12_4551_I_1 Safety Manager Experion PKS Integration (SCADA).ppt, 68 Slides

12_4551_I_2 Safety Manager Experion PKS Integration (SCADA).doc, 40 Pages

13_4551_I_1 Safety Manager Experion PKS Integration (CDA).ppt, 74 Slides

13_4551_I_2 Safety Manager Experion PKS Integration (CDA).doc, 58 Pages

 Introduction on Safety Instrumented Systems
(SIS)

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1 12/16/2016
Introduction Honeywell
• Module Description:
– This training module is a part of the Overview section of the training courses
for Safety Manager
– It will give an introduction on Safety Instrumented Systems

• Job Importance:
– This module is important for almost all jobs related to Safety Manager; e.g.
Planning & Design, Installation & Upgrades, Engineering, Operations and
Troubleshooting & Maintenance

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2 12/16/2016
Topics Honeywell
• Safety Instrumented System

• Different types of SIS

• Honeywell’s SIS

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What is Safety? Honeywell
• Safety
– The condition of being safe, freedom from danger, risk, or injury

• Process Safety
– Employees
– Process Equipment
– Company Image
– Environment
– Nearby cities, villages, etc

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Example Honeywell

Before an
Explosion….
275 alarms in
11 minutes

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Control Action Honeywell

Boom!
SIS controlled Mechanical Shutdown Action

Critical
Situation
Emergency Shutdown Action

Human controlled

Upset
Operator Action Condition

Process Control

Normal
Control Action Operation
Process Value

Time
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Layers of Protection Honeywell

COMMUNITY EMERGENCY RESPONSE

PLANT EMERGENCY RESPONSE

MITIGATION
Safety Layer(s)
Mechanical Mitigation System Mitigation:
Safety Instrumented Control System e.g. Fire and
Safety Instrumented Mitigation System
Gas
PREVENTION
Mechanical Protection System
Safety
Process Alarms system
Operator Supervision
Safety Instrumented Control System
Prevention:
Safety Instrumented Prevention System e.g. ESD Safety system
Basic Process Control Systems
Monitoring Systems(Process
Alarms) Operator Supervision

Process Design

IEC 61511
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IEC 61508 Honeywell

Machinery sector
Medical sector

IEC
62061

IEC IEC
61513

61508
Nuclear sector

IEC
61511

Process sector . . . . . . sector

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Safety Instrumented System Honeywell

Level_01

Logic Solver
Valve_01
L1

I CPU O

L2

Level_02

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Safety Instrumented System Honeywell

Temperature
SAFETY INSTRUMENTED FUNCTION
transmitter
Shut-off
Temperature Solenoid
valve
transmitter

Level switch
Logic Solver Pump
(PLC)

Globe
Solenoid
Flow valve
transmitter

Safety Instrumented System

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Topics Honeywell

• Safety Instrumented System

• Different types of SIS

• Honeywell’s SIS

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Types of Safety Instrumented System Honeywell

• Technologies applied during the last 50 years

– Electromechanical based technology: Replacement of hydraulic and

pneumatic operating equipment

– Electronic (solid state) technology: Replacement of relay based logic solvers

– Programmable electronic technology: Replacement of solid state logic

solvers

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Types and Names of SIS Honeywell
• Emergency Shut-down Systems (ESD)
• Fire & Gas Systems (F&G)
• Instrumented Protective Systems (IPS)
• Safety Interlocks
• Safety Related Systems
• Burner Management Systems (BMS)
• HI(P)PS

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Topics Honeywell
• Safety Instrumented System

• Different types of SIS

• Honeywell’s SIS

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14 12/16/2016
Honeywell’s SIS Honeywell
TÜV approved

TÜV approved 2004

Safety Manager
First Safety Manager
ordered
Honeywell
1994

1987 First FSC ordered

Pepperl & Fuchs
1984 Develop SIS based on
Diagnostics
Wildevuur 1980 Redundant “Standard” PLCs

1975 Relay-based technology

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Summary Honeywell
• Safety Instrumented System
– Sensing elements, a logic solver and actuating elements
– Ensure that the process situation is safe
• Different types of SIS
– Electromechanical, Electronic, Programmable Electronic
– ESD, F&G, BMS ……
• Honeywell’s SIS
– FSC
– Safety Manager

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Test Questions : Question 1 Honeywell

• What does a SIS typically comprise?

a) Fire & Gas sensors

b) Level switches and solenoid valves

c) Sensing elements, logic solver and actuating elements

d) None of the above

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Test Questions : Question 2 Honeywell
• Which SIS was introduced by Honeywell in 2004?

a) FSC

b) Experion PKS

c) Logic Manager

d) Safety Manager

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Test Questions : Question 3 Honeywell
• Is the SIS the only protection layer for a process?

a) Yes

b) No, an operator is also available

c) No, there is also a Basic Process Control system

d) No, the Layer of Protection model contains several layers

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Test Questions : Question 4 Honeywell
• Select some typical examples of SIS names?

a) BPCS, F&G , IPS

b) DCS, ESD, F&G

c) BPCS, DCS & C&E

d) ESD, F&G, BMS

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Test Questions : Question 5 Honeywell
• Which SIS was first sold in 1987?

a) Safety Manager

b) FSC

c) TDC-3000

d) Scan-3000

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Conclusion Honeywell

Describe Safety Instrumented System

Completion
Certificate

Proceed to the next lesson in your course material

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 Safety Concepts

Honeywell Confidential
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1 12/16/2016
Introduction Honeywell
• Module Description:
– This module is part of the overview section of the Safety Manager training
courses
– It will describe the Safety Concept of Safety Manager

• Job Importance:
– This module is important for everyone who is involved with Safety manager

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Topics Honeywell
• Why use a Safety Instrumented System for safe-guarding?

• How does Safety Manager provide reliability?

• What is Fault Tolerance for safety?

• What is Fault Tolerance for Availability?

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SIS for Safe-guarding Honeywell
• Achieving risk reduction

Mechanical Safety Layers

Safety Instrumented System

Alarms / operator
Safety Manager
Process Control System

Process
equipment

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Can a General Purpose PLC be used for Safeguarding? Honeywell

Process Signal Safety Action

Demand Instrumented Safe Status
for safety System

But what if…?!

Dangerous
State

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ESD Systems Honeywell

• Shutdown systems use normally energized mode of operation

Level_01
Logic “1” Valve_01
L1
at normal
process Inlet pipe
condition L2
Logic “1”
Level_02 at normal
process condition

Liquid

Logic Solver

Controller
I O

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Digital Output of General Purpose PLC Honeywell

What can
+ 24 Vdc
go wrong?
CPU SHORT CIRCUIT
Normally energized
=
Dangerous State

LEAD BREAKAGE
= LOAD,
Nuisance trip e.g. SOV

0 Vdc

A general purpose PLC is not reliable!

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Topics Honeywell
• Why use a Safety Instrumented System for safe-guarding?

• How does Safety Manager provide reliability?

• What is Fault Tolerance for safety?

• What is Fault Tolerance for Availability?

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How Safety Manager is Reliable Honeywell

• Digital Output Safety Manager + 24 Vdc

CPU
STATUS

LOAD,
e.g. SOV
0 Vdc
Diagnostics!

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Diagnostics within Safety Manager (System) Honeywell

• Memory check on processor and communication modules

• Voting on processor level (1oo2D)
• Independent Watchdog
• System Cycle Time check
• Walking bit tests on data-busses
• System temperature check
• Voltage monitoring
• Etc, etc, etc …………

• Remember
Hardware of Safety Manager which contains diagnostic
capabilities is called Safe!

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Diagnostics within Safety Manager (Field) Honeywell
• Loop monitoring available for AI, DI, AO, DO
• Short / open in field wiring and out-of range transmitter
• Reaction on loop fault is configurable / programmable

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Topics Honeywell
• Why use a Safety Instrumented System for safe-guarding?

• How does Safety Manager provide reliability?

• What is Fault Tolerance for safety?

• What is Fault Tolerance for Availability?

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Fault Tolerance for Safety Honeywell

• Digital Output Safety Manager

+ 24 Vdc

“0” de-
de-energized

CPU STATUS
Short circuit
STATUS
Defect

LOAD,
e.g. SOV
0 Vdc

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Fault Tolerance for Safety (Cont’d) Honeywell

+ 24 Vdc SMOD

“0” de-
de-energized

CPU STATUS
Short circuit

STATUS
Defect

LOAD,
e.g. SOV

0 Vdc
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Fault Tolerance for Safety (Cont’d) Honeywell
+ 24 Vdc
“0” de-
de-energize

Secondary means
of de-
de-energization &
via watchdog

CPU STATUS

STATUS

LOAD,
e.g. SOV
0 Vdc

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Topics Honeywell
• Why use a Safety Instrumented System for safe-guarding?

• How does Safety Manager provide reliability?

• What is Fault Tolerance for safety?

• What is Fault Tolerance for Availability?

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Fault Tolerance for Availability Honeywell

• Fault tolerance for availability via redundant hardware

“0” de-
de-energized “1” energized

Secondary means
of de-
de-energization & &

CPU STATUS STATUS

STATUS STATUS

“1” energized LOAD,

e.g. SOV

0 Vdc
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Summary Honeywell
• Safety Instrumented Systems are used for safeguarding because of their
reliability

• Safety Manager is reliable for safety

• Safety Manager is Fault Tolerant for safety

• Safety Manager is Fault Tolerant for availability

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Test Questions : Question 1 Honeywell
• What is a key aspect of the reliability of Safety Manager?

a) Risk reduction

b) Diagnostics coverage of 99,9% and higher

c) The Safety Manager architecture

d) None of the above

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Test Questions : Question 2 Honeywell
• Why is Safety Manager fault tolerant for availability?

a) Due to the Secondary Means Of De-energization

b) Safety Manager can handle process demands for safety

c) Answers a & b are both true

d) Due to the Redundant hardware

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Test Questions : Question 3 Honeywell
• Why is normally energized mode of operation used for shutdown
systems?

a) Logic “1” is used in the application

b) Lead breakage and loss of power, results in a safe condition

c) Field instruments are energized at normal process condition

d) None of the above

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Test Questions : Question 4 Honeywell
• What is Fault Tolerance for Safety?

a) If a fault is detected, Safety Manager can still drive to the safe state

b) Redundant hardware

c) Shutting down the process

d) Answers a & c are both true

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Test Questions : Question 5 Honeywell
• Why can a general purpose PLC NOT be used for safeguarding?

a) It can’t be used for normally energized technique

b) It isn’t fault tolerant for Availability

c) It is too expensive

d) It doesn’t contain diagnostics and isn’t Fault tolerant for safety

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Conclusion Honeywell

Describe Safety Concept for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Architectures

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1 12/16/2016
Introduction Honeywell
• Module Description:
– This module is part of the overview section of the training courses for
Safety Manager
– It will discuss the different architectures of Safety Manager

• Job Importance:
– This module is important for everyone who is involved with Safety Manager

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Topics Honeywell
• The reason behind Different architectures of Safety Manager

• Architectures of Safety Manager

• The Safety and Availability levels of the Architectures

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The Reasons for Different Architectures of SM Honeywell
• Different types of SIS with different safety and availability requirements
(BMS, ESD, F&G, etc.)

• Different types of processes are safeguarded with different safety and

availability requirements (small boiler vs high pressure reactor or CDU)

• Different environments (space & conditions) and geographical

distributions of the installations (refinery vs off-shore or distributed well-
heads)

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Topics Honeywell
• The reason behind Different architectures of Safety Manager

• Architectures of Safety Manager

• The Safety and Availability levels of the Architectures

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Architectures of Safety Manager Honeywell
• Type 1: Non Redundant Controller & Non Redundant Chassis IO
• Type 2: Redundant Controller & Non Redundant Chassis IO
• Type 3: Redundant Controller & Redundant Chassis IO
• Type 4: Redundant Controller, Redundant & Non Redundant Chassis IO
• Type 5: Redundant Controller, Non Redundant Universal Safety IO
• Type 6: Redundant Controller, Redundant Universal Safety IO
• Type 7: Redundant Controller, Mix of chassis IO and Universal Safety
IO

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Architecture Type 1 Honeywell
• Non Redundant Controller & Non Redundant Chassis IO

System Bus

QPP COM COM PSU BKM

Control Processor

I/O-Bus
I/O-Bus
1 2 21
I/O Chassis 1 I/O
SDI SDO SDI SDO Extender

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DMR Architecture Honeywell

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Architecture Type 2 Honeywell
• Redundant Controller & Non Redundant Chassis IO

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2 I/O-Bus 21
I/O Chassis n+1 I/O
SDI SDO SDI SDO Extender

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Architecture Type 3 Honeywell
• Redundant Controller & Redundant Chassis IO

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2
I/O-Bus 17 18 20 21
I/O I/O
I/O Chassis 1 SDI SDI SDO SDO
EXTENDER EXTENDER

I/O I/O
I/O Chassis n SDI SDI SDO SDO
EXTENDER EXTENDER

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Architecture Type 4 Honeywell
• Redundant Controller,Redundant & Non Redundant Chassis IO

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
s
1 2
I/O-Bus 17 18 20 21
I/O I/O
I/O Chassis 1 SDI SDI SDO SDO
EXTENDER EXTENDER

I/O I/O
I/O Chassis n SDI SDI SDO SDO EXTENDER EXTENDER

1 2 21
I/O Chassis n+1 I/O
SDI SDO SDI SDO Extender

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Communication Links Honeywell
• Geographically Distributed System Solutions
– Safety Manager with Distributed Safety Manager

– Safety Manager with Safety Manager Universal Safety IO

RUSIO

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Communication Links (Cont’d) Honeywell
• Geographically Distributed System Solutions
– Safety Manager with Safety Manager Universal safety IO

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Safety Manager with Distributed Safety Manager Honeywell
• Safety Manager controllers connected via Safe-Net with central control
room Safety Manager
– When IO is concentrated in auxiliary rooms
– When process safeguarding segregation is required
– When multiple units/plants are to be safeguarded
– Example: Distributed solution of 100+ Safety Managers

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Safety Manager with Distributed Safety Manager (Cont’d) Honeywell
• 1 main CCB (Central Control Building)
• 16 FAR’s (Field auxiliary Rooms)
2 offshore production platforms
• 107 SM systems
• 81 ESD
• 26 F&G
• All linked together via SIL4
• Safe-net

= FAR
= CCB

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Safety Manager with Safety Manager RUSIO Honeywell
• Remote Universal Safe IO cabinet connected through
SM RUSIO Link with central control room Safety Manager
– When small amounts of IO need to be interfaced per remote location
– When the IO is of varying types
– When a small foot print is required
– When no auxiliary room is available
• Platform
• FPSO, etc

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Architecture Type 5 Honeywell
• Redundant Controller, Non Redundant Universal Safety IO

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Architecture Type 6 Honeywell
• Redundant Controller, Redundant Universal Safety IO

Dedicated redundant Ethernet

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

SM RUSIO Network
A B
IOTA 01 RUSIO RUSIO

A B
IOTA n RUSIO RUSIO

32 Universal Safe I/O Channels

AI, DI (LM), AO, DO (LM)

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Architecture Type 7 Honeywell
• Redundant Controller, Mix of Chassis IO and Universal Safety IO

Dedicated redundant Ethernet

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2
I/O-Bus 17 18 20 21

SM RUSIO
I/O I/O A B
I/O Chassis EXTENDER EXTENDER IOTA 01 RUSIO

Network
SDI SDI SDO SDO RUSIO
1

I/O
I/O Chassis n I/O
EXTENDER EXTENDER
SDI SDI SDO SDO
A B
IOTA n RUSIO RUSIO

1 2 21
I/O Chassis n+1 I/O
SD SDO SDI SDO Extender
I

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Topics Honeywell
• The reason behind Different architectures of Safety Manager

• Architectures of Safety Manager

• The Safety and Availability levels of the Architectures

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The Safety and Availability Levels of the Architectures Honeywell

Safety Manager = SIL3

For all architectures

Safety Manager

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Architecture Availability Levels Honeywell

Controller IO Configuration Safety Availability

Configuration Integrity Level
Redundant Redundant SIL3 Optimal

Mixed-Redundant SIL3 Mixed Optimal and

And Non- Increased
Redundant

Non-Redundant SIL3 Increased

Non-Redundant Non-Redundant SIL3 Normal

Source: Honeywell SMS Planning & Design manual

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Architecture Type 1 Honeywell
• Availability Level: Normal

System Bus

QPP COM COM PSU BKM

Control Processor

I/O-Bus
I/O-Bus
1 2 21
I/O Chassis 1 I/O
SDI SDO SDI SDO Extender

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Architecture Type 2 Honeywell
• Availability Level: Increased

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2 I/O-Bus 21
I/O Chassis n+1 I/O
SDI SDO SDI SDO Extender

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Architecture Type 3 Honeywell
• Availability Level: Optimal

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2
I/O-Bus 17 18 20 21
I/O I/O
I/O Chassis 1 SDI SDI SDO SDO
EXTENDER EXTENDER

I/O I/O
I/O Chassis n SDI SDI SDO SDO
EXTENDER EXTENDER

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Architecture Type 4 Honeywell
• Availability Level: Optimal and Increased
System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

us
I/O-Bus

I/O-Bu
1 2 17 18 20 21
I/O I/O
I/O Chassis 1 SDI SDI SDO SDO
EXTENDER EXTENDER

I/O I/O
I/O Chassis n SDI SDI SDO SDO EXTENDER EXTENDER

1 2 21
I/O Chassis n+1 I/O
SDI SDO SDI SDO Extender

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Architecture Type 5 Honeywell
• Redundant Controller, Non Redundant Universal Safety IO

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Architecture Type 6 Honeywell
• Redundant Controller, Redundant RUSIO

Dedicated redundant Ethernet

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

SM RUSIO Network
A B
IOTA 01 RUSIO RUSIO

A B
IOTA n RUSIO RUSIO

32 Universal Safe I/O Channels

AI, DI (LM), AO, DO (LM)

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Architecture Type 7A Honeywell
• Redundant Controller, Redundant and Non Redundant Chassis IO and
Non Redundant Universal Safety IO

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Architecture Type 7B Honeywell
• Redundant Controller, Redundant and Non Redundant Chassis IO and
Redundant Universal Safety IO

Dedicated redundant Ethernet

System Bus

QPP COM COM PSU BKM QPP COM COM PSU

Control Processor 1 Control Processor 2

I/O-Bus
1 2
I/O-Bus 17 18 20 21

SM RUSIO
I/O I/O A B
I/O Chassis IOTA 01

Network
EXTENDER EXTENDER RUSIO RUSIO
SDI SDI SDO SDO
1

I/O I/O
I/O Chassis n SDO SDO EXTENDER EXTENDER
SDI SDI
A B
IOTA n RUSIO RUSIO

1 2 21
I/O Chassis n+1 I/O
SD SDO SDI SDO Extender
I

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Architectures for Different Types of Availability Honeywell
Usage Architecture
Boiler Management Systems (BMS) • Redundant Controller
• Non-redundant IO
(due to the increased availability
requirements of the boiler)
Emergency Shutdown (ESD) • Redundant Controller
• Redundant IO
(due to Optimum availability requirements)

Fire and Gas detection Systems (FGS) • Redundant Controller

• Non-redundant Input
(due to the increased availability of FGS
Sensors)
• 2003 voting configuration for the Sensors,
combined with redundant output with line
monitoring for alarming and monitoring

Source: Honeywell SMS Planning & Design manual

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Summary Honeywell
• Different types of SIS and different types of processes have different
safety and availability requirements;
Different environments (space & conditions) and geographical
distributions of the installations.
• Different Safety Manager architectures:
– Non Redundant Controller & Non Redundant Chassis IO
– Redundant Controller & Non Redundant Chassis IO
– Redundant Controller & Redundant Chassis IO
– Redundant Controller & Redundant & Non Redundant Chassis IO
– Redundant Controller, Non Redundant Universal Safety IO
– Redundant Controller, Redundant Universal Safety IO
– Redundant Controller, Mix of chassis IO and Universal Safety IO
• What are the Safety and Availability levels of the architectures?
– Safety Manager = SIL3 for all architectures
– Safety Manager architectures available from normal to optimal availability
level

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Test Questions: Question 1 Honeywell
• Which maximum safety level can Safety Manager provide for all
architectures?

a) SIL1

b) SIL2

c) SIL3

d) None of the above

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Test Questions: Question 2 Honeywell
• Which architecture has the optimal level of availability?

a) Non Redundant Controller & Non Redundant IO

b) Redundant Controller & Non Redundant IO

c) Redundant Controller & Redundant IO

d) Redundant Controller & Redundant & Non Redundant IO

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Test Questions: Question 3 Honeywell
• Why are different Safety Manager architectures useful?

a) The end user has more choice

b) Each architecture has a different level for Safety

c) Different type of processes have different requirement for Safety and

Availability

d) All of the above

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Test Questions: Question 4 Honeywell
• Why has the Redundant Controller & Non Redundant IO architecture an
increased availability level?

a) Due to the Non Redundant IO

b) Because this architecture is used for ESD systems

c) Due to the Redundant Controller

d) None of the above

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Test Questions: Question 5 Honeywell
• Can the – Non Redundant Controller & Non Redundant IO -architecture
be used for SIL3 applications?

a) Yes

b) No

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Conclusion Honeywell

Describe Architectures of Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Network Configurator

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the Safety Manager Training
courses.
– It will give a detailed insight in the Network Configurator of the Safety Builder
software of Safety Manager

• Job Importance:
– This module is important for everyone who is doing Engineering and
Installation & Upgrades

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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Safety Builder Screen Honeywell
• If the Safety Builder is opened, the following screen will be visible:

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Available Parts in Configuration Honeywell
• Network Configurator
• Hardware Configurator
• Point Configurator
• Application Editor
• Application Compiler

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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Purpose of the Network Configurator (Physical View) Honeywell
• Create a clear physical network overview

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Purpose of the Network Configurator (Logical View) Honeywell
• Create logical connections
• Define physical network & logical connection properties for all
components used in the networks of the plant

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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How to Configure a Network Honeywell

Safety Station

Safety Manager system

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Adding a Plant Honeywell
• Plant

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Plant Properties Honeywell

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Plant Properties (Cont’d) Honeywell
• Plant name
– Every plant must have a unique name
• Database path
– The location where the database
is stored on disk

• Plant Wide Properties can

be filled out, after the configuration
is started

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Starting Configuration Honeywell

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Symbol Library
• Defines sheet lay-out of the
FLD’s (Application Editor)

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Degree type:
• Defines how temperatures
are displayed

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Date Format:
• Defines the format of the dates
shown in Controller

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Time Zone
• Sets the Time Zone for the Controllers
which are used in the Plant, when the
external clock source device is used

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Unit of Length:
• The unit in which cabinet size is
displayed

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Plant Properties (Cont’d) Honeywell
• Plant wide properties:
– Honeywell, Customer and Plant:
• Contact information

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Adding a Safety Buider Honeywell
• Safety Builder

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Safety Builder Properties Honeywell
• Device Name
– Name of the Device running Safety Builder.
• Clock source allowed
– Defines whether the device can serve as the clock source

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Adding Physical Network Honeywell
• Physical Network

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Physical Network Properties Honeywell
• Network name
– Name of the physical network
connection

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Physical Network Properties (Cont’d) Honeywell
• Interface
– The hardware communication interface
used to connect a device to the network

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Physical Network Properties (Cont’d) Honeywell
• Baud rate
– Setting of the speed of the
communication

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Adding an SM Controller Honeywell
• SM Controller

• Plant
• Safety Builder
• Physical Network
• SM Controller

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SM Controller Properties Honeywell
• Controller name
– Every Safety Manager system
must have a unique name

• Project file directory

– The location where the database
is stored on disk

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SM Controller Properties (Cont’d) Honeywell
• Controller architecture
– Select a Redundant or
Non-Redundant SM Controller

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SM Controller Properties (Cont’d) Honeywell
• Diagnostic Test interval, Safety
integrity level, Controller node No,
Online modification, Com port:
– Safety Manager system related
information

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SM Controller Properties (Cont’d) Honeywell
• Automatic Cold Start
– Defines if the system is able to start
up without manual interaction, e.g.
after a power down

• Remote Load Enabled

– A Controller of a Safe-net network
can be stopped, loaded and started
from a remote location, if this
checkbox is checked

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SM Controller Properties (Cont’d) Honeywell
• Remote Reset Enabled
– Start a Control Processor and clear
faults from the Actual diagnostic
buffer via the Safety Builder

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SM Controller Properties (Cont’d) Honeywell
• IP protection Enabled
– Defines if IP (Intellectual Property)
protection of FLD’s is enabled (active)
or not
– Any FLD can be protected with password.
When an FLD is protected, FLD cannot be
viewed in offline and online mode without
entering the password

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SM Controller Properties (Cont’d) Honeywell
• COM Module_1
– Communication module type for
Controller chassis slot 2
& 7 can be selected.
IP addresses for ports 1A & 1B
can be set

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SM Controller Properties (Cont’d) Honeywell
• COM Module_2
– Communication module type for
Controller chassis slot 3 & 8 can be
selected. IP addresses for ports 2A
& 2B can be set

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SM Controller Properties (Cont’d) Honeywell

• SOE
– Sequence Of Events can be enabled
and the SOE ID Range can be set

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SM Controller Properties (Cont’d) Honeywell
• Clock Sources:
– Configure the Clock Source Priority
list for the selected SM Controller

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SM Controller Properties (Cont’d) Honeywell
• Additional Information
– This window can be used to fill
in additional system related
information

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How to Create a Network Honeywell
• First the Physical Network was created

• Now the logical Network will be created

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Create a Logical view of a Network Honeywell
• Generate a logical network can be done automatically
– To do so select File > Generate logical view in the menu bar

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Create a Logical View of a Network (Cont’d) Honeywell
• Add Logical Connection

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Physical & Logical views of a Network Honeywell

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Logical Network Properties Honeywell
• Node Id & Peer Id
– Two devices which are connected
via a Physical Network path and
which will exchange information

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Logical Network Properties (Cont’d) Honeywell
• Protocol
– Indicates which Communication
Protocol will be used for the
selected Logical Network

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Logical Network Properties (Cont’d) Honeywell
• Route
– Physical Network routing which
will be used for the Logical Network

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Logical Network Properties (Cont’d) Honeywell
• Device Address
– Communication address for the
Master node or Slave node

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Logical Network Properties (Cont’d) Honeywell
• Marker & Register bytes:
– Reserves memory space on
Communication Module
– Quantity of points which can be
transferred via the logical Network

• 24 marker bytes =
– 24 x 8 = 192 Digital points

• 100 register bytes =

– e.g. 100 / 4 = 25 Floating points
OR 100 / 2 = 50 Words

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Logical Network Properties (Cont’d) Honeywell
• PLC base in & out
– Start address for the range of
available communication
addresses for the individual
points

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Logical Network Properties (Cont’d) Honeywell
• Enable Timeout
– If checked, the Logical Network will
be tested for communication failure

• Timeout (ms)
– Sets the maximum communication
timeout

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Logical Network Properties (Cont’d) Honeywell
• Network delay (ms)
– Communication delay which is caused
by Physical Network components.
Only applicable for Safe-net Logical
Networks

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Logical Network Properties (Cont’d) Honeywell
• Update period
– Sets the time period in which all allocated points
must be processed

• Response timeout
– Sets the maximum time to wait for a
response to the request made

• Poll delay
– Sets the time period between the
moment a response is received and
a new request is sent.

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Logical Network Properties (Cont’d) Honeywell
• Maximum retries
– Defines the number of retries for any
single request

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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Other Communication Devices Honeywell
• Process Controller: Control Execution Environment C300

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Other Communication Devices (Cont’d) Honeywell
• Experion Server: The Honeywell DCS

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Other Communication Devices (Cont’d) Honeywell
• DCS: Any device that Uses the Modbus Protocol

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Other Communication Devices (Cont’d) Honeywell
• Modbus Slave: Component used to add a Modbus Slave device to your
network where the Modbus Master protocol applies.

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Other Communication Devices (Cont’d) Honeywell
• Gateway: Component used to add a Gateway to your network where the
Modbus Master protocol applies.

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Other Communication Devices (Cont’d) Honeywell
• External Clocksource: Independent clock that will provide the time to the
system

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Other Communication Devices (Cont’d) Honeywell
• FDM Server: Configuration tool for HART Devices

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Other Communication Devices (Cont’d) Honeywell
• Safety Historian: Sequence of Events collecting device

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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Backup & Restore Honeywell
• The Network Configurator is equipped with Backup & Restore function
for all the information of a Plant

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Backup Honeywell

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Restore Honeywell

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Audit Trail Honeywell
• Every time you make a functional change

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Audit Trail Viewer Honeywell

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Password Protection Honeywell

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Topics Honeywell
• What is Safety Builder?

• What is the Network Configurator?

• How to configure a Network?

• What are other Communication Devices?

• Additional Features

• How to re-use Configuration work?

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1. Re-Use your configuration work by: Honeywell
• Copying a SM controller, including point database, controller settings
and application logic and pasting it in your plant

• Copying a SM controller including communication allocation, the

connections and devices used for these allocations will be copied as
well

• Copying multiple SM controllers including a shared SafeNet

communication link

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Copy a Controller Honeywell

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Paste a Controller Honeywell
• In the Physical view click on the destination Plant node to paste the
Controller in the Explorer bar of that Plant

OR

• Open the destination Plant, select a Physical network connection and

paste the Controller

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Paste a Controller (Cont’d) Honeywell

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Paste a Controller (Cont’d) Honeywell

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Paste a Controller (Cont’d) Honeywell

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Paste a Controller (Cont’d) Honeywell
• Paste a controller will fail if:
– A version of the same SM controller already exists in the destination plant

– The SM controller name already exists in the destination plant

– The SM controller cabinet name already exists in the destination plant

– There is a conflict in communication configuration and/or allocation

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Paste a Controller (Cont’d) Honeywell
• Define a suitable unique name for the
copied SM controller. (The default
assigned name is its original name)

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Paste a Controller (Cont’d) Honeywell
• Check (and update) the project file
directory used to store the new SM
controller file. (The default assigned
project file directory is the Plant folder)

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Paste a Controller (Cont’d) Honeywell
• Check if the controller node number
matches the network architecture of
the Plant. Change the node number
if required

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Restrictions for Copy-Paste of a SM Controller Honeywell
• You cannot undo after pasting a SM controller

• To copy a controller including communication allocation, the connections

and devices used for these allocations will be copied as well
– If there is a (naming) conflict, copy will be aborted

• To copy SM controllers including a shared SafeNet communication link,

you should first copy the Node ID controller followed by the Peer ID
controller

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2. Re-Use Your Configuration Work By Honeywell
• Copying a complete Plant, including all the SM controllers it contains,
with their
– Point database
– Controller settings
– Application logic
– Communication allocation
• The connections and devices used for these allocations

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Copy a Plant Honeywell

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Copy a Plant (Cont’d) Honeywell

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Summary Honeywell
• What is Safety Builder?
– Configuration Tool
– Tool to check the on-line environment

• What is the Network Configurator?

– Create a clear physical network
– Create logical connections between nodes
– Define network properties for all components

• How to Configure a Network

– First create physical view
– Then create logical view

• What are other communication Devices of the Network Configurator:

– Process Controller, Experion Server, DCS, External Clocksource, FDM
Server, Modbus Slave, Gateway.

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Summary Honeywell
• Additional features:
– Backup and restore
– Audit trail
– Password

• How to Re-use configuration work

– Copy a complete Plant
– Copy a SM Controller

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Test Questions: Question 1 Honeywell
• Name one purpose of the Network Configurator?

a) Define network properties for all components

b) Making an overview of components

c) Create nodes

d) Non of the above

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Test Questions: Question 2 Honeywell
• Name all components which can be used in the network configurator?

a) Plant, Safety Builder, SM controller, Process Controller, Experion Server,

DCS, External Clocksource, Modbus Slave, Gateway, Physical network, Add
Logical network

b) Server, Physical network, Add Logical network

c) Plant, FSC system, SM controller, Process Controller, DCS, TPS, Physical

network, Add Logical network

d) Safety Builder, SMM, Experion Server

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Test Questions: Question 3 Honeywell
• Which component is used to add a Safety Manager system to a
network?

a) Experion PKS server

b) SM Controller

c) Plant

d) Physical Network

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Test Questions: Question 4 Honeywell
• Where can the “general information” of a Safety Manager system be
defined?

a) SM Controller properties

b) Hardware Configurator

c) Safety Builder properties

d) Logical view

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Test Questions: Question 5 Honeywell
• When can a logical network be created?

a) When Safety Builder is open

b) If at least one SM Controller is in the network

c) Answers a & b are both correct

d) After a physical network is created

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Test Questions: Question 6 Honeywell
• Which components are used to add a device to your network where the
Modbus Master protocol applies?

a) Experion PKS server, FDM Server

b) SM Controller, Safety Historian

c) Modbus Slave, Gateway

d) Physical Network

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Conclusion Honeywell

Describe Network Configurator for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: Network Configurator
Contents
Network Configurator ....................................................................................................................... 3

Network Configurator-Revisited ..................................................................................................... 23

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 Network Configurator
Network Configurator

Network Configurator
Introduction
Prerequisites
To qualify for these exercises a trainee should meet the following prerequisites:
• Gone through training module for Network Configurator
• Safety Builder installed on a PC
• Safety Manager™ system, with Remote Universal Safe I/O modules connected
Description
This lab procedure describes how to configure a network between a Safety Station and a
Safety Manager system.
Configuring the network requires a SM Controller node number and IP addresses. The
instructor will supply this information. The Instructor will also point out the Safety Manager
system, which will be used during the lab exercises.
Make sure that the hard disk of the PC contains a folder: My SM projects. The application
will be stored in this folder.
Audit trail

TIP
Audit Trail is an integrated tool, which logs all
the changes that are made to the application.

At some stages when executing the procedure, a window as shown in figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.

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Network Configurator

Check the checkbox for ‘Accept future changes with this justification’ to log, all work with
the same justification. After this is done just press OK.

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Network Configurator

Practice

Step Action

Create a Plant

1 Open the Network Configurator and drag a Plant to the work area.

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Step Action

2 A Window to Save Plant will open

Select the My SM projects folder and press the New Folder button
Give the Plant name as: MyPlant

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Step Action

3 Name the folder MyPlant and press the Open button to open the folder.

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Step Action

4 Now press the Open button to store the Plant in the My SM projects folder

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Step Action

After the Plant is stored press the OK button

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Step Action

6 Start configuration by right clicking on the Plant and select Start Configuration.

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Network Configurator

Step Action

Create Physical Network view

1 Add a Safety Builder to the Plant by dragging and dropping it.

2 Alter the Safety Builder properties:

Enter the Device name: Safety Station (this name needs to be a Plant unique name, but
can be chosen freely). Check the Clock Source Allowed box and press OK.

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Step Action

3 Add a Physical Network to the Safety Station.

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Network Configurator

Step Action

Alter the Physical Network properties:

Choose Ethernet as the Interface type. By doing this all other properties are defined.
The Network Name is a Plant unique name, which can be chosen freely. In this exercise
we use the name Fault Tolerant Ethernet.

Press OK after the alteration is done.

TIP

The Baud rate should normally be set at 100Mb/s full-

duplex unless instructed differently by the instructor.

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Step Action

5 Add a Safety Manager System (SM Controller) to the Physical Network.

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Step Action

6 Fill in the Controller Name: MySMController_XX.

Replace the XX with the Controller Node number, which is supplied by the instructor.
Also make sure that the Controller Architecture matches with the hardware of the
appointed Safety Manager system.
Now store the Controller in the MyPlant folder. Press Button to open explorer.

Press Open to store the controller

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Network Configurator

Step Action

7 Now the properties of the Controller need to be defined. First check the Remote load
enabled and Remote reset enabled checkboxes.

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Step Action

8 Secondly the Controller Node number should be selected.

The trainer will provide the correct number.

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Network Configurator

Step Action

9 Select the COM Module 1 tab page and fill out the IP Addresses of USI channel 1A for
both CP1 and CP2.
The trainer will also provide the correct IP Addresses.
Make sure the COM Module type - USI-0001 or USI-0002 - is set correctly.

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Step Action

10 The fields Subnet mask and Gateway address will be updated automatically after the
IP Address is entered. Leave these at their defaults.
Press OK when finished.

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Network Configurator

Step Action

Create Logical Network view

1 Select the Plant by double clicking on it. Then click File>Generate Logical View.

Press Translate and the Logical Network view will be generated.

The translation rules are OK for this lab procedure.

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Step Action

2 After the Logical Network view is generated some properties need to be set. First right
click the Logical Network symbol and select Properties.

Now fill out the Logical Network properties. For this lab exercise we have chosen 12
for the Marker bytes and 120 for the Register bytes. Press OK when finished.

3 The Network configuration is now completed!

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 Network Configurator
Network Configurator-Revisited

Network Configurator-Revisited
Introduction
The objective is to Re-Use the Configuration of a Safety Manager™ system by copying it,
including the Network Configuration is met with this lab exercise.
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Completed Lab exercise of Network Configurator
• Completed Lab exercise of Hardware Configurator
• Completed Lab exercise of Point Configurator
• Safety Builder installed on a PC
• Safety Manager™ system, with Remote Universal Safe I/O modules connected
Description
This lab procedure describes how to copy a Safety Manager system and its network
configuration.

Copying the controller requires a second Plant to paste it in. The instructor will supply this
Plant that already contains information you will need later on.
Make sure that the hard disk of the PC contains a folder: My SM projects. The application
will be stored in this folder.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.
At some stages when executing the procedure, a window as shown in the figure below will
appear.

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Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Practice

Step Action

Open and check the Plant received

1 Open the Network Configurator and drag a Plant to the work area.

2 Navigate to the My SM projects folder, select the folder where the Plant you received from
your instructor was stored (e.g. HAIL SMS) and press Open.

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Step Action

3 Select the .CAC file received and press the Open button to open the Plant.

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Step Action

Once the Plant opens press the OK button.

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Step Action

5 Start configuration by right clicking on the Plant and select Start Configuration.

6 Check that the Plant is not empty. Leave the information in the Plant as it is; you will need it
later.

7 Return to the Plant you have created in the previous lab exercises and open it by selecting
start configuration.

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Step Action

Copy your Controller

1 Right click on your Controller and select Copy.

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Step Action

Paste the Controller in the received Plant

1 Open the received Plant for configuration by double clicking it (or right clicking and selecting
Start Configuration) and Paste the controller on the Plant icon by right clicking the Plant and
selecting Paste.

2 Select Yes in the dialog to include the Safety Builder, the Physical Network and the Logical
Connection you configured before.

3 Select Yes in the warning dialog to continue with the paste action.

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Step Action

4 Before the paste action completes you get the opportunity to change / adjust the Controller
name and the Controller node number for the Safety Manager system (SM Controller) to
match the configuration in the Plant you pasted to. In this lab exercise we leave the name
and other properties unchanged. Press OK to continue.

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Step Action

5 Expand All in the Network Configurator and navigating the Hardware Configurator and
Point Configurator will now show the same network architecture and controller
configuration (including Hardware Configuration and Point Configuration) you created in the
previous lab exercises.

6 The copying of the Controller, including the Network Configuration is now complete!

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 Hardware General Overview

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Introduction Honeywell
• Module Description:
– This training module is a part of the hardware section of the training courses
for Safety Manager
– It will describe all the Hardware Modules & components of Safety Manager
in a general way

• Job Importance:
– This module is important for almost all jobs, related to Safety Manager; e.g.
Planning & Design, Installation & Upgrades, Engineering, Operations and
Troubleshooting & Maintenance

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Topics Honeywell
• What are the hardware components of Safety Manager?

• What is the general functionality of the hardware components?

• How are the Hardware components Linked within the system?

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Hardware Components of SM and its Functionality Honeywell
• Safety manager System SM Controller
– SM Controller is installed in the
controller chassis
– The SM Controller is Non-redundant,
containing one Control Processor or
Redundant containing two Control
Processors

Non-
Redundant

Redundant

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Maximum Chassis in SM Honeywell

IO Chassis

IO Chassis

Maximum 9 IO chassis
Maximum 8 IO chassis

IO Chassis IO Chassis

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Maximum Chassis in SM (Cont’d) Honeywell
• Maximum Safety Manager System consist of 4 Local Cabinets
• Maximum Distance allowed between Controller and IO modules is 2
Cabinets

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Safety Manager and Universal Safety IO Honeywell
• Maximum 28 Universal Safety IO modules per Safety Manager.

SM Controller
with local I/O
AND 1st LEVEL
switches

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SM Redundant Controller Honeywell

Redundant
Controller

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SM Non-Redundant Controller Honeywell

Non-
Redundant

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Control Processor Honeywell

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Quad Processor Pack (QPP-000x) Honeywell

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Quad Processor Pack (QPP-000x) Honeywell
• Functionalities Honeywell
– 2 Processors (1oo2D)
– Watchdog (1oo2D)
– 4 IO Controllers
– User Interface
display
push buttons

RUN
IDLE

STOP

STATUS key switch

led

QPP-0001
V1.0

quarter-turn fastener

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Universal Safety Interface (USI-000x) Honeywell

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Universal Safety Interface (USI-000x) Honeywell

Tx and Rx LED’s
Tx 1
Rx 1

Tx 2
Rx 2

Tx 3
Rx 3

Tx 4
Rx 4

STATUS

USI-0001
V1.0

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Communication (via Ethernet or FTE) Honeywell
• Communication Types
– Channels A & B - Ethernet or FTE connection

• Communication Solutions
– Process Controller (Fault Tolerant Ethernet)

– Experion PKS server (Fault Tolerant Ethernet)

– FDM Server (HART pass through Universal Safety IO)

– External Clock source device

– Modbus Slave (Ethernet)

– Gateway (Ethernet)

– Safenet

– Safety Station

– Safety Historian

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Communication (via RS-232 or RS-485 ) Honeywell
• Communication Types

– Channels C & D - RS-232 or RS-485 connection

• Communication Solutions

– Modbus RTU

– Safenet

– Safety Station

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5Vdc Power Supply Unit (PSU) Honeywell

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Battery and Key Switch Module (BKM-0001) Honeywell

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Battery and Key Switch Module (BKM-0001) Honeywell

CP 1 CP 2

Reset Key OFF

ON

RESET

OFF

ON

FORCE ENABLE

STATUS
Force Enable

BKM-0001
V1.0

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Battery and Key Switch Module (BKM-0001) Honeywell

CP1 battery CP2 battery

3.6 Volt

3.6 Volt
Reset key

Force Enable key

battery switch

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IO Chassis Honeywell

• An IO chassis can contain up to 18 local I/O modules;

• Different types of I/O modules can be mixed in IO chassis
• One type of external power per IO chassis;
• An IO chassis is either for Redundant or Non Redundant IO.

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Chassis Based IO Module Types Honeywell
• Digital Input modules

• Analog Input modules

• Digital Output modules

• Analog Output module

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Safe Digital Input Modules (Local I/O) Honeywell

Safe Digital Input Modules (Local I/O)

SDI-1624 Safe Digital Input Module
(24Vdc, 16 Channels)
SDI-1648 Safe Digital Input Module
(48Vdc, 16 Channels)
SDIL-1608 Safe Line-Monitored Digital Input Module with Earth
fault Monitor (16 Channels)

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Safe Analog Input Modules (Local I/O) Honeywell

Safe Analog Input Module (Local I/O)

SAI-0410 Safe Analog Input Module
(4 Channels)
SAI-1620m Safe High-density Analog Input Module
(16 Channels)

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Safe Digital Output Modules (Local I/O) Honeywell

Safe Digital Output Modules (Local I/O)

SDO-0824 Safe Digital Output Module (24Vdc, 0.55A, 8 Channels)

SDO-04110 Safe Digital Output Module (110Vdc, 0.32 A, 4 Channels)

SDO-0448 Safe Digital Output Module (48Vdc, 0.75 A, 4 Channels)

SDO-0424 Safe Digital Output Module (24Vdc, 2 A, 4 Channels)

SDOL-0424 Safe Loop-monitored Digital Output Module (24Vdc, 1 A, 4

Channels)
SDOL-0448 Safe Loop-monitored Digital Output Module (48Vdc, 0.5 A, 4
Channels)

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Digital Output Modules (Local I/O) Honeywell

Digital Output Modules (Local I/O)

DO-1224 Digital Output Module (24Vdc, 0.55A, 12 Channels)

RO-1024 Relay Output Module (Contacts, 10 Channels)

DO-1624 Digital Output Module (24Vdc, 0.1 A, 16 Channels)

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Safe Analog Output Modules (Local I/O) Honeywell

Safe Analog Output Module (Local I/O)

SAO-0220m Safe Analog Output Module
((0)4-20 mA, 2 Channels)

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Field Termination Assembly (FTA) Honeywell

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Field Wiring and Marshalling Honeywell

Junction Junction Marshalling Safety Manager

boxes box Cabinet
(FTA’s)

DI
AI
DO
AO

DI
AI
DO
AO Multi
Core
Cables

DI
AI
DO
AO

System Integration Cables

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Safety Manager System Remote Universal Safe I/O Honeywell

SWITCH
LEVEL 1
MAXIMUM OF
SIX (6) SWITCH
LEVELS SM RUSIO
with 2nd LEVEL
switches

SM RUSIO
with 2nd LEVEL
switches
SWITCH
LEVEL 2

SWITCH
LEVEL X
SM RUSIO
(MAX 6) With 6th LEVEL
switches
SM Controller
with local I/O
AND 1st LEVEL
switches

SUPPORTED MAXIMUM
DISTANCE IS 100 KM

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Field Wiring and Soft Marshalling Honeywell

SM RUSIO Field Junction Marshalling Safety Manager

Device Units box Cabinet

DI
AI
DO
AO

DI
AI
DO
Multi
AO Core
Cables
DI
AI
DO
AO

System Integration Cables

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Safety Manager Universal Safety I/O Honeywell
• Per Safety Manager system:
– 28 Remote Universal Safe I/O module pairs (nodes)
• Circa 900 remote I/O channels
• In addition to chassis based local I/O
– 1 Universal Safety I/O Network
• Dedicated USI required
• Dedicated redundant I/O network
• Maximum distance 100 Km
• Embedded fiber optic support
– 6 Switch layers
• Honeywell certified switches

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Universal Safety I/O Module Types Honeywell

Safe I/O Modules (Universal Safety I/O)

FC-RUSIO-3224 Safe Remote Input-Output Module
(24 Vdc, 32 Universal Channels)

Universal Safety input-output module with Logic Solver

FC-RUSLS-3224 capability
(24 Vdc, 32 universal channels)

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Special features Universal Safety I/O Honeywell
• FC-RUSIO-3224:
– 32 Universal channels which can be configured
as DI, AI, DO or AO via the Safety Builder software;
– Default Line Monitoring for all channels;
– Hart pass thru to Field Device Manager (FDM);
– Low latency sequence of events.

• FC-RUSLS-3224:
– All features of the FC-RUSIO-3224;
– Logic Solver (LS) capability.

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Topics Honeywell
• What are the hardware components of Safety Manager?

• What is the general functionality of the hardware components?

• How are the Hardware components Linked within the system?

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Linking of Hardware Components within the System Honeywell
• Controller Chassis

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I/O Buses and System Interconnection Cables Honeywell

= IO busses
= 5Vdc & Watchdog wiring
= 24Vdc wiring
I/O bus = SIC cables
I/O bus

= Communication wiring
= Remote I/O Network
wiring
= AC Feeder wiring
FS-SICC-0001

FTA

To next I/O chassis

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Power and Watchdog Distribution Honeywell
To HSE
RIO
Modules
Ethernet
Switches
To HSE
Plant
Ethernet
Ethernet
Switches

Internal 24V
power supply CPs

= IO busses
= 5Vdc & Watchdog wiring
WD and
Wd and 55 Vdc connection cables
= 24Vdc wiring

24 Vdc power supply rail

I/O bus
= SIC cables
I/O bus
ComFta
RS485

= Communication wiring
= Remote I/O Network
To User Stations 3. 2. 1. External power supply
wiring
External power supply

External power supply = AC Feeder wiring

Internal power supply

To next I/O chassis

FS-SICC-0001

FTA

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Remote I/O Network Honeywell

= 24Vdc wiring
= Universal Safe I/O Network wiring
= AC Feeder wiring

To Field = Field wiring

devices
Ch 1-16

To Field
devices
Ch 16-32

To
AC Power feeders

To
Safety Manager
System

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Summary Honeywell
• Safety Manager Hardware Consists of
– Controller
• Control Processor
– QPP
– USI
– 5Vdc PSU
• BKM
– I/O Chassis & local I/O Modules
– FTAs
– Remote Universal Safe I/O Modules
• Connection between Hardware Components
– I/O Busses
– System Interconnection Cables
– Power and Watchdog Distribution
– Remote I/O Network
– Communication Distribution
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Test Questions : Question 1 Honeywell
• What are the general functionalities of the QPP?

a) Force enable & Fault reset.

b) 2 processors (1oo2D), Watchdog, User display & 4 IO Bus controllers

c) 2 processors (1oo2D).

d) 2 processors (1oo2D), Watchdog & User display.

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Test Questions : Question 2 Honeywell
• Which modules are part of a Control Processor?

a) QPP, USI, 5Vdc PSU and BKM

b) The Controller and the IO chassis

c) QPP, USI and 5Vdc PSU

d) None of the above

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Test Questions : Question 3 Honeywell
• At which hardware component is the field wiring connected ?

a) RUSIO module

b) Controller back plane

c) IO chassis

d) Field Termination Assembly

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Test Questions : Question 4 Honeywell
• What type of communication channels contains the USI?

a) 2 Ethernet channels and 2 RS-232/485 channels

b) 4 Ethernet channels

c) The USI isn't a communication module

d) 2 Remote I/O channels and 2 RS-485 channels

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Test Questions : Question 5 Honeywell
• What is the maximum number SM RUSIO module pairs (nodes) for one
system?

a) 81

b) 28

c) 38

d) 48

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Conclusion Honeywell

Describe Hardware of Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Hardware Configurator

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the training courses for Safety
Manager
– It will give a detailed insight in the Hardware Configurator of the Safety
Builder of Safety Manager

• Job Importance:
– This module is important for everyone who is doing Engineering and
Installation & Upgrades

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Topics Honeywell
• What is the Hardware Configurator?

• How Can the Hardware of a Safety Manager be configured?

• What are the engineering considerations using the Hardware

Configurator?

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Hardware Configurator Honeywell
• The Safety Builder tool for configuring the Safety Manager Hardware

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Access the Hardware Configurator Honeywell

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Topics Honeywell
• What is the Hardware Configurator?

• How Can the Hardware of a Safety Manager be configured?

• What are the engineering considerations using the Hardware

Configurator?

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Initial Hardware Configurator Screen Honeywell

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Safety Manager System Honeywell
XX-ESD-01 XX-ESD-02

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Changing the Name of the Initial Cabinet Honeywell

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Adding the Second Local Cabinet to the System Honeywell

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Placing the CP Chassis in the Correct Location Honeywell

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The CP Chassis Content Honeywell

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The CP Chassis Content (Cont’d) Honeywell

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Setting the Correct QPP Module Type Honeywell

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Setting the Controller Hardware Properties Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell
XX-ESD-01 XX-ESD-02

XX-FDU-01

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Setting the Controller Hardware Properties (Cont’d) Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell

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Setting the Controller Hardware Properties (Cont’d) Honeywell

XX-ESD-01 XX-ESD-02

XX-FDU-01

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Setting the Controller Hardware Properties Honeywell

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Adding an IO Chassis for Redundant Chassis IO Honeywell

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Adding a Redundant Chassis IO Module pair Honeywell

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Adding a Redundant Chassis IO Module pair Honeywell

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Adding an IO Chassis for Non-Redundant Chassis IO Honeywell

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Changing Chassis IO Module Properties (test settings) Honeywell

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Changing Chassis IO Module Properties (test settings) Honeywell

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Changing Chassis IO Module Properties (test settings) Honeywell

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Adding a Remote Cabinet for the RUSFDU Honeywell

XX-ESD-01 XX-ESD-02

XX-FDU-01

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Adding a Remote Cabinet for the RUSFDU (Cont’d) Honeywell

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Adding a Remote Cabinet for the RUSFDU (Cont’d) Honeywell

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Selecting a Carrier for the RUSFDU Honeywell

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Adding a Carrier for the RUSFDU Honeywell

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Selecting the IOTA for the RUSFDU Honeywell

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Adding the IOTA for the RUSFDU Honeywell

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Setting the IOTA Properties Honeywell

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The RUSIO / RUSLS Module(s) are added with the IOTA Honeywell

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Setting the RUSIO / RUSLS Module Properties Honeywell

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Setting the RUSIO / RUSLS Module Properties (Cont’d) Honeywell

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Setting the RUSIO / RUSLS Module Properties (Cont’d) Honeywell

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Topics Honeywell
• What is the Hardware Configurator?

• How Can the Hardware of a Safety Manager be configured?

• What are the engineering considerations using the Hardware

Configurator?

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Engineering Considerations Using Hardware Configurator Honeywell
• For each Safety Manager system a maximum of 4 local cabinets can be
configured

• The Cabinet which contains the Controller Chassis can be maximum 2

positions away from a local IO Cabinet

• Each cabinet in a plant has its own unique name

• In a local IO chassis only one IO module voltage can be used (24 VDC,
48 VDC or 110VDC)

• For each Safety Manager system a maximum of 28 IOTA’s can be

configured.

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Summary Honeywell
• The Hardware Configurator is:
– The Hardware Configurator is the tool for - graphically - configuring the
Safety Manager Hardware
– It is also used for setting the Controller Properties related to this hardware
• How can the Hardware of Safety Manager be configured:
– Select the Controller, Set the controller properties
– Set up the local cabinets
– Place the controller chassis in the cabinets
– Set the QPP Module type
– Set the Controller Properties
– Place the IO chassis and chassis IO modules
– Set the chassis IO module properties
– Set up the remote cabinets, Carriers and IOTA’s
– Set the IOTA and RUSIO/RUSLS module properties
• What are the engineering considerations using the Hardware
Configurator
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Test Questions: Question 1 Honeywell
• Question 1: When can the Hardware Configurator be started?

a) If the Safety Builder is started

b) If a SM Controller is created in the Network Configurator

c) Always

d) If a SM Controller is created and selected in the Network Configurator

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Test Questions: Question 2 Honeywell
• Question 2: Name four components of the hardware configurator?

a) Cabinets, Control processor chassis, IO chassis, Modules

b) Cabinet, Central part chassis, Racks, Modules

c) Cabinet, Central part chassis, IO chassis, Modules

d) Cabinet1, Controller chassis, IO chassis, Cabinet 2

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Test Questions: Question 3 Honeywell
• Question 3: How many local cabinets can be configured in a Safety
Manager system?

a) 3

b) 4

c) 5

d) 6

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Test Questions: Question 4 Honeywell
• Question 4: What must be done before a Non Redundant IO chassis can
be selected?

a) A Non-Redundant IO bus must be selected at controller properties

b) A chassis must be selected

c) A Redundant Controller must be selected

d) A Non Redundant Controller must be selected

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Test Questions: Question 5 Honeywell
• Question 5: What can be set at the IO module properties?

a) Type of IO module

b) Nothing

c) Redundancy

d) Test settings

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Conclusion Honeywell

Describe Hardware Configurator for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Honeywell

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Topic: Hardware Configurator
Contents
Hardware Configurator .................................................................................................................... 3

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 Hardware Configurator
Hardware Configurator

Hardware Configurator
Introduction
The objective of configuring hardware is met with this lab exercise.
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module Hardware Configurator
• Safety Builder installed on a PC
• Executed lab exercise Network Configurator
• Safety Manager™ training unit, with Remote Universal Safe I/O modules connected
Description
This lab procedure describes how to configure the hardware of a Safety Manager system
including the connected Remote Universal Safe I/O modules. The systems that are used
for this training are standard Safety Manager training units with a standard RUSIO training
unit attached.

Such a training unit contains a redundant Controller chassis and a redundant IO chassis
and the connected RUSIO unit contains one redundant RUSIO module pair. The goal of
this lab procedure is to configure the hardware of these training units.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

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Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Practice

Step Action

Add the Controller Chassis

1 Make sure that the system is selected in the Network Configurator. This can be done
by double clicking the Controller symbol.

2 Open the Hardware Configurator by pressing the “Hardware Configurator” button.

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Step Action

3 Before we continue configuring our system, we are going to rename the Local Cabinet
Cabinet1 to SM Controller_XX where XX stands for the Controller Nodenumber again.
To do this, right click the on cabinet name Cabinet1 and select Rename.

4 Add a Controller Chassis to the empty Cabinet by clicking the CPCHAS component and
drag and dropping it on Chassis 01 of the Cabinet.

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Step Action

Add a redundant IO Chassis

1 Add a redundant IO Chassis by clicking the IOCHAS-R component and drag and
dropping it on the Chassis 02 of the Cabinet.

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Step Action

Add the IO Modules

1 The redundant IO chassis of the Safety Manager™ training unit contains a certain
number of redundant IO modules and a number of simulation cards. The simulation
cards (SIMDI-1624, SIMAI-1620m & SIMDIL-1608) simulate the field devices and are
therefore not a part of the configured Hardware of Safety Manager. The goal of this part
of the lab procedure is to configure all the IO modules that are installed in the training
unit. To do so check the front of the IO modules and configure them in Hardware
Configurator. As an example we will configure one module; the SDI-1624.
Right click the correct slot of the IO Chassis, select Add and select the desired IO
Module.

2 Repeat step 6 for all IO modules of the training unit.

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Step Action

Add a (dedicated) USI-000x Module for connecting the RUSIO/RUSLS

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 For adding the dedicated USI-000x Communication Modules to the system, we need to
return to the Properties of the SM Controller in the Network Configurator. This can be
done by right clicking the Controller symbol and selecting Properties.

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Step Action

2 Select the tab COM Module 2 in the properties dialog and depending on the actual
system configuration, set the type for the second communication module to USI-0001 or
USI-0002 and select OK. Now return to the Hardware Configurator.

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Step Action

Change the QPP type to QPP-0002

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Back in the Hardware Configurator; change the QPP Module type to QPP-0002 in the
QPP Properties. Access the QPP Properties by right clicking on the QPP module in
Chassis 01.

2 Change the QPP Module type to QPP-0002 and press OK.

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Step Action

Add a Remote I/O Network

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Open the Controller Properties in the Hardware Configurator by selecting the related
menu item.

2 In the Controller Properties dialog select the Remote I/O tab to configure the Remote I/O
Network. Select COM port 2B for Remote I/O Network 1 and click OK.

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Step Action

3 The Remote I/O Network has been added to the controller and the Hardware
Configurator now shows the tabs for selecting the Local I/O View and the Remote I/O
View.

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Step Action

Add a Remote Cabinet and the RUSIO/RUSLS modules

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Open the Remote I/O View in the Hardware Configurator by selecting the “Remote I/O
View” tab.

2 Add a Remote Cabinet to hold the RUSIO/RUSLS modules by selecting the related
menu option or by pressing the “Add Remote Cabinet” button.

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Step Action

3 Change the name of the Remote Cabinet to XX-FDU-01 where XX stands for the
Controller Node number.

4 Add a Carrier to hold the RUSIO/RUSLS modules by selecting the “Carrier” button and
drag and dropping the carrier into the Remote Cabinet called XX-FDU-01.

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Step Action

5 Add an I/O Termination Assembly (IOTA) to the Remote Cabinet to hold the
RUSIO/RUSLS modules by selecting the “IOTA” button and drag and dropping the IOTA
onto the Carrier. When adding the IOTA, the RUSIO/RUSLS Module(s) are included.

6 Select the correct module type FC-RUSIO-3224 or FC-RUSLS-3224 and click OK in the
IOTA Properties dialog to add the IOTA on the carrier.

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Step Action

7 Access the RUSIO/RUSLS Module Properties by right clicking on the RUSIO or RUSLS
module in IOTA_1, Slot 2 and selecting Properties.

8 Set the RUSIO/RUSLS module properties as shown below to turn off the ESD input and
spare channel diagnostics. Make sure the correct module type as either FC-RUSIO-3224
or FC-RUSLS-3224 is selected. Click OK in the RUSIO/RUSLS Module Properties dialog
to save the settings.

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 Point Configurator

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the Safety Manager training
courses
– It will give a detailed insight in the Point Configurator of the Safety Builder of
Safety Manager

• Job Importance:
– This module is important for everyone who is doing Engineering and
Installation & Upgrades

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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The Safety Builder tool for managing SM Points Honeywell

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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The Initial Point Configurator Screen - Areas Honeywell

Point List

Explorer
Bar

Point Properties

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Creating Points in Point Configurator Honeywell

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Configuring a Digital Input in Point Configurator - Type Honeywell

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The Point Types available in Safety Manager Honeywell

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Configuring a Digital Input in Point Config. – Tag number Honeywell

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Configuring a Digital Input in Point Config. – Description Honeywell

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Configuring a Digital Input in Point Config. – Location Honeywell

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Point Location Honeywell
• Safety Manager has a number of reserved locations:

– COM: Point that is altered or read via a communication link (DI, BI, DO and
BO only)

– SYS: System point (reserved for use by Safety Manager programs).

– FSC: Point that is used on a Safenet communication network and can

therefore be configured as safe.

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Point Location (Cont’d) Honeywell
• Safety Manager has a number of non-reserved locations:

– FLD: Short for field

– CAB: Short for Cabinet (Typically used for read-back signals).

– PNL: Short for Panel (Mimic panel with lamps/LED’s)

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Configuring a Digital Input in Point Config. – (Sub) Unit Honeywell

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Configuring a Digital Input in Point Config. – SIL Honeywell

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Configuring a Digital I/P in Point Config. – Safety Related Honeywell

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Configuring a Digital Input in Point Config. – FLD Honeywell

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Configuring a Digital Input in Point Config. – State Text Honeywell

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Configuring a Digital I/P in Point Config. – Chassis/IOTA Honeywell

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Configuring a Digital Input in Point Config. – Slot Honeywell

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Configuring a Digital Input in Point Config. – Channel Honeywell

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Configuring a Digital I/P in Point Config. – Device Type Honeywell

SDIL-1608

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Configuring a Digital I/P in Point Config. – Transit Time Honeywell

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Configuring a Digital I/P in Pt. Config. – Loop Monitoring Honeywell

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Configuring a Digital I/P in Point Config. – Force Enable Honeywell

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Configuring a Digital I/P in Point Config. – Fault Reaction Honeywell

For more information about Fault reaction see training module: System Fault reactions

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Configuring a Digital Input in Point Config. – SOE Honeywell

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Configuring an Analog Input in Point Configurator Honeywell

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Configuring an Analog Input in Point Config. - EU Honeywell

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Configuring an Analog I/P in Point Config. – Signal Type Honeywell

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Configuring an Analog I/P in Pt Config. – Transmitter alarm Honeywell

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Configuring an Analog Input in Point Config. – IOTA Honeywell

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Configuring an Analog Input in Point Config. – Slot Honeywell

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Configuring an Analog Input in Point Config. – Channel Honeywell

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Configuring an Analog Input in Point Config. – Scaling Honeywell

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Configuring an Analog I/P in Pt Config. – RIO channel prop. Honeywell

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Configuring an Binary Input in Pt Config. – Data Type Honeywell

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Data Type Honeywell
• The data type defines the format of BI’s and BO’s. There are four
different data types.

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Configuring an Binary Input in Pt Config. – Comm. alloc. Honeywell

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Configuring Binary I/P in Pt Config. – Comm. alloc.(Contd’) Honeywell

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Configuring Binary I/P in Pt Config. – Power up Value Honeywell

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Configuring a Digital Output in Point Configurator Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc. Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Deleting Points from Safety Manager System Honeywell
• Deleting points from the point list can be done by selecting the complete
row in the point list, right click the selected row, choose “Delete point” or
by using the delete button.

• Deleting points in the “application editor" will not delete points from the
point list.

• Deleting points in the Point Configurator will free-up the I/O channel or
plc address

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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Additional Features- Import/Export Points Honeywell

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Additional Features- Views Honeywell

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Additional Features- Standard Views Honeywell

• Selecting a view:
– A view can be activated by double
clicking it. The point list will then
automatically switch to the selected
view.

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Additional Features- Custom Views Honeywell

• Creating a Custom view:

– Create a new folder

– Create a new view

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Additional Features- Modifying Custom Views Honeywell
• A number of point list elements can be customized:

– Column Configuration

– Filter Configuration

– Sort Configuration

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Summary Honeywell
• Purposes of the Point Configurator are:
– Create points in a Safety Manager Controller.
– View and modify the properties of the selected Safety Manager system.
– Delete points of the selected Safety Manager system.
– Print reports of points of the selected Safety Manager system.

• Components of the Point Configurator:

– Explorer bar
– Point list
– Detailed view

• Define different type of points:

The number of point viewer elements that can be customized:
– Create points
– Delete points.
– Point attributes.

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Test Questions: Question 1 Honeywell
• Question 1: Name one purpose of the Point Configurator?

a) Change properties of an IO module

b) View points On-line

c) Create points for a Safety Manager system

d) None of the above

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Test Questions: Question 2 Honeywell
• Question 2: In which order must a point be allocated on an IO module?

a) Chassis or IOTA, Slot, Channel

b) Slot, Channel, Chassis

c) Channel; IOTA; Slot

d) All above answers are true

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Test Questions: Question 3 Honeywell
• Question 3: What is a tag number?

a) The sheet number on which the point is used

b) The number of the channel where the point is allocated

c) The number of the point in the point list

d) The name of a point

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Test Questions: Question 4 Honeywell
• Question 4: Which location can be used for allocating points to
communication links?

a) FLD

b) COM

c) SYS

d) CAB

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Test Questions: Question 5 Honeywell
• Question 5: How can a selection of the point list with only DI points with
location COM be created?

a) Use one of the standard views

b) Create a custom view and use Column Configuration

c) Create a custom view and use filter Configuration

d) None of the above possibilities is correct

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Conclusion Honeywell

Describe Point Configurator for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Honeywell

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Topic: Hardware Configurator
Contents
Hardware Configurator .................................................................................................................... 3

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 Hardware Configurator
Hardware Configurator

Hardware Configurator
Introduction
The objective of configuring hardware is met with this lab exercise.
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module Hardware Configurator
• Safety Builder installed on a PC
• Executed lab exercise Network Configurator
• Safety Manager™ training unit, with Remote Universal Safe I/O modules connected
Description
This lab procedure describes how to configure the hardware of a Safety Manager system
including the connected Remote Universal Safe I/O modules. The systems that are used
for this training are standard Safety Manager training units with a standard RUSIO training
unit attached.

Such a training unit contains a redundant Controller chassis and a redundant IO chassis
and the connected RUSIO unit contains one redundant RUSIO module pair. The goal of
this lab procedure is to configure the hardware of these training units.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

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Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Practice

Step Action

Add the Controller Chassis

1 Make sure that the system is selected in the Network Configurator. This can be done
by double clicking the Controller symbol.

2 Open the Hardware Configurator by pressing the “Hardware Configurator” button.

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Step Action

3 Before we continue configuring our system, we are going to rename the Local Cabinet
Cabinet1 to SM Controller_XX where XX stands for the Controller Nodenumber again.
To do this, right click the on cabinet name Cabinet1 and select Rename.

4 Add a Controller Chassis to the empty Cabinet by clicking the CPCHAS component and
drag and dropping it on Chassis 01 of the Cabinet.

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Step Action

Add a redundant IO Chassis

1 Add a redundant IO Chassis by clicking the IOCHAS-R component and drag and
dropping it on the Chassis 02 of the Cabinet.

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Step Action

Add the IO Modules

1 The redundant IO chassis of the Safety Manager™ training unit contains a certain
number of redundant IO modules and a number of simulation cards. The simulation
cards (SIMDI-1624, SIMAI-1620m & SIMDIL-1608) simulate the field devices and are
therefore not a part of the configured Hardware of Safety Manager. The goal of this part
of the lab procedure is to configure all the IO modules that are installed in the training
unit. To do so check the front of the IO modules and configure them in Hardware
Configurator. As an example we will configure one module; the SDI-1624.
Right click the correct slot of the IO Chassis, select Add and select the desired IO
Module.

2 Repeat step 6 for all IO modules of the training unit.

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Step Action

Add a (dedicated) USI-000x Module for connecting the RUSIO/RUSLS

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 For adding the dedicated USI-000x Communication Modules to the system, we need to
return to the Properties of the SM Controller in the Network Configurator. This can be
done by right clicking the Controller symbol and selecting Properties.

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Step Action

2 Select the tab COM Module 2 in the properties dialog and depending on the actual
system configuration, set the type for the second communication module to USI-0001 or
USI-0002 and select OK. Now return to the Hardware Configurator.

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Step Action

Change the QPP type to QPP-0002

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Back in the Hardware Configurator; change the QPP Module type to QPP-0002 in the
QPP Properties. Access the QPP Properties by right clicking on the QPP module in
Chassis 01.

2 Change the QPP Module type to QPP-0002 and press OK.

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Step Action

Add a Remote I/O Network

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Open the Controller Properties in the Hardware Configurator by selecting the related
menu item.

2 In the Controller Properties dialog select the Remote I/O tab to configure the Remote I/O
Network. Select COM port 2B for Remote I/O Network 1 and click OK.

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Step Action

3 The Remote I/O Network has been added to the controller and the Hardware
Configurator now shows the tabs for selecting the Local I/O View and the Remote I/O
View.

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Step Action

Add a Remote Cabinet and the RUSIO/RUSLS modules

(This procedure is only to be executed when RUSIO/RUSLS modules are connected.)

1 Open the Remote I/O View in the Hardware Configurator by selecting the “Remote I/O
View” tab.

2 Add a Remote Cabinet to hold the RUSIO/RUSLS modules by selecting the related
menu option or by pressing the “Add Remote Cabinet” button.

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Step Action

3 Change the name of the Remote Cabinet to XX-FDU-01 where XX stands for the
Controller Node number.

4 Add a Carrier to hold the RUSIO/RUSLS modules by selecting the “Carrier” button and
drag and dropping the carrier into the Remote Cabinet called XX-FDU-01.

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Step Action

5 Add an I/O Termination Assembly (IOTA) to the Remote Cabinet to hold the
RUSIO/RUSLS modules by selecting the “IOTA” button and drag and dropping the IOTA
onto the Carrier. When adding the IOTA, the RUSIO/RUSLS Module(s) are included.

6 Select the correct module type FC-RUSIO-3224 or FC-RUSLS-3224 and click OK in the
IOTA Properties dialog to add the IOTA on the carrier.

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Step Action

7 Access the RUSIO/RUSLS Module Properties by right clicking on the RUSIO or RUSLS
module in IOTA_1, Slot 2 and selecting Properties.

8 Set the RUSIO/RUSLS module properties as shown below to turn off the ESD input and
spare channel diagnostics. Make sure the correct module type as either FC-RUSIO-3224
or FC-RUSLS-3224 is selected. Click OK in the RUSIO/RUSLS Module Properties dialog
to save the settings.

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 Point Configurator

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the Safety Manager training
courses
– It will give a detailed insight in the Point Configurator of the Safety Builder of
Safety Manager

• Job Importance:
– This module is important for everyone who is doing Engineering and
Installation & Upgrades

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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The Safety Builder tool for managing SM Points Honeywell

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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The Initial Point Configurator Screen - Areas Honeywell

Point List

Explorer
Bar

Point Properties

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Creating Points in Point Configurator Honeywell

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Configuring a Digital Input in Point Configurator - Type Honeywell

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The Point Types available in Safety Manager Honeywell

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Configuring a Digital Input in Point Config. – Tag number Honeywell

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Configuring a Digital Input in Point Config. – Description Honeywell

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Configuring a Digital Input in Point Config. – Location Honeywell

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Point Location Honeywell
• Safety Manager has a number of reserved locations:

– COM: Point that is altered or read via a communication link (DI, BI, DO and
BO only)

– SYS: System point (reserved for use by Safety Manager programs).

– FSC: Point that is used on a Safenet communication network and can

therefore be configured as safe.

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Point Location (Cont’d) Honeywell
• Safety Manager has a number of non-reserved locations:

– FLD: Short for field

– CAB: Short for Cabinet (Typically used for read-back signals).

– PNL: Short for Panel (Mimic panel with lamps/LED’s)

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Configuring a Digital Input in Point Config. – (Sub) Unit Honeywell

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Configuring a Digital Input in Point Config. – SIL Honeywell

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Configuring a Digital I/P in Point Config. – Safety Related Honeywell

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Configuring a Digital Input in Point Config. – FLD Honeywell

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Configuring a Digital Input in Point Config. – State Text Honeywell

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Configuring a Digital I/P in Point Config. – Chassis/IOTA Honeywell

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Configuring a Digital Input in Point Config. – Slot Honeywell

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Configuring a Digital Input in Point Config. – Channel Honeywell

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Configuring a Digital I/P in Point Config. – Device Type Honeywell

SDIL-1608

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Configuring a Digital I/P in Point Config. – Transit Time Honeywell

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Configuring a Digital I/P in Pt. Config. – Loop Monitoring Honeywell

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Configuring a Digital I/P in Point Config. – Force Enable Honeywell

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Configuring a Digital I/P in Point Config. – Fault Reaction Honeywell

For more information about Fault reaction see training module: System Fault reactions

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Configuring a Digital Input in Point Config. – SOE Honeywell

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Configuring an Analog Input in Point Configurator Honeywell

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Configuring an Analog Input in Point Config. - EU Honeywell

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Configuring an Analog I/P in Point Config. – Signal Type Honeywell

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Configuring an Analog I/P in Pt Config. – Transmitter alarm Honeywell

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Configuring an Analog Input in Point Config. – IOTA Honeywell

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Configuring an Analog Input in Point Config. – Slot Honeywell

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Configuring an Analog Input in Point Config. – Channel Honeywell

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Configuring an Analog Input in Point Config. – Scaling Honeywell

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Configuring an Analog I/P in Pt Config. – RIO channel prop. Honeywell

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Configuring an Binary Input in Pt Config. – Data Type Honeywell

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Data Type Honeywell
• The data type defines the format of BI’s and BO’s. There are four
different data types.

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Configuring an Binary Input in Pt Config. – Comm. alloc. Honeywell

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Configuring Binary I/P in Pt Config. – Comm. alloc.(Contd’) Honeywell

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Configuring Binary I/P in Pt Config. – Power up Value Honeywell

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Configuring a Digital Output in Point Configurator Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc. Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Configuring Digital O/P in Pt Config. – Comm. alloc.(Cont’d) Honeywell

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Deleting Points from Safety Manager System Honeywell
• Deleting points from the point list can be done by selecting the complete
row in the point list, right click the selected row, choose “Delete point” or
by using the delete button.

• Deleting points in the “application editor" will not delete points from the
point list.

• Deleting points in the Point Configurator will free-up the I/O channel or
plc address

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Topics Honeywell
• What is the Point Configurator?

• How can Safety Manager Points be configured?

• What are the Additional Features of the Point Configurator?

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Additional Features- Import/Export Points Honeywell

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Additional Features- Views Honeywell

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Additional Features- Standard Views Honeywell

• Selecting a view:
– A view can be activated by double
clicking it. The point list will then
automatically switch to the selected
view.

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Additional Features- Custom Views Honeywell

• Creating a Custom view:

– Create a new folder

– Create a new view

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Additional Features- Modifying Custom Views Honeywell
• A number of point list elements can be customized:

– Column Configuration

– Filter Configuration

– Sort Configuration

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Summary Honeywell
• Purposes of the Point Configurator are:
– Create points in a Safety Manager Controller.
– View and modify the properties of the selected Safety Manager system.
– Delete points of the selected Safety Manager system.
– Print reports of points of the selected Safety Manager system.

• Components of the Point Configurator:

– Explorer bar
– Point list
– Detailed view

• Define different type of points:

The number of point viewer elements that can be customized:
– Create points
– Delete points.
– Point attributes.

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Test Questions: Question 1 Honeywell
• Question 1: Name one purpose of the Point Configurator?

a) Change properties of an IO module

b) View points On-line

c) Create points for a Safety Manager system

d) None of the above

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Test Questions: Question 2 Honeywell
• Question 2: In which order must a point be allocated on an IO module?

a) Chassis or IOTA, Slot, Channel

b) Slot, Channel, Chassis

c) Channel; IOTA; Slot

d) All above answers are true

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Test Questions: Question 3 Honeywell
• Question 3: What is a tag number?

a) The sheet number on which the point is used

b) The number of the channel where the point is allocated

c) The number of the point in the point list

d) The name of a point

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Test Questions: Question 4 Honeywell
• Question 4: Which location can be used for allocating points to
communication links?

a) FLD

b) COM

c) SYS

d) CAB

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Test Questions: Question 5 Honeywell
• Question 5: How can a selection of the point list with only DI points with
location COM be created?

a) Use one of the standard views

b) Create a custom view and use Column Configuration

c) Create a custom view and use filter Configuration

d) None of the above possibilities is correct

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Conclusion Honeywell

Describe Point Configurator for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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 Honeywell

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Topic: Point Configurator
Contents
Point Configurator............................................................................................................................ 3

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 Point Configurator
Point Configurator

Point Configurator
Introduction
The objective to create and allocate Points is met with this lab exercise.
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module Point Configurator
• Safety Builder installed on a PC
• Executed lab exercise Hardware Configurator
• Safety Manager™ training unit, with Remote Universal Safe I/O modules connected
Description
This lab procedure describes how to create the Points and allocate them on hardware,
using the Point Configurator. The Points used for this exercise are listed in Table 1
below
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Point Configurator

Point Configurator lab procedures

Table 1 Point list

Type Tag number Description Status 0 Text Status 1 Text Location

DI XX-HS-001 Start pump Not Activated Activated FLD

DI XX-HE-002 Trip from panel activated Not activated PNL

DI XX-PZA-003 Pump oil pressure Low Not Low FLD

DI XX-TEA-004 Temperature HH High High Not High High FLD

DI XX-XEA-005 Vibration trip Trip Not Trip FLD

DI XX-LEA-006 Level Switch T101L Not Low Low FLD

DI XX-LEA-006_2 Level Switch T101H Not High High FLD

DI XX-LEA-008 Level Switch 1 High Not High FLD

DI XX-LEA-009 Level Switch 2 High Not High FLD

DI XX-LEA-010 Level Switch 3 High Not High FLD

DI XX-HS-0281 RESET Not RESET RESET RLC

DI XX-LEA-020 Level Switch A High High Not High High RLC

DI XX-LEA-021 Level Switch B High High Not High High RLC

DI XX-LEA-022 Level Switch C High High Not High High RLC

AI XX-FE-001 Flow measure Not applicable Not applicable FLD

AI XX-FE-002 Flow measure Not applicable Not applicable RLC

DO XX-SOV-002 Outlet valve Close Open FLD

DO XX-P-003 Start/stop pump Stop Run FLD

DO XX-SOV-001 Inlet valve Close Open FLD

DO XX-FEA-004 Outlet valve Close Open FLD

DO XX-SOV-025 Inlet valve Close Open RLC

The points with location ‘RLC’ are only to be created and allocated when RUSIO/RUSLS modules are connected.

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Point Configurator

BO XX-FEA-001 Value Not applicable Not applicable COM

Practice

Step Action

Create Points

1 Make sure that the system is selected in the Network Configurator. This can be done
by double clicking the Controller symbol.

2 Open the Point Configurator by clicking the “Point Configurator” button.

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Point Configurator

Step Action

3 Make sure that the View All points sorted on Type and Tag is selected.

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Point Configurator

Step Action

4 Create a Point by clicking the “Digital Input” button.

The new DI is now added to the point list. The Tag number Digital Input is used. The
user can alter the point details as desired.

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Point Configurator

Step Action

5 Alter the Point details of the created Digital Input by using the first Point from the Point
list of the Description paragraph of this lab exercise. So fill in the following details:
• Tag number: XX-HS-001 replace XX with your system node
number!
• Description: Start pump
• Status 0 Text: Not Activated
• Status 1 Text: Activated
• Location: FLD

TIP
After the information is entered in a field, press the Tab
button on the keyboard of your PC.
If this is forgotten the information will not be recorded.

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 Point Configurator
Point Configurator

Step Action

6 Repeat steps 4 and 5 for all the Points from the point list in Table 1 Point. Please note
that the list also contains the Point type AI, DO and BO.
Make sure the correct selection is made when these Point types are created.

Allocate local digital Inputs (DI) and Outputs (DO)

The Points from the Table below are to be used during this part of the lab exercise.

Table DI and DO Point allocation list

Type Tag number Chassis/IOTA Slot Channel

DI XX-HS-001 01.02 1 1

DI XX-HE-002 01.02 1 2

DI XX-PZA-003 01.02 1 3

DI XX-TEA-004 01.02 1 4

DI XX-XEA-005 01.02 1 5

DI XX-LEA-006 01.02 1 6

DI XX-LEA-006_2 01.02 1 7

DI XX-LEA-008 01.02 1 8

DI XX-LEA-009 01.02 1 9

DI XX-LEA-010 01.02 1 10

DO XX-SOV-002 01.02 17 1

DO XX-P-003 01.02 17 2

DO XX-SOV-001 01.02 17 3

DO XX-FEA-004 01.02 17 4

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Step Action

Allocate local digital Inputs (DI) and Outputs (DO)

1 Select the View All non-allocated points.

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Point Configurator

Step Action

2 Select the first Point from the table of this chapter: XX-HS-001, navigate to the
Options tab and click the check box Force Enable.

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Point Configurator

Step Action

3 Navigate back to the Main tab and set the field Safety Related to Yes.

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Point Configurator

Step Action

4 Allocate the point to the designated chassis, slot and channel. For XX-HS-001 the
following information is available from the table:
Chassis/IOTA: 01.02
Slot: 1
Channel: 1

5 Repeat steps 2, 3 and 4 for other points from Table DI and DO Point.
Note:
There is no difference in allocating digital Inputs and digital Outputs.

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Point Configurator

Allocate local analog inputs

The Points from the Table below are to be used during this part of the lab exercise.

Table AI Point allocation list

Type Tag number Chassis/IOTA Slot Channel

AI XX-FE-001 XX.02 5 1

Step Action

Allocate local Analog inputs

1 Select the View All non-allocated points.

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Point Configurator

Step Action

2 Select XX-FE-001, navigate to the Options tab, and click the checkbox Force
Enable.

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Point Configurator

Step Action

3 Define the bottom scale and top scale (in engineering units) for XX-FE-001. The
following information needs to entered:
Bottom scale: 0
Top scale: 100

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Point Configurator

Step Action

4 Navigate back to the Main tab and set the field Safety Related to Yes.
Define the engineering units for XX-FE-001. The following information needs to be
entered:
Engineering units: M3/h

TIP
After information is entered in a field, press the Tab
button on the keyboard of your PC.
If this is forgotten the information will not be recorded.

TIP
For analog Inputs, the signal type should be
defined. In this lab procedure the signal type should
be 4-20mA. This is the default value. Therefore no
change is necessary now.

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Point Configurator

Step Action

5 Allocate the point to the designated chassis, slot and channel. For XX-FE-001 the
following information is available from the table:
Chassis/IOTA: 01.02
Slot: 5
Channel: 1

6 Repeat steps 2, 3, 4 and 5 for other points from the Table above.

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Point Configurator

Allocate Binary output with location COM

The Points from the Table below are to be used during this part of the lab exercise.

Table BO Point allocation list

Type Tag number Logical Connection PLC address

BO XX-FEA-001 Safety Builder - MySMController_XX 32120

Step Action

Allocate Binary output with location COM

1 Select the View All points location COM.

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Point Configurator

Step Action

2 Select XX-FEA-001, navigate to the Options tab, and click the checkbox Force
Enable.

3 Navigate back to the Main tab and select the Register type Float.

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 Point Configurator
Point Configurator

Step Action

4 Allocate XX-FEA-001 to the Logical connection Safety Builder -

MySMController_XX and select the address.
Double click and select the desired Logical Connection and PLC Address in
Communication allocation

5 Repeat steps 2, 3 and 4 for other points from the Table.

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 Point Configurator
Point Configurator

Allocate Points to the RUSIO or RUSLS Modules

The Points from the Table below are to be used during this part of the lab exercise.

Table Remote Universal Safe IO Point allocation list

Type Tag number Chassis/IOTA Slot Channel

DI XX-HS-028 IOTA_1 1 26

DI XX-LEA-020 IOTA_1 1 17

DI XX-LEA-021 IOTA_1 1 18

DI XX-LEA-022 IOTA_1 1 19

AI XX-FE-002 IOTA_1 1 20

DO XX-SOV-025 IOTA_1 1 27

Step Action

Allocate Points to the RUSIO or RUSLS Modules

1 Select the View All non-allocated points.

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Point Configurator

Step Action

2 Select the first Point from the table of this chapter: XX-HS-028, navigate to the
Options tab, and click the check box Force Enable.

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 Point Configurator
Point Configurator

Step Action

3 Navigate back to the Main tab and set the field Safety Related to Yes.
(The points with location ‘RLC’ are only to be created and allocated when RUSIO/RUSLS
modules are connected.)

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Point Configurator

Step Action

4 Allocate the point to the designated IOTA, slot and channel. For XX-HS-028 the
following information is available from the table:
Chassis/IOTA: IOTA_1
Slot: 1
Channel: 26

5 Repeat steps 2, 3 and further from the previous chapters for other points from the
“Remote Universal Safe IO Point allocation list” Table

TIP
Except for the Chassis/IOTA, Slot and Channel
selection, there is no difference in allocating Local
and Remote points.

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 Application Editor

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the training courses for Safety
Manager
– It will give a detailed insight in the Application Editor of the Safety Builder of
Safety Manager

• Job Importance:
– This module is important for everyone who is doing Engineering and
Installation & Upgrades

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Topics Honeywell
• What is the Application Editor?

• How Can a Logic Sheet be Created?

• What are Additional Features?

• What are the engineering considerations using the Application Editor?

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What is Application Editor? Honeywell

Start Application Editor

either way

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What are Functional Logic Diagrams? Honeywell
• Combination of logic operators that connects input signals with output
signals

Inputs Control Execution Outputs

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What are Functional Logic Diagrams? Honeywell
• There are 2500 FLD pages available for use

Sheet Number Used For

1 Cover Sheet
2…9 FLD Index
10…29 Tag Number Index
30…49 Legends of Symbols
50…99 System Utilities
100…1999 Program Block
2000…2400 Function Block
2401…2499 Equation Block

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What are Functional Logic Diagrams? (Cont’d) Honeywell
• The SM Controller will execute the sheets one by one, from the lowest
number up to the highest number. When it has completed the sequence
it will return to the lowest sheet and begin the execution sequence
again.

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Application Editor Configuration Pane Honeywell

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The Configuration Pane Consists of Honeywell

Title of
Current FLD

Symbol
Library

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Topics Honeywell
• What is the Application Editor?

• How Can a Logic Sheet be Created?

• What are Additional Features?

• What are the engineering considerations using the Application Editor?

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Opening an FLD Honeywell
• When the Application Editor is started the FLD’s bar will show a list of
existing FLD’s.
• To open an FLD, double click its name or number in the FLD list.
Opening another FLD, the current FLD will be automatically saved.

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Adding an FLD Honeywell

• To create an new FLD select FLD>Create New FLD from the menu, or
use the button The number of the new FLD has to be defined,
followed by properties of new FLD

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FLD Properties Honeywell
• Edit properties and defining FLD block types of the current FLD, can be
done in the properties window. In addition, the properties window
contains a Revisions section, in which the revision data of the selected
FLD can be viewed

• To open the FLD properties window, select FLD>PROPERTIES or click

the button

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FLD Properties (Cont’d) Honeywell
• Sheet Number
– Displays FLD number
• Tag Name:
– FLD and Current Sheet Number
• Title:
– Name of the new FLD
• Unit:
– Process unit
• Subunit:
– Subunit of the Process unit
• Password Confirm Password:
– Password for this sheet
• Confirm Password:
– Confirmation

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FLD IP (Intellectual Property) Protect Properties Honeywell
• FLD Protect is only enabled when IP Protect is enabled in SM Controller
Properties

• If the FLD is configured with FLD Protection, then password must be

entered to,
– View the FLD in Offline and Online Environment
– Edit the FLD
– Renumber the FLD

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FLD Properties (Cont’d) Honeywell
• Block type:
– Type of block used for the current FLD
• Execution Environment:
– Indicates where the FLD will
be executed

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Block Types: Comment Block Honeywell
• A comment block is an FLD that contains descriptive text and/or
symbols which are not placed in the point list
• FLD’s of this type are ignored by the compiler
• This type of FLD is typically used as a cover sheet, legend of symbols or
just as a comment between two normal FLD’s

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Block Types: FLD Index Honeywell
• This type of FLD contains no logics, but is only used for printing FLD’s
• It is used to generate an index of all FLD’s used in the application
• Once an FLD index has been defined, it is updated automatically by the
Application Editor
• FLD’s of this type are ignored by the compiler

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Block Types: Tag Number Index Honeywell
• This type of FLD contains no logics, but is only used for printing FLD’s
• It is used to generate an index off all tag numbers used in the application
• Once a tag number index has been defined, it is updated automatically
by the Application Editor
• FLD’s of this type are ignored by the compiler
• For each IO point the Tag number index lists:
– The IO type
– The Tag Number
– The FLD on which the IO signal is used

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Block Types: Program Block Honeywell
• This is the most common FLD type, which defines the application
• Sheets which are defined as Program Block, contain Input, Output and
other logic symbols

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Block Types: Function Block Honeywell
• This is an FLD type that is used as a subroutine function in another FLD
(program blocks or other function blocks)

FLD for the

Function Block

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Block Types: Equation Block Honeywell
• This is an FLD type that contains an equation approximation, which can
be used as a macro function on other functional logic diagrams (program
blocks or function blocks)

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FLD Properties (Cont’d) Honeywell
• Revision:
– Revision Control

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Adding a Symbol Honeywell
• To add a symbol to an FLD, click the relevant symbol in the “Symbol
library”. The symbol will immediately be added. Use the mouse to move
the new symbol to the correct location and click to fix it in that location.

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Symbols Honeywell
• IO Symbols:
– IO symbols are used to link FLD’s with the “Outside world”. For example
“input sensors” or “output actuators”. All IO points defined in the point
configurator can be used here.

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Which Symbols are available? Honeywell

Input Type Source

Analog Input Field Equipment

Boolean Input Field Equipment, Process Computer, Other Safety Manager

Numerical Input Field Equipment Process Computer, Other Safety Manager

Diagnostic Input Diagnostic status of Safety Manager IO Interfaces

Loop Status Input Field loop status of Safety Manager IO interfaces with loop
monitoring
System Alarm Input Safety Manager controller

Sheet Transfer Other FLDs

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Which Symbols are available? (Cont’d) Honeywell

Output Type Destination

Analog Output Field Equipment

Boolean Output Field Equipment, Process Computer, SMs

Numerical Output Field Equipment, Process Computer, SMs

Sheet Transfer Other FLDs

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Drawing Logic’s Honeywell

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Drawing Logic’s (Cont’d) Honeywell

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Drawing Logic’s (Cont’d) Honeywell

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Counters Honeywell
• The counter symbol can be used to count 1 up (or down) per cycle.
• If the counter reaches the maximum counter value, it will be
automatically reset to 0

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Registers Honeywell
• A Register can be used as:
– Storage element of intermediate calculation results.
– Memory element for numbers, and
– Counter for large numbers.

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Timers Honeywell
• The following time functions are available:
– Pulses
– Timers with constant timer value
– Timers with variable timer value

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Constants Honeywell
• A constant is a unit that outputs a constant value to the Logic

• When adding a constant the type and the value of the constant should
be entered.

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Sheet Transfers Honeywell
• Sheet transfers are used to connect an output (off-sheet) of one FLD
with an input on another FLD

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Sheet Transfers (Cont’d) Honeywell
• The left pane lists all possible
sheets. By selecting the
desired destination sheet and
clicking the “Point selection”
button the correct connection
between sheets can be made

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FLD Control Functions Honeywell

Data type conversion INT SINT

functions DINT INT, SINT
Real DINT, INT, SINT

Boolean functions Boolean Constant, AND, OR, XOR, NOT, NAND, NOR,
XNOR, flip-flop set and reset dominant

Arithmetic functions Numerical Constant, AND filter, ADD, SUB, MUL, DIV, SQR,
SQRT, in(x) exponents

Comparison functions EQ, NEQ, GT, GTE, LT, LTE

Timer functions (with constant Pulse, Pulse-retriggerable, Delayed-ON, Delayed-Off,

or variable values) Delayed-ON memorize

Count and Storage Functions Counter, Register

User-definable blocks Equation Block, Function Blocks

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Drawing Connection Lines Honeywell
• To draw connection lines between symbols:
– Select the correct connection line from the symbol library (select the single
or double line). Use a single line for Boolean data and use a double line for
Value (e.g. analogue as float) data

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Drawing Connection Lines (Cont’d) Honeywell
• To draw connection lines between symbols:

– Select the relevant connection line from the symbol library (select the
connection lines tab).

– Use a single line for Boolean data and use a double line for analogue data.

– Click the starting point of the connection line.

– Route the connection line to the end point. Using the left mouse button,
corners or connections of lines to symbols can be made.

– Use the right mouse button to end the line without connecting it.

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Topics Honeywell
• What is the Application Editor?

• How Can a Logic Sheet be Created?

• What are Additional Features?

• What are the engineering considerations using the Application Editor?

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Additional Features Honeywell

Drag Dragging a symbol will change its location, but leave its
connection intact.

Move When moving a symbol, its location will change, but the
connection lines will be left in place.

Change Some symbols (for example an AND-gate) can be

changed in size.

Delete Deleting a symbol

Help By pressing “help” or F1 additional information will appear

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Copy a FLD Honeywell
• With the Copy FLD function it’s possible to copy an existing FLD into the
current FLD
• To open the “FLD copy” window select FLD>COPY from the menu, or
use the button

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Import FLD’s Honeywell

• With the Import FLD’s function it is possible to import one ore more
FLD’s from another Safety Manager system into the current application
including all the tag numbers from the imported FLD’s

• To open the “Import FLD’s” window select FLD>IMPORT FLD’s from the
menu, or use the button

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Import FLD’s (Cont’d) Honeywell

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Deleting an FLD Honeywell

• A complete FLD can be deleted via the button.

Or by selecting FLD> Clear FLD from the menu.

• If an FLD was deleted by mistake, the FLD can be undeleted by using

the button This option is only available direct after the
FLD was deleted.

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Re-number an FLD Honeywell
• To renumber an existing FLD click on Renumber FLD and change the
FLD number

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Browse through FLD’s Honeywell
• With the Forward and Back buttons it is possible to browse through the
FLD’s

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Zoom in/Zoom out Honeywell
• This zoom in/zoom out functionality will use increments of 10%

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Import/Export FLD Properties Honeywell
• FLD Properties can be imported or exported in Excel Sheet

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Topics Honeywell
• What is the Application Editor?

• How Can a Logic Sheet be Created?

• What are Additional Features?

• What are the engineering considerations using the Application Editor?

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Engineering considerations using the Application Editor Honeywell
• Following issues must be taken into account when drawing FLD’s:
– Prevent loop-back references as much as possible
– Avoid as much as possible line crossings and angles in lines
– Keep FLD’s survey able, clear and easy to understand

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Summary Honeywell

• What is the Application Editor?

– Tool to create Functional Logic Diagrams (FLD’s) in a easy way
• What are the different components of the Application Editor?
– Symbol library toolbar
– FLD’s bar
– Design screen
• How to create FLD’s with the Application Editor?
– Using the Application Editor
– Drawing Logic
– Symbols
• What are the engineering considerations using the Application Editor?
– Prevent loop-back references as much as possible
– Avoid as much as possible line crossings and angles in lines
– Keep FLD’s survey able, clear and easy to understand

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Test Questions: Question 1 Honeywell
• Question 1: What are FLD’s?

a) Combination of logic operators that connects input signals with

output signals

b) Logic symbols

c) Inputs and outputs

d) Network connections

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Test Questions: Question 2 Honeywell
• Question 2: Which button can be used to copy a sheet from another
system of another plant?

a) Save FLD

b) Copy

c) Copy FLD

d) None of the above

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Test Questions: Question 3 Honeywell
• Question 3: Is it possible to undelete a deleted FLD sheet?

a) Yes, this is always possible

b) Yes, but only direct after the deletion is performed

c) No

d) None of the above

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Test Questions: Question 4 Honeywell
• Question 4: Which symbol can be used to connect a sheet with another
sheet?

a) Timers

b) Constants

c) A Boolean or Binary off-sheet transfer

d) Registers

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Test Questions: Question 5 Honeywell
• Question 5: What are the engineering considerations using the
Application Editor?

a) Keep FLD’s survey able, clear and easy to understand

b) Avoid as much as possible line crossings and angles in lines

c) Prevent loop-back references as much as possible

d) All of the above

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Conclusion Honeywell

Describe Application Editor for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: Application Editor
Contents
Application Editor ............................................................................................................................ 3

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Application Editor
Introduction
The objective of Creating Functional Logic Diagram and Compile the Application is met
with this lab exercise
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module Application Editor
• Safety Builder installed on a PC
• Executed lab exercise Point Configurator
• Safety Manager™ training unit shots/pictures
Description
This lab procedure describes how to create Functional Logic Diagrams, using the
Application Editor. After the FLDs are created the application will be compiled using the
Application Compiler.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. Once done just press OK.

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Functional Logic Diagrams
The following FLD sheets will be used in the lab procedure.
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Application Editor Lab procedures
Practice

Step Action

Create FLD 2490

1 Make sure that the system is selected in the Network Configurator. This can be done
by double clicking the Controller symbol.

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Step Action

2 Open the Application Editor by pressing the “Application Editor” button.

3 Click on Create New FLD

 Step Action

The Create FLD window appears. Fill in the Sheet number: 2490 and Press Tab

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Step Action

5 Fill in the Title and select the Block type. For FLD 2490 the following information is
applicable:
Title: Voter 2oo3
Block type: Function block
Execution environment: All
Press OK after the information is filled in.
 Step Action

6 Now draw the Function block:

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Step Action

7 Start by drawing the input symbols. Select the Boolean input for Function
blocks from the Function blocks palette.

Use the mouse to move the input symbol to the correct spot and fix it by clicking the left
mouse button.

After the symbol is fixed the properties window appears. Fill in the Description of this
symbol. In this case it is the letter A. Repeat this step for other inputs of this Function
block.
 Step Action

8 After the input symbols draw all the logic symbols of Function block 2490. Select the And
gate from the Logical Palette.

After the And gate is selected the Symbol properties window appears. This window is
used to define the height of the And gate. Choose the correct height and press OK.

Now use the mouse to move the And gate to the desired spot and fix it by clicking the left
mouse button.

Repeat step 8 for all AND and OR gates of this Function block.

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Step Action

9 Select the Delayed Off timer with constant timer value from the Counters,
Registers and Timers Palette of the Symbol library toolbar.

Use the mouse to move the timer to the correct spot and fix it by clicking the left mouse
button.

After the timer is fixed the Timer properties window appears. Select Seconds (s) as the
Timer base and fill in 15 as the Timer value. Press OK after the properties are
altered.
 Step Action

10 Draw the outputs for FLD 2490. This can be done in the same way as the inputs.
So repeat step 7 but now choose Boolean output for Function blocks, instead
of Boolean input for Function blocks.

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Step Action

11 The last step for drawing the function block is to connect the symbols. Select the Single
line. The mouse pointer will be changed into a cross.

Move the cross over a symbol,

Left click and drag a line from the input to the And gate. Fix the line by dragging it into
the And gate and left click.

Repeat this step for all the connecting lines.

TIP
The short cut key of the Single line is S. Pressing
S in the Application Editor will change the mouse
pointer into a cross.
 Step Action

Intellectual Property (IP) FLD Protection

1 To Password protect the FLD enable IP protection in SM Controller Properties

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Step Action

2 When IP Protection is enabled ‘Password’ and ‘Confirm Password’ option in FLD

properties is enabled

Enter the Password to protect FLD and Click OK

3 After enabling IP Protection option in SM Controller Properties and entering the

Password in FLD Properties, FLD cannot be viewed in offline and online mode without
entering the password

4 All or selected FLDs in application editor can be password protected

 Step Action

Create FLD 10

1 Click on Create New FLD

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Step Action

2 The Create FLD window appears. Fill in the Sheet number: 10 and Press Tab
 Step Action

3 Fill in the Title and select the Block type. For FLD 10 the following information is
applicable:
Title: Input validation
Block type: Program block
Execution environment: MySMController_XX

Press OK after the information is filled in.

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Step Action

4 Now draw FLD 10:

 Step Action

5 Start by drawing the input symbols. Select the Analog input from the IO palette from
the Symbol library toolbar.

Use the mouse to move the input symbol to the correct spot and fix it by clicking the left
mouse button.

After the symbol is fixed the Select point dialog appears. Select the correct Tag
number, by left clicking it and press OK. Repeat step 5 for all the inputs of this FLD. Be
aware that other Inputs of FLD 10 are digital Inputs.

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Step Action

6 After the input symbols draw all the logic symbols of program block 10. In this part of the
procedure we will explain only the symbols, which were not yet used in the previous part
of this lab procedure.
We will start this part of the procedure with the Constant Value.

Select the Constant value symbol from the Other Palette. After the Constant
value is selected the Constant properties window appears. In this window select Float
as the Constant type and fill in the Value of the constant. In FLD 10, the Constant
values 20 and 70 are used.
After the value is entered press OK and fix the symbol on the sheet.

The next symbol which is on FLD 10 is the Greater Than OR Equal gate.
 Step Action

7 Select the Greater Than OR Equal gate from the Compare & Calculation palette
and fix the symbol on the correct spot on the sheet.

The last special logic symbol is the Function Block symbol. Select it from the
Function & Equation blocks Palette and fix the symbol on the correct spot on the
sheet.

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Step Action

8 Now draw the outputs for FLD 10. This sheet contains a special type of output; the Off-
sheet transfer.

Select the Boolean off-sheet transfer from the IO Palette and fix the symbol at
the correct spot on the sheet.

After the Off-sheet transfer is fixed the Sheet transfer properties window
appears.
The Destination is the FLD number were the Off-sheet transfer is connected via
an On-sheet transfer. In this case FLD 20 does not exist yet. So the destination
should be left 0. The Description as: flow range and the Status as: OK must be
filled in. Then press OK.

Repeat this step for the other Off-sheet transfers on this FLD.
The digital output of FLD 10 can be done in the same way as the inputs of this sheet. So
repeat step 5. But now choose the digital output symbol.
 Step Action

9 The last step for drawing FLD 10 is to connect the symbols. Select the Double line.
The mouse pointer will change into a cross. Move the cross above the Analog input
and left click.

Drag the line to the Greater than OR equal gate, create corners by left clicking and
fix the line by dragging it into the symbol and left click.

TIP
The short cut key of the Double line is D. Pressing
D in the Application Editor will change the mouse
pointer into a cross.
Repeat this step for all Double lines of FLD10 and
do the same for all the single lines.

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Step Action

Create FLD 20

1 Click on Create New FLD

 Step Action

2 The Create FLD window appears. Fill in the Sheet number: 20 and Press Tab

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Step Action

3 Fill in the Title and select the Block type. For FLD 10 the following information is
applicable:
Title: Field Control 1
Block type: Program block
Execution environment: MySMController_XX

Press OK after the information is filled in.

 Step Action

4 Now draw FLD 20:

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Step Action

5 Start by drawing the input symbols. This sheet contains a special type of input: the On-
sheet transfer.

Select the Boolean on-sheet transfer from the tab IO Palette and fix the symbol at the
correct spot on the sheet.
 Step Action

6 After the On-sheet transfer is fixed the Sheet transfer properties window appears. The
goal is now to connect the On-sheet transfer to the correct Off-sheet transfer. This can
be done by pushing the button Point Selection.

7 After Point Selection is pushed, the Sheet transfer properties window appears. This
window provides a list of all the available Off-sheet transfers. Select the appropriate Tag
number, push the > button and press OK.

For the digital Inputs of this sheet, just repeat step 5 of the procedure for FLD 10. But
now choose the digital input symbol instead of the Analog input signal.

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Step Action

8 After the input symbols are created, draw all the logic symbols of Program block 20. In
this part of the procedure we will explain only the symbols, which were not yet used in
this lab procedure.
FLD 20 only contains one symbol that has not been used yet: Pulse Retriggerable
timer with constant timer value. Select this symbol from the Counters,
Registers and Timers Palette in the Symbol library toolbar.

Use the mouse to move the timer to the correct spot and fix it by clicking the left mouse
button.

After the timer is fixed the Timer properties window appears. Select Seconds (s) as the
Timer base and fill in 15 as the Timer value. Press OK after the properties are altered.

9 Now draw the outputs of FLD 20 (this is already explained during creation of FLD 10).
 Step Action

10 The last step for drawing FLD 20 is to connect the symbols (this is already explained
during creation of FLD 2490 and FLD 10).

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 Step Action

Create FLD 30

1 Click on Create New FLD

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Step Action

2 The Create FLD window appears. Fill in the Sheet number: 30 and Press Tab
 Step Action

3 Fill in the Title and select the Block type. For FLD 10 the following information is applicable:
Title: Field Control 2
Block type: Program block
Execution environment: MySMController_XX

Press OK after the information is filled in.

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Step Action

4 Now draw FLD 30:

 Step Action

5 Start by drawing the input symbols. This sheet contains a special type of on-sheet transfer:
the Binary On-sheet transfer that is directly linked to an analog Input.

Draw this On-sheet transfer by repeating step 5 of FLD 20. Instead of choosing a Boolean
On-sheet transfer, choose the Binary On-sheet transfer.

After the Sheet transfer properties are done, a box will be created with the information of
the analog input on sheet 10. This only occurs in the case of a direct connection to an input
signal.
For the digital Inputs of this sheet, just repeat step 5 of the procedure for FLD 10. But now
choose the digital input symbol instead of the Analog input signal.

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Step Action

6 Draw all the logic symbols of program block 30. We will explain only the symbols, which were
not used before in this lab procedure.
To draw the Set Reset Flip-flop, select it from the Logical Palette and fix the symbol at the
correct spot.
 Step Action

7 The next logic symbol is the Addition gate. Select the Addition gate from the Compare &
Calculation Palette and fix the symbol at the correct spot.

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Step Action

8 The final logic symbol is the Register. Select this symbol from the Counters, Registers and
Timers Palette and fix it at the correct spot.

9 Now draw the outputs of FLD 30 (this is already explained during creation of FLD 10).

10 The last step for drawing FLD 30 is to connect the symbols (this is already explained during
creation of FLD 2490 and FLD 10).
 Step Action

Create FLD 40
(This FLD is only to be created when RUSIO modules are connected)

1 Click Create New FLD

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Step Action

2 The Create FLD window appears. Fill in the Sheet number: 40 and Press Tab
 Step Action

3 If you have RUSIO modules connected to your system, fill in the Title and select the Block
type. For FLD 40 the following information is applicable:
• Title: Field Control RUSIO
• Block type: Program block
• Execution environment: MySMController_XX

Press OK after the information is filled in. Continue with step 5.

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Step Action

4 If you have RUSLS modules connected to your system, fill in the Title and select the Block
type. For FLD 40 the following information is applicable:
• Title: Field Control RUSLS
• Block type: Program block
• Execution environment: IOTA_1

Press OK after the information is filled in. Continue with step 5.

 Step Action

5 Now draw FLD 40:

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Step Action

6 Start by drawing the input symbols. This sheet contains only inputs which were used before
in this lab procedure. For the Analog input signal of this sheet, just repeat step 5 of the
procedure for FLD 10.
For the digital Inputs of this sheet, just repeat step 5 of the procedure for FLD 10. But now
choose the digital input symbol instead of the Analog input signal.

7 Draw all the logic symbols of program block 40. This sheet contains only symbols, which
were used before in this lab procedure.

8 Now draw the outputs of FLD 40 (this is also already explained during the creation of FLD
10).

9 The last step for drawing FLD 40 is to connect the symbols (already explained during the
creation of FLD 2490 and FLD 10).
 Application Editor
Application Editor

Step Action

Compile the Application

1 Select the Application Compiler by pressing the “Application Compiler” button.

2 Confirm the selection of the Application Compiler, by pressing Yes.

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 Application Editor
Application Editor

Step Action

3 If the compilation is successful, the last message of the compiler log file is: Compilation
completed.

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 Application Editor
Application Editor

Step Action

4 If there are errors in the application, it will show in red in the Application Log File. And
the indication ERROR will be in front of the message. The last message of the Compiler
Log File will be: Compilation not completed correctly.

TIP
Solve the errors and repeat steps 1, 2 and 3 of this
procedure until the compilation is successful.
If you are unable to solve the errors, seek help from
your Instructor.

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 Application Editor
Application Editor

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 On-line Environment

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Introduction Honeywell
• Module Description:
– This module is part of the software section of the training courses for Safety
Manager
– It will give a detailed insight in the On-line part of the Safety Builder of Safety
Manager

• Job Importance:
– This module is important for everyone who is doing Engineering, Operations
or Troubleshooting and Maintenance

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Topics Honeywell
• What is the On-line environment of Safety Builder?

• How can Controller Management be used?

• How can Point Viewer be used?

• How can Application Viewer be used?

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On-line Environment of Safety Builder Honeywell
• User Interface to Safety Manager systems

Manage a Safety
Manager system
On-line

Safety Station

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Online Honeywell

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Topics Honeywell
• What is the On-line environment of Safety Builder?

• How can Controller Management be used?

• How can Point Viewer be used?

• How can Application Viewer be used?

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Controller Management Honeywell

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How to Load A Controller Honeywell

More than one

Controllers

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Load Controller Honeywell

• Download a system which is off-line

• Download a system via an On Line
modification

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Load Application to an Off-line Safety Manager Honeywell

Control Processor 1 BKM Control Processor 2

Halt Halt

Download
Application.

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Load Application to an Off-line SM (Cont’d) Honeywell

Control Processor 1 BKM Control Processor 2

Halt Halt
Application
downloaded

Loading the application from CP1 to CP2.

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• Start the system by turning the keys on both QPP’s to Run (CP Ready)
and toggling the Reset key on the BKM

Control Processor 1 BKM Control Processor 2

CP Ready CP Ready
Application Application
downloaded downloaded

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• System is now running on the downloaded application

Control Processor 1 BKM Control Processor 2

Running Running

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To Load the
controller

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Instruction Bar

Execute
Button

Status
Area

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Progress Bar

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System Information Honeywell

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Status Control Processors Honeywell

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Information About Forces Honeywell

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Controller Temperature Honeywell

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Status and Temperature RUSIO Modules Honeywell

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Communication Status Honeywell

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Communication Statistics Honeywell

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Link Status Report Honeywell

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Actual Diagnostics Honeywell

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Actual Diagnostics (Cont’d) Honeywell

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Actual Diagnostics (Cont’d) Honeywell

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Actual Diagnostics (Cont’d) Honeywell

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Actual and Historical Diagnostics Honeywell

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Actual and Historical Diagnostics (Cont’d) Honeywell

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Actual and Historical Diagnostics (Cont’d) Honeywell

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Actual and Historical Diagnostics (Cont’d) Honeywell

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Actual and Historical Diagnostics (Cont’d) Honeywell

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Diagnostics from Database Honeywell

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Loop Monitoring Honeywell

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Loop Monitoring (Cont’d) Honeywell

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Loop Monitoring (Cont’d) Honeywell

Update the
Screen

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Time Synchronization Honeywell

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Time Synchronization (Cont’d) Honeywell

Honeywell Confidential
On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
40 12/16/2016
Remote Reset Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Remote Reset (Cont’d) Honeywell

Honeywell Confidential
On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
42 12/16/2016
Remote Reset (Cont’d) Honeywell

Honeywell Confidential
On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Remote Reset (Cont’d) Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Topics Honeywell
• What is the On-line environment of Safety Builder?

• How can Controller Management be used?

• How can Point Viewer be used?

• How can Application Viewer be used?

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Point Veiwer Honeywell

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Create Screen Honeywell

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Add Point Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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View Application Value Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Point Properties Honeywell

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Point Properties (Cont’d) Honeywell

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Force Point Honeywell

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Point Forced Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Channel Defect Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
54 12/16/2016
View all Forces Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
55 12/16/2016
Clear All Forces Honeywell

Honeywell Confidential
On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
56 12/16/2016
Write Point Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
57 12/16/2016
Topics Honeywell
• What is the On-line environment of Safety Builder?

• How can Controller Management be used?

• How can Point Viewer be used?

• How can Application Viewer be used?

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Application Viewer Honeywell

Honeywell Confidential
On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Application Viewer (Cont’d) Honeywell

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Application Viewer (Cont’d) Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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FLD’s Online Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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For Logic “1” and Logic “0” Honeywell

High (Logic 1)

Low (Logic 0)

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Analogue Value Honeywell

Analogue Value

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To Find the Point Honeywell

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Use Sheet Markers Honeywell

Double Click

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How to Force the Point Honeywell

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Force Point (Cont’d) Honeywell

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Force Point (Cont’d) Honeywell

Application value = High (Logic “1”)

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View All Forces Honeywell

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Clear All Forces Honeywell

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On-line Environment Copyright © 2014 Honeywell International Inc. On-line Environment
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Write Option Honeywell

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Summary Honeywell
• What is the On-line environment of Safety Builder?
– Controller Management
– Application Viewer
• How can Controller Management be used?
– System Information
– Communication Statistics
– Load Controller
– Actual and Historical diagnostics
– Diagnostics from Database
– Loop Monitoring
– Time Synchronization
– Remote Reset

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Summary Honeywell
• How can Point Viewer be used?
– Build screens for live monitoring of process values
– Force Points
– Write Points
• How can Application Viewer be used?
– Live monitoring of FLD’s
– Force Points

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Test Questions: Question 1 Honeywell
• At which part of the On-line environment can it be viewed if the Force
enable key is activated?

a) View All Forces

b) Actual Diagnostics

c) Load Controller

d) System Information

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Test Questions: Question 2 Honeywell
• When are the Actual Diagnostics moved to the Historical diagnostic
buffer?

a) Every hour

b) Never

c) When the Reset key is cycled

d) When the Actual Diagnostic buffer is full

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Test Questions: Question 3 Honeywell
• At which occasion does a code need to be retyped when a Remote
Reset is performed?

a) At all times

b) When a Control Processor is started

c) When a Safety Related Fault is present

d) Answers b & C are correct

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Test Questions: Question 4 Honeywell
• What are possibilities to navigate through on-line FLD’s?

a) Find Point

b) Clear all forces

c) Double click on- and off-sheet markers

d) Answers a and c are true

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Test Questions: Question 5 Honeywell
• What can be viewed at Actual Diagnostics?

a) Any detected fault which exists in the system at the moment

b) All the diagnostics which are relevant for the user

c) All detected faults form start up of the system

d) None of the above

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Conclusion Honeywell

Describe Online Environment for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: On-line Environment
Contents
On-line Environment ........................................................................................................................ 3

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 On-line Environment
On-line Environment

On-line Environment
Introduction
The objective of Loading an application and using the Application Viewer to implement
forces are met with this lab exercise,

Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module On Line environment
• Safety Builder installed on a PC
• Safety Manager™ system, with Remote Universal Safe I/O modules connected
• Ethernet connection between Safety Station and Safety Manager system
Description
This lab procedure describes how to load an application to a Safety Manager system,
which is in off-line mode. After the system is running on the loaded application, the
Application Viewer will be used to put forces on the points.
Audit trail

TIP
Audit Trail is an integrated tool, which logs all the
changes that are made to the application.

At some stages when executing the procedure, a window as shown in figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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On-line Environment

On-line environment lab procedures

Practice

Step Action

Set IP address of the Safety Station

™
1 To be able to communicate with the Safety Manager training unit, we have to set the IP
address of the PC (the Safety Station). We will explain this routine for Windows 7/ 2008
users.
Push the Start button and select Control Panel.
Click on Network and Sharing Centre from the All Control Panel Items menu.

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On-line Environment

Step Action

2 Select the Ethernet connection that is used to connect to the Safety Manager training
unit. Click on the connection.

TIP
The above screenshot is just an example. If you are
not sure which one is the correct connection, ask your
instructor.

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On-line Environment

Step Action

3 Select Internet Protocol (TCP/IP) by left clicking it and press the Properties button.

4 Select Use the following IP address and fill in the IP address and Subnet mask that is
given by the instructor. Make sure to press the Tab key of the PC keyboard after both the
addresses are filled in.

After the information is filled in press OK twice.

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On-line Environment

Step Action

Check the connection

1 Push the Start button and select All Programs > Accessories > Command prompt.

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On-line Environment

Step Action

2 Type in ping followed by the IP address that was used in the Network Configurator to
configure the connection between the Safety Station and the Safety Manager system.
The instructor will supply this IP address.
After the information is typed in, press the Enter key of the PC keyboard.

TIP
The IP address that is used for this screenshot is just an example.

3 Check the ping statistics:

• If the 4 packages are received and 0 lost, the connection is OK.
• If the statistics are different inform the instructor.

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On-line Environment

Step Action

Load the application

1 Make sure that the system is selected in the Network Configurator. This can be done
by double clicking the Controller symbol.

2 Select Controller Management via the Tools > On-line menu.

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On-line Environment

Step Action

3 Check if the connection with the Controller is established. The buttons System
Information, Actual Diagnostics, Actual and Historical Diagnostics, Diagnostics
from Database and Load Controller should be available.

If connection is not established, inform the instructor.

Make sure that the key switches of both the QPP’s of the Controller are in the idle
position.

5 Push the Load Controller button.

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Step Action

6 Press the Start button to start loading of the Control Processor.

7 Press the Continue button to load the redundant Control Processor.

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On-line Environment

Step Action

8 Turn the key switch of both the Control Processors in the Run position and wait until both
the Control Processors show CP Ready on the QPP display. This can take some time!
Now cycle the Reset key switch on the BKM to start-up the redundant Control Processor.

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Step Action

9 The system is now running. The Load Controller screen is showing the following
message:

10 Check the display of the QPP of both the Control Processors. The message Running
should be displayed.

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On-line Environment

Step Action

Force Digital Input

The goal of this part of the Lab exercise is to force the digital input with tag number XX-
PZA-003 High. After the force is set, we will clear it.
Start by setting the Force enable key on the BKM in the ON position.

2 Select the Application Viewer by pushing the related button.

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On-line Environment

Step Action

3 Push the Find point button, select Point type DI and select the tag number XX-PZA-003.

4 Right click XX-PZA-003 and select Force.

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On-line Environment

Step Action

5 Select High and press OK.

Now change the simulated Field Value by toggling the associated switch (s3 on SIMSDI-
6 1624, Chassis 02, and position 3) and check for any changes in the Application Viewer.

7 XX-PZA-003 is now forced. The letter H is indicating the scan value.

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Step Action

8 To clear the force on XX-PZA-003, right click the point and select Clear.

9 Now force the point high again before continuing.

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On-line Environment

Step Action

Force Analog Input

1 The goal of this part of the Lab exercise is to force the Analog input on FLD 10 to 50
m3/hr. After the force is set we will clear it.

Double click on FLD 10 in the FLD bar.

2 Right click on the Analog input symbol and select Force.

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On-line Environment

Step Action

3 Enter 50 in the Force XX-FEA-001 window...

... and press OK.

4 The analog value is now forced. The scan value is indicated in the column next to the
analog input symbol.

5 Now change the simulated field value by turning the associated knob () and check for
any changes in the Application Viewer.

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Step Action

6 Press the View all forces button to get an overview of all the points with an active force.

7 The list with all active forces shows the Actual value (scan value) and the Forced value
of the points.

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Step Action

8 Now clear all the forces by pushing the button Clear All Forces.

9 Press OK to confirm the Clear of all Forces.

10 If now the button View all Forces is pushed the message...

... is displayed.

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On-line Environment

Step Action

Creating and using Screens

The goal of this part of the lab exercise is to create a Screen and use it for monitoring
XX-PZA-003 and XX-FE-001 at the same time, although they are not on the same FLD.
We will also force the points from the Screen. After the forces are set we will clear them.
Start by making sure the Force enable key on the BKM is in the ON position.

2 Select the Point Viewer by pushing the related button.

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Step Action

3 Create a New Screen and set its name to My Screen.

... and press OK.

4 The Screen is now created and we can add points to the 64 available slots.

Use the Add Point function to add the points XX-PZA-003 and XX-FE-001 to your
Screen.

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Step Action

5 Force the Digital Input point XX-PZA-003 High and the Analog Input XX-FE-001 to 50
M3/h.
6 Now change the simulated field values for the points using the associated knob and
switch and check for any changes in the Point Viewer.
7 Now clear the forces by pushing the buttons Clear Force and Clear All Forces.

8 Press OK to confirm the Clear of all Forces.

9 If now the button View all Forces is pushed the message...

... is displayed.

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 System Fault Reactions

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
1 12/16/2016
Introduction Honeywell
• Module Description:
– This training module is a part of the System Diagnostics section of the
training courses for Safety Manager
– It describes the System Fault Reactions of Safety Manager

• Job Importance:
– The module is important for everyone who is doing Planning & Design,
Engineering and Troubleshooting & Maintenance related to Safety
Manager

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
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Topics Honeywell
• How does Safety Manager react to faults in a general way?

• Can the user influence the fault reaction?

• How does Safety Manager react to IO faults?

• What are the Engineering considerations?

• What are the Troubleshooting & Maintenance considerations?

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
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How does SM React to Faults in a General Way? Honeywell
• Diagnostics within Safety Manager
– Memory check on processor and communication modules;
– Voting on processor level (1oo2D)
– Independent Watchdog
– System Cycle Time check
– Walking bit tests on data-busses
– System temperature check
– Voltage monitoring
– Etc, etc, etc …………..

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General Fault Reaction Safety Manager Honeywell
• Store fault in actual diagnostic buffer
Display fault message on QPP

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QPP Overview Honeywell

Running/
Wth FLT

QPP-000x

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General Fault Reaction Safety Manager Honeywell
• Store fault in actual diagnostic buffer
• Display fault message on QPP
Set applicable alarm markers to “0”

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Alarm Markers Examples Honeywell

TempL_Alarm

Source: Honeywell SMS Safety manual

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
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General Fault Reaction Safety Manager Honeywell
• Store fault in actual diagnostic buffer
• Display fault message on QPP
• Set applicable alarm markers to “0”
If the fault is critical for safety, it will be isolated

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Digital Output Safety Manager Honeywell
+ 24 Vdc

Secondary means
of de-energization
& “0” de-energized

CPU STATUS
Short circuit

STATUS
Defect

LOAD,
“0” de-energized
e.g. SOV
0 Vdc

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
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Topics Honeywell
• How does Safety Manager react to faults in a general way?

• Can the user influence the fault reaction?

• How does Safety Manager react to IO faults?

• What are the Engineering considerations?

• What are the Troubleshooting & Maintenance considerations?

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Can the User Influence the Fault Reaction? Honeywell
• Fault reaction settings:
– Controller and Universal Safety IO temperature limits
– Repair Timer
– Diagnostic Test Interval
– Communication Timeout
– Clock Source Timeout
– IO Point settings

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System Temperature Limits Honeywell

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Universal Safety IO Module Temperature Limits Honeywell

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Repair Timer Honeywell

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Diagnostic Test Interval Honeywell

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Communication Time-Out Honeywell

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Clock Source Timeout Honeywell

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Topics Honeywell
• How does Safety Manager react to faults in a general way?

• Can the user influence the fault reaction?

• How does Safety Manager react to IO faults?

• What are the Engineering considerations?

• What are the Troubleshooting & Maintenance considerations?

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Diagnostics Copyright © 2014 Honeywell International Inc. System Fault Reactions
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How does Safety Manager React to I/O Faults? Honeywell
• General I/O fault reaction:
– Fault stored in Actual diagnostic buffer
– Display fault message on QPP
– Input/Output Fault alarm marker set to “0”

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Input/Output Fault Alarm Marker Honeywell

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General IO Fault Reaction Honeywell
• Fault stored in Actual diagnostic buffer
• Display fault message on QPP
• Input/Output Fault alarm marker set to “0”
• Diagnostic Marker(s) of faulty channel set to “0”

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Diagnostic Marker Honeywell

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General IO Fault Reaction Honeywell
• Fault stored in Actual diagnostic buffer
• Display fault message on QPP
• Input/Output Fault alarm marker set to “0”
• Diagnostic Marker(s) of faulty channel set to “0”
• Fault reaction depends on
– Fault Reaction setting (Point level)
– Redundant or Non Redundant IO

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Fault Reaction Setting Honeywell

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Safety Manager Architectures Honeywell

Non Redundant Redundant Controller Full Redundant

Architecture Non Redundant IO Architecture

I I I I

CP1 CP1 CP2 CP1 CP2

O O O O

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Digital Input Fault Reaction Honeywell

• Safe reaction:
• Low
• High
• Not Safe reaction:
• Scan
• Hold

All DI points on the same local Digital Input or remote RUSIO

module can have a different fault reaction setting

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Digital Input Fault Reaction (Cont’d) Honeywell

Non Redundant
Architecture

DI

CP1

DO

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Chassis Non Redundant DI Honeywell
Normal process
status “1” Fault reaction: Low

Fault Sensor
DI

CP1 Sensor = “0”

“0”

DO

Actuator

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Chassis Non Redundant DI (Cont’d) Honeywell
Normal process
status “0”
Fault reaction: High

Fault Sensor
DI

CP1 Sensor = “1”

“1”

DO

Actuator
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Chassis Non Redundant DI (Cont’d) Honeywell
Normal process
status “0” or “1”
Fault reaction: Scan

Fault Sensor
DI

CP1 Sensor = “Scanned Value”

“Scanned Value”
DO

Actuator
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Chassis Non Redundant DI (Cont’d) Honeywell
Normal process
status “0” or “1”
Fault reaction: Hold

Fault Sensor
DI

CP1 Sensor = “value before fault”

“value before fault”

DO

Actuator
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Redundant Controller & Chassis Non Redundant DI Honeywell
Normal process
status “1”

Fault Sensor Fault reaction: Low

DI

Sensor = CP1 CP2 Sensor = “0”

“0”

DO

Actuator
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Redundant Controller & Universal Safety Non Redundant DI Honeywell

Normal process Fault reaction: Low

status “1”

Fault
Sensor
RUSIO

Sensor =“0” CP1 CP2 Sensor = “0”

RUSIO

Actuator

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Redundant Controller & Universal Safety Non Redundant DI Honeywell

Normal process
status “1” Fault reaction: Low

Sensor

Fault
RUSLS Sensor = “0” Sensor = “0”CP1 CP2 Sensor = “0”

“0”

Actuator
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Redundant Controller & Chassis Redundant DI Honeywell
Normal process
status “1”

Sensor
Fault reaction: Low
Fault

DI DI Sensor = “1”

CP1 CP2 Sensor = “1”

DO DO

Actuator
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Redundant Controller & Universal Safety Redundant DI Honeywell
Normal process
status “1”

Sensor
Fault Fault reaction: Low
RUSIO RUSIO Sensor = “1”

CP1 CP2 Sensor = “1”

RUSIO RUSIO

Actuator
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Redundant Controller & Universal Safety Redundant DI Honeywell

Fault reaction: Low

Normal process
status “1”

Sensor

Fault
Sensor = “1” RUSLS RUSLS Sensor = “1” Sensor = “1” CP1 CP2 Sensor = “1”

Actuator
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Analog Input Fault Reaction Honeywell

• Safe reaction:
– Bottom scale
– Top scale
• Not Safe reaction:
– Scan
– Hold

All AI points on the same local Analog Input or remote RUSIO module
can have a different fault reaction setting

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Configure AI Honeywell

• In Main Tab • In Options Tab

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Non Redundant AI Honeywell
Analog process
value

Fault reaction: Bottom

Sensor Scale
Fault
AI

CP1 Sensor = “Bottom scale”

DO

Actuator
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Digital Output Fault reaction Honeywell

• Safe reaction:
– Low
• Not Safe reaction:
– Application

All DO points on the same Local Digital Output module should have the
same fault reaction setting. DO points on the same remote RUSIO
module can have different fault reaction settings

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Chassis Non Redundant DO Honeywell

Fault reaction: Low

Sensor
DI

Repair Timer
started

CP1 DO

1234 5678
Diagnostic routine to prove
0000 0000 that outputs are switched off.
DO
Fault
Confirmed
De-
De-energized
“0”
Module can be pulled from
Actuator the system without further
consequences.
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Chassis Non Redundant DO (Cont’d) Honeywell
• Fault reaction: Low 1oo2in1 S
Off1
&
Reset R
FF
>1 WDout
(redundant IO)

Sensor wired OR
Watchdog
DI section 1 &
Non Redundant WD
Repair Timer
1oo2in2 S
Off2 Is de-
de-energized
started
Reset R
&
CP1 DO FF

1234 5678
Watchdog
section 2 & >1 WDout
(single IO)
0000 0000 wired OR

single IO_ON
DO
Fault
Not confirmed 1oo2out1

FF
De-
De-energized
1oo2out2
“0”

Actuator FF

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 Redundant Controller & Chassis Non Redundant DO Honeywell

Fault reaction: Low

Sensor

DI
Repair Timer Repair Timer
started started

DO
CP1 CP2
Diagnostic routine to
1234 5678 prove that outputs are
0000 0000
switched off
DO
Fault Confirmed

De-
De-energized
“0” Module can be pulled
from the system without
Actuator further consequences
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Redundant Controller & Chassis Non Redundant DO (Cont’d) Honeywell
Off1
1oo2in1 S
&
Sensor
Reset R
FF
>1 WDout
(redundant IO)
wired OR

DI Watchdog
section 1 &
Repair Timer
started Non Redundant WD
1oo2in2 S
Off2 Is de-
de-energized
Reset R
&
CP1 CP2 DO
FF

1234 5678
Watchdog
section 2 & >1 WDout
(single IO)
0000 0000 wired OR

DO single IO_ON
Fault
Not confirmed 1oo2out1

FF
De-
De-
1oo2out2
energized
“0”
Actuator FF

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Redundant Controller & Universal Safety Non Redundant DO Honeywell

Fault reaction: Low

Sensor
RUSIO

CP1 CP2 RUSIO

DO
DO
DO
Repair Timer 1 2 3 4 5 6 7 8…
started 0
RUSIO
Fault
Normal process
status “1”

Actuator

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Redundant Controller & Universal Safety Non Redundant DO (Contd’) Honeywell

Fault reaction: Low

Sensor
RUSIO

CP1 CP2 RUSIO

DO
DO
DO
Module Repair Timer 1 2 3 4 5 6 7 8…
Halted expired 0 00
RUSIO
Fault
Normal process
status “1”

Actuator

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Redundant Controller & Chassis Redundant DO Honeywell

Fault reaction: Low

Sensor

DI DI

Repair Timer
started
CP1 CP2 DO
Diagnostic routine to
prove that outputs are
1234 5678
0000 0000

DO DO switched off.
Fault
“1” Confirmed

“1”
Normal process
Module can be pulled
status “1”
from the system without
Actuator further consequences.
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Redundant Controller & Local Redundant DO (Cont’d) Honeywell

Fault reaction: Low

Sensor

DI DI

CP Halted

CP1 CP2 DO

1234 5678
Diagnostic routine to
0000 0000 prove that outputs are
DO DO
Fault
switched off
Not
“1” Confirmed
“1”
Normal process
status “1” CP will be
halted
Actuator
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Redundant Controller & Universal Safety Redundant DO Honeywell

Sensor

RUSIO RUSIO Fault reaction: Low

CP1 CP2 RUSIO

DO

DO
DO
Repair Timer 1 2 3 4 5 6 7 8…
started 0
RUSIO RUSIO

“1” Fault

“1”
Normal process
status “1”

Actuator

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Redundant Controller & Remote Redundant DO (Cont’d) Honeywell

Sensor

RUSIO RUSIO Fault reaction: Low

CP1 CP2 RUSIO

DO

DO
DO
Module Repair Timer
1 2 3 4 5 6 7 8…
Halted expired 0 00
RUSIO RUSIO

“1” Fault

“1”
Normal process
status “1”

Actuator

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Short Circuit in the Loop Honeywell

Fault reaction: Low

DO

1234 5678
0 0

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Chassis Non Redundant DO Honeywell

Sensor
Fault reaction: Appl
DI

CP1

DO
Fault

“0” or “1”

Actuator
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Analog Output Fault Reaction Honeywell

• Safe reaction:
– 0mA
• Not Safe reaction:
– Application

• All AO points on the same Local Analog Output module should have the same fault
reaction setting. AO points on the same remote RUSIO module can have different
fault reaction settings

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Chassis Non Redundant AO Honeywell

Fault reaction: 0mA

Sensor

DI

Repair Timer
started

CP1 AO

1 2 Diagnostic routine to
prove that outputs are
0mA 0mA

switched off
AO
Fault
Confirmed

Module can be pulled from

0 mA.
the system without further
consequences
Actuator

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Redundant Controller & Chassis Redundant AO Honeywell

Sensor
Fault reaction: 0mA

DI DI

Repair Timer
started

CP1 CP2
AO
Diagnostic routine to
1 2 prove that outputs are
AO AO switched off
0mA 0mA
Fault
0 – 20mA.
20mA Confirmed

0 – 20mA.
20mA
Module can be pulled from
the system without further
Actuator consequences
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Redundant Controller & Chassis Redundant AO (Cont’d) Honeywell

Sensor
• Fault reaction: 0mA

DI DI

CP
Halted
CP1 CP2
AO
Diagnostic routine to
1 2 prove that outputs are
AO AO switched off
0mA 0mA
Fault
0 – 20mA. Not
Confirmed

0 – 20mA.
CP will be halted
Actuator
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Redundant Controller & Universal Safety Redundant AO Honeywell

Sensor Fault reaction: 0mA

RUSIO RUSIO

CP1 CP2
RUSIO

AO
AO
AO
Repair Timer 1 2 3 4 5 6 7 8…
started 0mA
RUSIO RUSIO
Fault
0 – 20mA.
20mA

0 – 20mA.
20mA

Actuator
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Redundant Controller & Remote Redundant AO (Cont’d) Honeywell

Sensor
Fault reaction: 0mA

RUSIO RUSIO

CP1 CP2
RUSIO

AO
AO
AO
Module Repair Timer 1 2 3 4 5 6 7 8…
Halted expired 0 00
mA mA mA
RUSIO RUSIO
Fault
0 – 20mA.

0 – 20mA.

Actuator
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Topics Honeywell
• How does Safety Manager react to faults in a general way?

• Can the user influence the fault reaction?

• How does Safety Manager react to IO faults?

• What are the Engineering considerations?

• What are the Troubleshooting & Maintenance considerations?

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What are the Engineering Considerations? Honeywell
• Points which are part of Safety Functions
and therefore have a SIL requirement 1,2 or 3……

• Need to be configured with a Safe fault reaction setting.

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Safe Fault Reaction Settings Honeywell
• Digital input

– Low - normally energized

– High - normally de-energized

• Analog Input

– Bottom scale - low trip point

– Top scale - high trip point

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Troubleshooting and Maintenance Considerations Honeywell
• If temperature > 75 degrees Celsius = Trip

Top Scale

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Safe Fault Reaction Settings Honeywell
• Digital output
– Low

• Analog output
– 0 mA

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Topics Honeywell
• How does Safety Manager react to faults in a general way?

• Can the user influence the fault reaction?

• How does Safety Manager react to IO faults?

• What are the Engineering considerations?

• What are the Troubleshooting & Maintenance considerations?

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Troubleshooting & Maintenance Considerations Honeywell
• Be aware how the system reacts, if Troubleshooting and Maintenance
actions are performed!

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Exchanging Chassis Non Redundant Input Modules Honeywell
Normal process Normal process
status status

Sensor
Sensor
I
Exchange I

CP1 CP1 CP2

O O

Actuator Actuator
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Exchanging Chassis Non Redundant Input Modules Honeywell
Normal process
Normal process
status
status

Sensor
Sensor
I
Forces I

CP1 CP1 CP2

O O

Actuator
Actuator
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Exchanging Chassis Redundant Input Modules Honeywell
Normal process
status “1”

Sensor

Exchange I I Process value

Process value CP1 CP2 Process value

O O

Actuator
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Exchanging Chassis Non Redundant Output Modules Honeywell
Normal process
status

Sensor

I • Before pulling the module check:

• Actual Diagnostics shows
Repair Timer message: ‘Module Faulty’
started

CP1
• No forces are applied on the
module

O
Exchange

Actuator
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Exchanging Chassis Redundant Output Modules Honeywell
Normal process
status

Sensor

I I • Before pulling the module check:

• Actual Diagnostics shows
message: ‘Module Faulty’
CP1 CP2 • No forces are applied on the
module

O O
Exchange

Actuator
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Exchanging Remote Redundant Universal Safety IO Modules Honeywell
Normal process
status “1”

Sensor

Exchange RUSIO RUSIO Process value

Process value CP1 CP2 Process value

!
RUSIO RUSIO

Actuator
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Exchanging Remote Redundant Universal Safety IO Modules Honeywell
Normal process
status

Sensor
!
RUSIO RUSIO

CP1 CP2

RUSIO RUSIO
Exchange

Actuator
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Summary Honeywell
• General fault reaction Safety Manager:
– Store fault in actual diagnostic buffer
– Display fault message on QPP
– Set applicable alarm markers to “0”
– If the fault is critical for safety, it will be isolated
• Fault reaction settings:
– Temperature limits
– Repair Timer
– Diagnostic Test Interval
– Communication Timeout
– Clock Source Timeout
– I/O Point settings
• I/O fault reaction:
– Fault reaction setting on point level;
– Safe settings;
– Not Safe settings.

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 Engineering, Troubleshooting & Maintenance Honeywell
• Engineering considerations:
– Use Safe settings if SIL 1,2 or 3 is required

• Troubleshooting & Maintenance considerations:

– Be aware how the system reacts, if Troubleshooting and Maintenance
actions are performed

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Test Questions : Question 1 Honeywell
• What are general System Fault Reactions?

a) Store fault in actual diagnostic buffer, display fault on the QPP, Set
applicable alarm markers to “0”

b) Set diagnostic Input marker to “0”

c) De-energize a group of output channels

d) None of the above.

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Test Questions : Question 2 Honeywell
• What is the Safe Fault reaction setting for Digital Output Points?

a) High

b) Low

c) Scan

d) Application

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Test Questions : Question 3 Honeywell
• Where can a communication time out be configured?

a) In the Point Configurator

b) At the properties of the Logical Network

c) It cannot be configured

d) At the Universal Safety Interface

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Test Questions : Question 4 Honeywell
• What are the Safe Fault reaction settings for Analog Input Points?

a) Application

b) Scan and Hold

c) Low and High

d) Bottom Scale and Top Scale

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Test Questions : Question 5 Honeywell
• What happens if a Local Digital Input module with the Fault Reactions
configured as “Low” is pulled from a full Non Redundant architecture?

a) Nothing

b) The Repair Timer is started

c) The Non Redundant Watchdog output is de-energized

d) The application value of all channels of the module will go to a “logic 0”

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Conclusion Honeywell

Describe System Fault Reactions for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: Diagnostics
Contents
Fault Reaction Implementation ........................................................................................................ 3

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 Diagnostics
Fault Reaction Implementation

Fault Reaction Implementation

Introduction
The objective of Creating an FLD for 2oo3 voting on temperature sensors with a high trip
point is met with this lab exercise:

Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module System Fault Reactions
• Safety Builder installed on a PC
• Safety Manager™ system, with Remote Universal Safe I/O modules connected and
the training application loaded
• Ethernet connection between Safety Station and Safety Manager system
Description
The temperature inside a reactor is at the moment measured by one temperature sensor.
To have a more reliable value, the existing sensor is going to be replaced by 3 new ones.
If the temperature inside the reactor rises above 85 degrees Celsius, the reactor has to
shut down. 2-o-o-3 voting will be applied on the individual trip values.
The change to the application will be done in a shutdown period. For the moment (for test
purpose) the trip value will be connected to a LED on a local panel.
Implementation
Add FLD 50 to the application, which was already created in the Safety Builder lab
procedures. Put the 3 temperature sensors and their individual trip values on this new
FLD. Use the 2-o-o-3 voter which already was created on Function Block 2490 to create
one trip value. Allocate the points to the hardware and set the correct fault response.
Compile the application, and load the application via an off line modification.

Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

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Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Fault reaction implementation lab procedures

Practice

Step Action

Make a back up of the project

1 Go to the Network Configurator and select the Plant. Select Backup Configuration
from the File menu.

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Step Action

2 Press the New Folder button.

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Step Action

3 Give the new folder an appropriate name. (It is advisable to include the date in the
name) and press Open.

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Step Action

4 Give the backup a name and press Open.

The backup has been now created.

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 Diagnostics
Fault Reaction Implementation

Create the Points

Table below shows the application details of the point used in this Lab exercise.

Table: Point application details

Type Tag number Description Status Location

AI xx-tmp-02a Reactor Temperature A Not Applicable FLD

AI xx-tmp-02b Reactor Temperature B Not Applicable FLD

AI xx-tmp-02c Reactor Temperature C Not Applicable FLD

DO xx-tmp-02 Reactor Temperature Not High PNL

Replace xx with your system node number.

Step Action

Create the Points

1 Use the Point Configurator to create the points from the above point list. The lab
procedure of the Point Configurator describes how to do this.

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Step Action

Create FLD 50

1 Create FLD 50 as learned in the lab procedure of the Application Editor. For FLD 50
the following information is applicable:
• Execution environment: My SM Controller_XX

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Allocate Points
Table below shows the allocation details of the points used in this Lab exercise.

Table: Point allocation details

Type Tag number Chassis Slot Channel

AI xx-tmp-02a 01.02 5 2

AI xx-tmp-02b 01.02 5 3

AI xx-tmp-02c 01.02 5 4

DO xx-tmp-02 01.02 17 5

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Step Action

Allocate Points

1 Use the Point Configurator to allocate the points from the above point list. The lab
procedure of the Point Configurator describes how to do this.
The below screenshot shows how to allocate the first temperature sensor.

TIP
Normally when 2-o-o-3 voting is applied, the 3 sensors
will be allocated at three separate input modules. In
™
this lab procedure, the Safety Manager training
system is used. This training unit only contains one
redundant analog input module. The three sensors of
this lab exercise are therefore allocated at the same
module.

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Step Action

2 Set the fault response of the analog inputs to TopScale. This can be done in the Point
Configurator or from the Application Editor by selecting the properties of the point.

TIP
In case of the training application 01-FE-001 is
already allocated on the AI module. 01-FE-001 has a
high (70 m3/hr) and a low (20 m3/hr) trip point. So both
Bottomscale and Topscale can be used for this point.

3 Compile the application using the Application Compiler as described in the

Application Editor lab exercise.

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Step Action

Load and test the application

1 Load the application via an Off-line modification as learned in the lab procedure of the
On Line environment.

2 Test if the application is working by using the Application Viewer and the
™
potentiometers on the simulation module (SIMAI-1620m) of the Safety Manager training
system.
™
3 When does the Safety Manager system apply the configured fault response
(TopScale) for the Analog Input channel?
>
When....................................................................................................................................
.....

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 Diagnostics
Fault Reaction Implementation

Fault Reaction Implementation

Introduction
The objective of Creating an FLD for 2oo3 voting on temperature sensors with a high trip
point is met with this lab exercise:

Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module System Fault Reactions
• Safety Builder installed on a PC
• Safety Manager™ system, with Remote Universal Safe I/O modules connected and
the training application loaded
• Ethernet connection between Safety Station and Safety Manager system
Description
The temperature inside a reactor is at the moment measured by one temperature sensor.
To have a more reliable value, the existing sensor is going to be replaced by 3 new ones.
If the temperature inside the reactor rises above 85 degrees Celsius, the reactor has to
shut down. 2-o-o-3 voting will be applied on the individual trip values.
The change to the application will be done in a shutdown period. For the moment (for test
purpose) the trip value will be connected to a LED on a local panel.
Implementation
Add FLD 50 to the application, which was already created in the Safety Builder lab
procedures. Put the 3 temperature sensors and their individual trip values on this new
FLD. Use the 2-o-o-3 voter which already was created on Function Block 2490 to create
one trip value. Allocate the points to the hardware and set the correct fault response.
Compile the application, and load the application via an off line modification.

Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

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Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Fault reaction implementation lab procedures

Practice

Step Action

Make a back up of the project

1 Go to the Network Configurator and select the Plant. Select Backup Configuration
from the File menu.

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Step Action

2 Press the New Folder button.

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Step Action

3 Give the new folder an appropriate name. (It is advisable to include the date in the
name) and press Open.

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Step Action

4 Give the backup a name and press Open.

The backup has been now created.

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Create the Points

Table below shows the application details of the point used in this Lab exercise.

Table: Point application details

Type Tag number Description Status Location

AI xx-tmp-02a Reactor Temperature A Not Applicable FLD

AI xx-tmp-02b Reactor Temperature B Not Applicable FLD

AI xx-tmp-02c Reactor Temperature C Not Applicable FLD

DO xx-tmp-02 Reactor Temperature Not High PNL

Replace xx with your system node number.

Step Action

Create the Points

1 Use the Point Configurator to create the points from the above point list. The lab
procedure of the Point Configurator describes how to do this.

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Step Action

Create FLD 50

1 Create FLD 50 as learned in the lab procedure of the Application Editor. For FLD 50
the following information is applicable:
• Execution environment: My SM Controller_XX

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Allocate Points
Table below shows the allocation details of the points used in this Lab exercise.

Table: Point allocation details

Type Tag number Chassis Slot Channel

AI xx-tmp-02a 01.02 5 2

AI xx-tmp-02b 01.02 5 3

AI xx-tmp-02c 01.02 5 4

DO xx-tmp-02 01.02 17 5

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Step Action

Allocate Points

1 Use the Point Configurator to allocate the points from the above point list. The lab
procedure of the Point Configurator describes how to do this.
The below screenshot shows how to allocate the first temperature sensor.

TIP
Normally when 2-o-o-3 voting is applied, the 3 sensors
will be allocated at three separate input modules. In
™
this lab procedure, the Safety Manager training
system is used. This training unit only contains one
redundant analog input module. The three sensors of
this lab exercise are therefore allocated at the same
module.

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Step Action

2 Set the fault response of the analog inputs to TopScale. This can be done in the Point
Configurator or from the Application Editor by selecting the properties of the point.

TIP
In case of the training application 01-FE-001 is
already allocated on the AI module. 01-FE-001 has a
high (70 m3/hr) and a low (20 m3/hr) trip point. So both
Bottomscale and Topscale can be used for this point.

3 Compile the application using the Application Compiler as described in the

Application Editor lab exercise.

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Step Action

Load and test the application

1 Load the application via an Off-line modification as learned in the lab procedure of the
On Line environment.

2 Test if the application is working by using the Application Viewer and the
™
potentiometers on the simulation module (SIMAI-1620m) of the Safety Manager training
system.
™
3 When does the Safety Manager system apply the configured fault response
(TopScale) for the Analog Input channel?
>
When....................................................................................................................................
.....

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 On-line Modification

Honeywell Confidential
On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
1 12/16/2016
Introduction Honeywell
• Module Description:
– This training module describes all aspects of performing an On Line
modification on the Safety Manager system

• Job Importance:
– The module is important for everyone who is involved in Installation &
Upgrades or Troubleshooting & Maintenance related to Safety Manager

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On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
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Topics Honeywell
• What is On Line Modification?

• What are the preparation and execution considerations of the OLM?

• How is an On Line Modification performed?

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What is On Line Modification? Honeywell

=
Process
Availability

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What is On Line Modification? (Cont’d) Honeywell

MODIFICATIONS

????
Safety Manager

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What is On Line Modification? (Cont’d) Honeywell

MODIFICATIONS

OLM!

Safety Manager

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On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
6 12/16/2016
What is On Line Modification? (Cont’d) Honeywell
• On Line Modification Safety Manager
– Change software and hardware while the process stays on line and is still
safeguarded
– Redundant SM Controller needed

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Redundant Safety Manager Controller Honeywell

Control Processor 1 BKM Control Processor 2

Running &
Halt
Safeguarding

Downloading
software upgrade

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Redundant Safety Manager Controller (Cont’d) Honeywell

Control Processor 1 BKM Control Processor 2

Running &
Safeguarding on Halt
new software

Loading
software upgrade

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On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
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Redundant Safety Manager Controller (Cont’d) Honeywell

Control Processor 1 BKM Control Processor 2

Running & Running &

Safeguarding on new Safeguarding on new
software software

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Functions of On-Line Modification Honeywell
• On Line Modification Safety Manager
– Change software and hardware while the process stays on line and is still
safeguarded
– Redundant SM Controller needed
– Safety Manager OLM is TÜV approved

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On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
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Topics Honeywell
• What is On Line Modification?

• What are the preparation and execution considerations of the OLM?

• How is an On Line Modification performed?

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Preparation and Execution Considerations of OLM Honeywell
• Modification Safety Manager

Planning

Preparation Change application

Execute Modify the system On Line

modification

Report /
Review

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Changing the Application Honeywell
• Check that controller is loaded

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System Information Honeywell

Application log file

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Application Load Check Honeywell

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Changing the Application – Important Checks Honeywell
• Changing the application
– Check that the controller is loaded
– Verify the application
– Check if OLM is set at Yes
– Change the application
– Compile the changed application
– Check the compile log
– Test the application

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Important Checks (Online Modification) Honeywell

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On-line modification Copyright © 2014 Honeywell International Inc. On-line Modification
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Application Compiler Honeywell

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Compile Log Honeywell

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Tools Used to Test Application Honeywell
• Test the application using
– UNISIM SIM-SM140
– Simulation Mode (R145 +)

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Test the Application Using UNISIM Honeywell

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Test the Application Using Simulation Mode Honeywell
• Application load and execution in
redundant Controller
• Does not require matching IO
• Allows testing of communication
infrastructure
• Allows Experion interface and
graphics testing
• Supports on-line modification

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Test the Application Using Simulation Mode Cont’d Honeywell
• Application load and execution in
redundant Controller
• Does not require matching IO
• Allows testing of communication
infrastructure
• Allows Experion interface and
graphics testing
• Supports on-line modification
• Compile for Simulation Mode

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Topics Honeywell
• What is On Line Modification?

• What are the preparation and execution considerations of the OLM?

• How is an On Line Modification performed?

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Performing the On Line Modification Honeywell
• Go to Controller Management

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Controller Management Screen Honeywell

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Performing the On Line Modification Honeywell
• Go to Controller Management
• Select the Load Controller function

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Controller Load Screen Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle

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Press Start to Download New Application Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle
• Click the ‘Start’ button

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Application Download Progress Bar Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle
• Click the ‘Start’ button
• When CP1 loaded & ready, Cycle Reset switch

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Application Download Progress Bar Honeywell

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Actual Diagnostics Screen Honeywell

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Application Download Progress Bar (Cont’d) Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle
• Click the ‘Start’ button
• When CP1 loaded & ready, Cycle Reset switch
• Click the ‘Continue’ button

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Application Download Progress Bar (Cont’d) Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle
• Click the ‘Start’ button
• When CP1 loaded & ready, Cycle Reset switch
• Click the ‘Continue’ button
• When CP2 loaded & ready, Cycle Reset switch

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Application Download Progress Bar (Cont’d) Honeywell

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Application Download Progress Bar (Load Successful) Honeywell

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Performing the On Line Modification (Cont’d) Honeywell
• Go to Controller Management
• Select the Load Controller function
• Switch Control Processor 1 to Idle
• Click the ‘Start’ button
• When CP1 loaded & ready, Cycle Reset switch
• Click the ‘Continue’ button
• When CP2 loaded & ready, Cycle Reset switch
• Create a back-up of the application

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Summary Honeywell
• On-Line modification
– Modifying the Safety Manager system without interrupting the process;
– TÜV approved.
• Preparation and execution considerations
– Planning the resources, ordering materials, documentation and changing the
application.
• Performing the On-Line Modification
– The actual On-Line Modification, loading the new application to the
controller.

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Test Questions : Question 1 Honeywell
• What is the correct order of steps when changing the application?

a) Check OLM setting, change application, compare CRC’s, compile,

check compile log
b) Compile, check compile log, check OLM setting, compare CRC’s,
change application
c) Compare CRC’s, check OLM setting, change application compile,
check compile log
d) None of the above

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Test Questions : Question 2 Honeywell
• Why is the OLM TÜV approved?

a) Because Safety Manager is a Safety Instrumented System

b) During the OLM the inputs are scanned, the application is executed and the
outputs are controlled by Safety Manager. This means that the process is
safeguarded during the entire OLM

c) Safety Manager has a diagnostic coverage factor of 99% and higher

d) None of the above

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Test Questions : Question 3 Honeywell
• What is the correct order of steps when performing the actual OLM?

a) Check OLM setting, change application, verify, compile,

check compile log, load

b) Switch QPP to idle, click ‘Start’, cycle Reset switch, click ‘Continue’,
cycle Reset switch

c) Switch QPP to Stop, click ‘Start’, click ‘Continue’, cycle Reset switch

d) All of the above

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Test Questions : Question 4 Honeywell
• When does the controller start executing the new application?

a) After clicking the ‘Start’ button in Safety Builder

b) After clicking the ‘Continue’ button in Safety Builder

c) After cycling the Reset switch for the 1st time

d) After cycling the Reset switch for the 2nd time

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Test Questions : Question 5 Honeywell
• Which check(s) do we have to perform before changing the application?

a) The OLM check

b) The CRC check

c) Checking the compiler log for errors

d) Comparing CRC’s using compiler log and system information, checking

OLM is set to Yes in network configurator

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Conclusion Honeywell

Describe Online Modification for Safety Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: On-line modification
Contents
Perform On-Line Modification .......................................................................................................... 3

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 On-line modification
Perform On-Line Modification

Perform On-Line Modification

Introduction
The objective of performing on-line modification is met with this lab exercise:

Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module On Line Modification
• Knowledge of how to configure a Safety Manager™ system
• Safety Builder installed on PC
• Knowledge Builder installed on PC
• Safety Manager system, with Remote Universal Safe I/O modules connected and
the training application loaded
• Modified the training application with the Fault Reactions lab procedure
• Ethernet connection between Safety Station and Safety Manager system
Description
In the Fault reaction lab procedure, 2-o-o-3 voting on temperature sensors was added to
the earlier created training application via an off line modification. It is the goal of this lab
procedure to connect the trip point of the 2-o-o-3 voting on FLD 50 to the trip logic of FLD
20. The trip point from the 2-o-o-3 voting replaces the temperature sensor XX-TEA-004 of
FLD 20.

Implementation
Add an Off-sheet transfer to the trip point on FLD 50. Delete the digital input with tag
number XX-TEA-004 and replace it with an On-sheet transfer. Connect the On-sheet
transfer with the Off-sheet transfer of FLD 50.

TIP
The above implementation is an example of a
loop back reference. The first application
cycle after the OLM is performed; the On-
sheet transfer on FLD 20 doesn’t have the
correct application value (it’s getting that from
FLD 50, the next cycle). The QPP will
therefore use the power up value of the On-
sheet transfer. This is logic 0 and will
therefore cause a process trip.

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 On-line modification
Perform On-Line Modification

Make sure the process will not trip. Performing two On Line modifications can do this. In
the first OLM additional logics need to be included, to make sure the process will stay
alive. With the second OLM the additional logics will be removed.
On-line Modification Guide
Whenever OLMs are performed, the step-by-step procedure of the On-Line Modification
guide which is part of Installation and Upgrades should be used. This guide is available in
the Safety Manager Knowledge builder. In this lab procedure we will refer to the step-by-
step procedure of chapter 4 of the OLM guide.

Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in the figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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 On-line modification
Perform On-Line Modification

Lab procedure On-line modification

Practice

Step Action

Stage A: preparing the On-line Modification

A1 Make sure the application in the SM Controller and the Safety Station are identical.
To do so, perform steps A.1.a to A.1.f of the On-Line Modification procedure in the On-
line Modification Guide.

TIP
The On-line Modification Guide is located in the
category “Installation and Upgrades” of the Honeywell
Knowledge Builder

A2 Make a backup of the application files in your project folders.

To do so, perform steps A.2.a to A.2.c of the On-Line Modification procedure in the On-
line Modification Guide.
A3 Make sure the on-line modification option is activated.
To do so, perform steps A.3.a to A.3.f of the On-Line Modification procedure in the On-
line Modification Guide.

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 On-line modification
Perform On-Line Modification

Step Action

Stage B: Modifying the Application

B1 Make the required modifications to the application and verify

To do so perform steps B.1.a to B.1.h for the On-Line Modification procedure in the On-
line Modification Guide.
For step B.1.b modify the application according the narratives (Description) in the
Introduction of this exercise.
First add the Off-sheet transfer to FLD 50:

Leave the destination 0 and fill in the description:

Temperature reactor and the status: Not high.
Now modify FLD 20 by deleting the digital input with tag number 01-TEA-004.

Replace the digital input with an On-sheet transfer and connect the On-sheet
transfer with the Off-sheet transfer of FLD 50.

Now include the additional logics to make sure the process will stay alive. Insert an OR
gate in between the On-sheet transfer and the AND gate and add a Constant 1
symbol to the OR gate.

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 On-line modification
Perform On-Line Modification

Step Action

B1

Cont

TIP
The additional logics will be deleted with the second
OLM.

Select the Point Configurator and delete the digital input with tag number XX-TEA-004.

Continue with steps B.1.c to B.1.h.

B2 Make a backup of the application files in your project folders.

To do so perform steps B.2.a to B.2.c for the On-Line Modification procedure in the On-
line Modification Guide.

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Perform On-Line Modification

Step Action

Stage C: Upgrading the SM Controller

C1 Check the SM Controller before upgrading.

To do so perform steps C.1.a to C.1.d for the On-Line Modification procedure in the On-
Line modification guide.
C2 Upgrading the SM Controller.
To do so perform steps C.2.a to C.2.w for the On-Line Modification procedure in the On-
line Modification Guide.
C3 Make a backup of the loaded application files.
To do so perform steps C.3.a to C.3.d for the On-Line Modification procedure in the On-
line Modification Guide.

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Perform On-Line Modification

Second OLM
Stage A: preparing the On-line Modification

TIP
This stage is the same as “Stage A: Preparing the On-
line Modification.”

Step Action

Stage A: preparing the On-line Modification

A1 Make sure the application in the SM Controller and the Safety Station are identical.
To do so, perform steps A.1.a to A.1.f of the On-Line Modification procedure in the On-
line Modification Guide.

TIP
The On-line Modification Guide is located in the
category “Installation and Upgrades” of the Honeywell
Knowledge Builder

A2 Make a backup of the application files in your project folders.

To do so, perform steps A.2.a to A.2.c of the On-Line Modification procedure in the On-
line Modification Guide.
A3 Make sure the on-line modification option is activated.
To do so, perform steps A.3.a to A.3.f of the On-Line Modification procedure in the On-
line Modification Guide.

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Perform On-Line Modification

Step Action

Stage B: Modifying the Application

B1 Make the required modifications to the application and verify

To do so perform steps B.1.a to B.1.h for the On-Line Modification procedure in the On-
line Modification Guide.
For step B.1.b modify the application according to the narratives (Description) in the
Introduction of this exercise.
Delete the OR gate and the Constant 1 symbol from FLD 20:

Reconnect the On-sheet transfer to the AND gate:

Continue with steps B.1.c to B.1.h.

B2 Make a backup of the application files in your project folders
To do so perform steps B.2.a to B.2.c for the On-Line Modification procedure in the On-
line Modification Guide.

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Perform On-Line Modification

Stage C: Upgrading the SM Controller

TIP
This stage is the same as ”Stage C: Upgrading the SM
Controller” above.

Step Action
Stage C: Upgrading the SM Controller

C1 Check the SM Controller before upgrading

To do so perform steps C.1.a to C.1.d for the On-Line Modification procedure in the On-
line Modification Guide.
C2 Upgrading the SM Controller.
To do so perform steps C.2.a to C.2.w for the On-Line Modification procedure in the On-
line Modification Guide.
C3 Make a backup of the loaded application files.
To do so perform steps C.3.a to C.3.d for the On-Line Modification procedure in the On-
line Modification Guide.

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 Communication Overview - Implementation

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Communication Overview Copyright © 2014 Honeywell International Inc. Communication Overview - Implementation
1 12/16/2016
Safety Manager Communication Overview Honeywell
• Module Description
– This training module is a part of the Communication section of the training
courses for Safety Manager. It will describe all the possible Communication
solutions and will explain the essential configuration aspects

• Job Importance
– This module is important for everyone who is involved in Engineering or
Installation & Upgrades or Troubleshooting & Maintenance concerning
Safety Manager

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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Safety Manager Communication Overview Honeywell
• Create Physical Network
– Step 1: Add Communication device to Plant
– Step 2: Add Physical Network to Communication Device
– Step 3: Add Controller to Physical Network

• Create Logical Network

– Step 1: Add Logical Network and select Node and Peer Id
– Step 2: Define Logical Network properties

• Adjust Clock Source Priority List

– Step 1: Adjust Clock source priority list

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Safety Manager Communication Overview Honeywell
• Allocate points
– Step 1: Select Point
– Step 2: Select Logical Network
– Step 3: Select PLC Address

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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What is External Clocksource? Honeywell
• Synchronize Safety Manager controllers via
– Precision Time Protocol (PTP - IEEE1588)
– Network Time Protocol (NTP - RFC1305 & 2030)

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External Clock source in a SafeNet network Honeywell
• Connect the External Clock source to the main Controller
• The SafeNet Network can be synchronized via that node

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Create Physical Network (External Clocksource) Honeywell
• Step 1: Add Communication device to Plant

Clock source time out

PTP: Depends on
used device.

NTP: Minimum 15
minutes.

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Create Physical Network (External Clocksource) Honeywell
• Step 2: Add Physical Network to Communication Device

Physical Network

PTP & NTP: Use Ethernet

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Create Physical Network (External Clocksource): Honeywell
• Step 2: Define Logical Network properties

Logical Network

PTP & NTP: In the LN

properties the choice between
NTP & PTP is made.

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Additional step when NTP is configured Honeywell
• Additional Step: Configure IP Address of NTP device

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Timezone Honeywell
• When the clock source device uses UTC the controllers in the Plant will
use the Time zone setting (Plant Properties) to set the real time clock to
the local time.

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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What is Modbus? Honeywell
Transfer non Safe information from Safety Manager to other Device and
vice versa

• Safety Manager as Modbus Slave

– Standard Modbus RTU

– Ethernet or Serial connection

– ET-GT-ST-2/3 (MVIP) can be used as Modbus master.

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What is Modbus? (Cont’) Honeywell
• Safety Manager as Modbus Master

– Modbus Slave device is used where the Modbus Master protocol applies

– Redundant communication only

– 1 Modbus Master per USI

– Ethernet connection

– ModbusRTU support via Gateway

– Max 32 logical links per USI (this includes Safety Builder, Experion, Modbus
slave links )

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Create Physical Network (Modbus) Honeywell
• Step 1: Add Communication device to Plant

SM as Slave SM as Master

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Create Physical Network (Modbus) Honeywell
• Step 1: Add Communication device to Plant

SM as Slave

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Create Physical Network (Modbus) (Contd’) Honeywell

SM as Master (Modbus Slave) SM as Master (Gateway)

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Create Physical Network (Modbus) Honeywell
• Step 2: Add Physical Network to Communication Device
SM as Slave

Physical Network
Modbus: Uses Serial or
Ethernet connection

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Create Physical Network (Modbus) (Contd’) Honeywell

SM as Master

Physical Network
Modbus: Use Ethernet
connection

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Create Physical Network (Modbus) Honeywell
• Step 2: Define Logical Network properties
SM as Slave Device Address: Sets the
Communication address for the
Safety Manager controller which will
be used by the Modbus device

PLC base in & out : Sets the

Modbus start address for the
Markers and Registers

Enable Timeout:
Sets time out of
the Modbus device

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Create Physical Network (Modbus) (Contd’) Honeywell
SM as Master
Device Address: Sets the
Communication address for the
Safety Manager controller which will
be used by the Modbus device

Architecture: Defines the

communication architecture
for this logical connection

PLC base in & out : Sets the

Modbus start address for the
Markers and Registers

Enable Timeout:
Sets time out of
the Modbus device

Update the Slave

device properties

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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What is SafeNet? Honeywell

• Transfer Safe information (SIL 3) between Safety Manager Controllers

• Retrieve information of all controllers of a SafeNet network via one
Safety Builder
• Remote Management of all Safety Manager controllers via SafeNet
• SafeNet via Ethernet is Peer to Peer communication
• SafeNet via serial connection is Master Slave Communication
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Create Physical Network (SafeNet) Honeywell
• Step 1: Add Communication device to Plant

SafeNet Network
Safety Manager Node:
Always needs to be connected
to a “first level” device (e.g Safety
Builder, Experion server etc.) first,
as a Controller is a “second level”
device in the Network Configurator.

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Create Physical Network (SafeNet) Honeywell
• Step 2: Add Physical Network to Communication Device

Physical Network
SafeNet: Is possible via
Ethernet and serial connection.
When Ethernet is used, we
strongly advice using a dedicated
network.

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Create Physical Network (SafeNet) Honeywell
• Step 2: Add Physical Network to Communication Device

Ethernet Network for My SM

Controller 1
192.168.10.1 (COM 1 Link A)
192.168.10.2 (COM 1 Link B)
Packet Losses and Network congestion can
occur if several devices start
transmitting packets at the same time
or single device generates a peak in
network traffic. Using a dedicated
network just for SafeNet this can be
avoided.
SafeNet Network for My SM
Controller 1
192.168.11.1 (COM 2 Link A)
192.168.11.2 (COM 2 Link B)

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Create Physical Network (SafeNet) Honeywell
• Step 3: Add Controller to Physical Network

Controller node number

The Controller node number of the
Controllers which are connected
via SafeNet networks need to be
different.

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Create Physical Network (SafeNet) Honeywell
• Step 3: Add Controller to Physical Network

Remote Load Enabled

If checked: The system can be
stopped, loaded, and started from a
remote location via the main node of the
SafeNet network.

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Create Physical Network (SafeNet) Honeywell
• Step 3: Add Controller to Physical Network

Remote Reset Enabled

If checked: Resetting of the Controller
can be done via a button in the Safety
Builder which is connected to the
SafeNet network.

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Create Physical Network (SafeNet) Honeywell
• Step 3: Add Controller to Physical Network

SafeNet via Ethernet:

The IP addresses of the USI’s of CP1 &
CP2 have to be defined. They need to
have the same subnet as the connected
Peers

SM Controller 2
COM MODULE 2A
192.168.11.3
192.168.11.4

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Create Physical Network (SafeNet) Honeywell
• Step 3: Add Controller to Physical Network

SafeNet via Ethernet:

The IP addresses of the USI’s of CP1 &
CP2 have to be defined. They need to
have the same subnet as the connected
Peers

SM Controller 1
COM MODULE 2A
192.168.11.1
192.168.11.2

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Create Logical Network (SafeNet) Honeywell
• Step 2: Define Logical Network properties

Logical Network
Marker & Register bytes:
A maximum of 2.000 bytes are
available for 1 LN. In total 4.000
bytes for all LN’s of 1 Master Slave
network
Timeout:
Within this period the Master expects to
communicate with the connected slave at
least twice

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Create Logical Network (SafeNet) Honeywell
• Step 2: Define Logical Network properties

Logical Network
Network Delay: Defines the
communication delay which is
caused by the physical connection
(e.g. length, medium, converters)

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Allocate points (SafeNet) Honeywell
• Step 1: Select Point

My SM Controller 1: A Digital Input 01-LEA-008 Location: Field

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Allocate points (SafeNet) Honeywell
• Step 2: Select Logical Network

My SM Controller 1: A Digital Input 01-LEA-008 Location: Field

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Allocate points (SafeNet) Honeywell
• Step 3: The Point in the other Controller

Note:
The Location has changed
since we changed to the other
controller. Now FSC is the
Location and the output from
the other Controller is shown as
an Input in the Logical
Connection of this controller

SM Controller 2: A Digital Input 01-LEA-008 Location: FSC

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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What is the Field Device Manager? Honeywell
• Connecting FDM server to the
SM Controller enables HART pass thru on Universal Safety IO

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A. Create Physical Network (FDM server) Honeywell
• Step 1: Add Communication device to Plant

Configuration file name:

Name for XML file which
contains exported HART
data. XML file can be used for
FDM import.

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D. Allocate points (FDM server) Honeywell

RIO channel properties:

Allocate AI or AO as HART
enable .

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Additional Step Honeywell
• Export to FDM

Export to FDM:
Use this option to export HART pass
thru information to an XML file. This
file can be imported in FDM.

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Topics Honeywell
• How to configure Communication solutions?

• What are the specifics of the External Clock source?

• What are the specifics of Modbus?

• What are the specifics of SafeNet?

• What are the specifics of FDM Server?

• What are the specifics of Safety Historian?

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What is Safety Historian? Honeywell

Safety Historian:
Records and logs process events, alarm
events, and diagnostic events detected by
the SM and stores them in a database
including time-stamp information.

These events can be displayed, analyzed,

printed, and exported based on user-
definable selection filters.

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A. Create Physical Network (Safety Historian) Honeywell
• Step 1: Add Communication device to Plant

Clock Source allowed:

Safety Historian can be used as
Clock Source device when
checked.

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A. Create Physical Network (Safety Historian) Honeywell
• Step 3: Add Controller to Physical Network

SOE ID Range:
Sets the quantity of events
which can be configured and
recorded.

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D. Allocate points (Safety Historian) Honeywell

Enable:
Enables SOE and creates an
SOE ID for the point.

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D. Allocate points (Safety Histiorian) (Cont’d) Honeywell

Low Latency SOE:

If point is allocated at a
Universal Safety IO module Low
Latency SOE can be selected.
Resolution = 1 msec.

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Configure FSCSOE (Safety Historian) Honeywell
• In Network Architecture Choose “Add”

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Configure FSCSOE (Safety Historian) (Cont’d) Honeywell
• The Controller is considered an Event Detecting Device

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 Configure FSCSOE (Safety Historian) (Cont’d) Honeywell

3 other windows are available An Error is immediately generated since the Controller is
for viewing not cabled yet for communication

The Controller has been

added

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Configure FSCSOE (Safety Historian) (Cont’d) Honeywell

Add the Process Variables point by point or Import

the database from the Controller

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Configure FSCSOE (Safety Historian) (Cont’d) Honeywell
• Example of Process Variable Property Box

Process Variable
Screen

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Summary Honeywell
• How to configure Communication solutions?
– Create Physical Network
– Create Logical Network
– Adjust Clock source priority list
– Allocate Points

• What are the specifics of the External Clocksource?

– Network Time Protocol (NTP)
– Precision Time Protocol (PTP)

• What are the specifics of Modbus?

– Transfer non Safe information from Safety Manager to other Device
– Standard Modbus RTU
– Modbus TCP/IP

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Summary Honeywell
• What are the specifics of the SafeNet?
– Transfer Safe information between Safety Manager controllers
– Retrieve information of all controllers of a SafeNet network via one Safety
Builder
– Remote management of nodes possible via SafeNet

• What are the specifics of Safety Station?

– Safety Builder installed on a PC is called a Safety Station
– It’s used to download the application to controllers
– It’s used to retrieve system and process information from controllers

• What are the specifics of Safety Historian?

– Records and logs events detected by the SM and stores them in a database
including time-stamp information
– Safety Historian can be used as Clock Source device.

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Test Questions: Question 1: Honeywell
• What is the Safety Manager Controller communication address for the
Modbus device?

a) The Controller node number

b) The PLC address of the Controller

c) The Device address which is filled in at Logical Network properties

d) The Controller node number + 4

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Test Questions: Question 2: Honeywell
• For which External clock source protocol does an IP address needs to
be configured for the clock source device?

a) NTP

b) PTP

c) For both protocols

d) For neither protocols

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Test Questions: Question 3: Honeywell
• Which statement is true about Safety Builder acting as a clock source
device?

a) Safety Builder can not act as a clock source device

b) Safety Builder will synchronize the connected controllers automatically

c) Safety Builder should be the last priority in a clock source priority list

d) None of the above

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Test Questions: Question 4: Honeywell
• Can SafeNet be used via a Ethernet connection?

a) No

b) Yes, but using a dedicated network is advised

c) Yes, but the IP addresses of the Node and Peer Controllers have to be

configured in the same subnet

d) Answers b & c are both correct

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Test Questions: Question 5: Honeywell
• What is remote load?

a) Loading a stand alone controller from a remote location

b) Changing a Controller in the Network Configurator from compiled to loaded

c) Loading a Safety Manager master via the Main Controller

d) Stopping, loading and starting a slave via the Main Controller

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Conclusion Honeywell

Describe Communication Overview for Safety

Manager

Completion
Certificate

Proceed to the next lesson in your course material

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Topic: Communication Overview
Contents
Modbus Slave Configuration ............................................................................................................ 3

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Modbus Slave Configuration
Introduction
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module for Network Configurator, Point Configurator, Application
Editor and Online Environment.
• Safety Builder installed on a PC
• Safety Manager™ system, with Modbus Slave device or Simulator connected
Description
This lab procedure describes how to configure a network between a Safety Manager and a
Modbus Slave Simulator where the Safety Manager will be the Modbus Master.
Configuring the network requires a SM Controller node number and IP addresses. The
instructor will supply this information. The Instructor will also point out the Safety Manager
system, which will be used during the lab exercises.
Make sure that the hard disk of the PC contains a folder: My SM projects. The application
will be stored in this folder.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

At some stages when executing the procedure, a window as shown in figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
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Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Practice

Step Action

Add Modbus Master Components

1 Open the Network Configurator and open the application built in the previous labs. Add
Modbus Master components as shown below.
Refer the Network Configurator and Hardware Configurator Lab.

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 Step Action

2 Select the COM Module tab page and fill out the IP Addresses of USI channel 2A
(Modbus_Network) for both CP1 and CP2.
The trainer will provide the correct IP Addresses.

Attention

QPP-0002 and USI-0002 are mandatory for this

configuration.

Attention

If Modbus and Safety manager are configured on

same network then subnet of COM ports cannot
overlap. Therefore note that for configuring Modbus
network we have used COM port 2A

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 Step Action

3 Physical Network properties for Modbus_network:

Choose Ethernet as the Interface type. By doing this, all other properties are defined.

Press OK when Finished

4 Modbus Slave properties added to the Physical Network (Modbus_Network):

The trainer will provide the correct IP Addresses for Modbus Slave Device or Simulator.

Press OK when Finished

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 Step Action

Create Logical Network view

1 After the Physical Network is correctly configured, the Logical Network for the
Experion Server needs to be added.
Select the Logical View via the Logical View tab.

2 Right-click the new logical connection row and select Properties from the pop-up menu..

3 Right-click the new logical connection row and select Properties from the pop-up menu

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 Step Action

4 The Logical Network Properties dialog will appear.

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 Step Action

5 Set the properties for the logical as shown in the below screenshot:

Press OK when finished

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 Step Action

Point Configurator

1 Modbus Master address settings:

When a SM Controller acts as a Modbus Master, the PLC address must be entered as a
string by the user.
An address string consists of two or three elements, divided by colons
Function Code: Address: Bit Offset
The number of elements and the content of a string mainly depend on the type of point
that is configured; DI, DO, BI, or BO.
The table below shows the string addresses for the different point types.

Point Type Allocation 1st element 2nd element 3rd element

Type Function Code Address Bit offset in
(FC) word

DI Input 1 or 2 1 to 65536 Not applicable

DI Input 3 or 4 1 to 65536 0-15

DI Output 5 or 15 1 to 65536 Not applicable

DI Output 6 or 16 1 to 65536 0-15

DO Output 5 or 15 1 to 65536 Not applicable

DO Output 6 or 16 1 to 65536 0-15

BI Input 3 or 4 1 to 65536 Not applicable

BI Output 6 or 16 1 to 65536 Not applicable

BO Output 6 or 16 1 to 65536 Not applicable

For More details refer to the Safety Builder help file.

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 Step Action

2 Create points as shown in table below. Refer to the Point Configurator Lab.
Table 1: Point List

Type Tag Description Location Logical Connection PLC

Number Add

DI DI_1 FC2 COM SM_Mbmaster-Modbus Slave 2:1

DI DI_2 FC1 COM SM_Mbmaster-Modbus Slave 1:1

DI DI_3 COM SM_Mbmaster-Modbus Slave 1:2

DI DI_4 COM SM_Mbmaster-Modbus Slave 1:3

DI DI_5 FC4 COM SM_Mbmaster-Modbus Slave 4:1:1

DI DI_6 FC3 COM SM_Mbmaster-Modbus Slave 3:1:1

DI DI_7 FC3 COM SM_Mbmaster-Modbus Slave 3:2:1

DI DI_8 FC3 COM SM_Mbmaster-Modbus Slave 3:2:2

DO DO_1 FC5 COM SM_Mbmaster-Modbus Slave 5:1

DO DO_2 COM SM_Mbmaster-Modbus Slave 15:2

DO DO_3 COM SM_Mbmaster-Modbus Slave 15:3

DO DO_4 COM SM_Mbmaster-Modbus Slave 6:1:1

DO DO_5 COM SM_Mbmaster-Modbus Slave 16:2:1

DO DO_6 COM SM_Mbmaster-Modbus Slave 16:2:2

BI BI_1 FC4 COM SM_Mbmaster-Modbus Slave 4:1

BI BI_2 FC3 COM SM_Mbmaster-Modbus Slave 3:3

BI BI_3 FC3 COM SM_Mbmaster-Modbus Slave 3:4

BI BI_4 FC4 COM SM_Mbmaster-Modbus Slave 4:1

BI BI_5 FC3 COM SM_Mbmaster-Modbus Slave 3:5

BI BI_6 FC4 COM SM_Mbmaster-Modbus Slave 4:1

BI BI_7 FC3 COM SM_Mbmaster-Modbus Slave 3:7

BO BO_1 FC6 COM SM_Mbmaster-Modbus Slave 6:3

BO BO_2 COM SM_Mbmaster-Modbus Slave 16:4

BO BO_3 FC16 COM SM_Mbmaster-Modbus Slave 16:5

BO BO_4 COM SM_Mbmaster-Modbus Slave 16:7

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 Step Action

Application Editor

1 Create FLDs as shown below, Refer to the Application Editor Lab

Create FLD 210
Fill in the FLD 210 Properties

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 Step Action

2 Create FLD 210

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 Step Action

3 Fill in the FLD 220 Properties

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 Step Action

4 Create FLD 220:

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 Step Action

Hardware Configurator

1 For Hardware Configurator Settings, refer to the Hardware Configurator Lab.

Make sure that the Hardware Configuration matches with the hardware of the appointed
Safety Manager system.

Step Action

Load Application

1 Compile and load the application

Refer to the Load the Application steps from the On-Line Environment Lab
2 Check the display of the QPP of both the Control Processors. The message Running
should be displayed.

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 Step Action

Modbus Simulator Settings

1
Attention

Modbus simulator is used for this lab purpose. If class

has physical devices then configuration will differ. Your
instructor will help with class specific configuration.

Open the Modbus Simulator (mod_RSsim) provided by instructor.

Select the MODBUS TCP/IP port and click on the Set up Communication Icon

The following dialog box appears. Remote IP will display the Safety Manager IP address

Click OK when Finished.

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 Step Action

2 When Successful Connection has been established, Connected message will appear on
the Modbus Simulator

Station 01 enabled

TIP

If the successful connection has not been established,

then allow the Modbus Simulator program to
communicate through Windows Firewall.

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 Communication Overview
Modbus Slave Configuration

Step Action

Application Online Test Environment

1 Force DI-1 tag and check the output on Modbus simulator

Alter the Modbus Simulator Properties as

Address: Dec
I/O: Coil Outputs
Fmt: decimal

The Forced Output for DI_1 (Plc Add 2:1) is visible on the simulator as above

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 Communication Overview
Modbus Slave Configuration

Step Action

2 Similarly, Force DI_2 tag and check the output on Modbus Simulator

3 For the forced DI_5 tag,

Alter the Modbus Simulator Properties as,
I/O : Holding Registers

4 Similarly, Force DI_6 tag and check the output on Modbus Simulator

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 Communication Overview
Modbus Slave Configuration

Step Action

5 For Binary Inputs BI_1, BI_4 and BI_6

Alter the Modbus Simulator Properties as
I/O : Holding Registers
Force the tags and check the output on Modbus Simulator
BI_1:

BI_4:

BI_6:

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Modbus Slave Configuration

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 Safety Manager Experion PKS Integration
(SCADA)

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Introduction Honeywell
• Module Description:
– This module is part of the communication solutions section of the Safety
Manager training courses
– It will give an explanation of the Integration of Safety Manager in Experion
PKS using the PCDI Protocol

• Job Importance:
– This module is important for everyone who is doing Planning & Design,
Engineering, Installation & Upgrades or Troubleshooting & Maintenance

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

• What are the Troubleshooting & Maintenance aspects of the

Integration?

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Honeywell Architecture Overview Honeywell

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Safety Manager is Part of Honeywell Network Honeywell

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SM Interfaces via FTE to the Experion Servers Honeywell

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SM Interfaces to Process Controllers (C300) via FTE Honeywell

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Safety Builder Engineering Tool Honeywell
• Safety Station can also be part of FTE

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Features and Characteristics Honeywell
• Total Plant wide System Integration
– Detailed Safety Manager extended diagnostic information on Experion
Server
– Integrated Alarms & Sequence Of Events on Experion Server

• Approved Data exchange

– TÜV approved
– Achilles level 1 certified
– ISA Secure Level 1 certified

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Approved Data Exchange Honeywell

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Features and Characteristics Honeywell
• Total Plant wide System Integration
– Detailed Safety Manager extended diagnostic information on Experion
Server
– Integrated Alarms & Sequence Of Events on Experion Server

• Approved Data exchange

– TÜV approved
– Achilles level 1 certified
– ISA Secure Level 1 certified

• Reduced Engineering

• Peer to Peer Connection to Process Controllers

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Peer to Peer Connection to Process Controllers Honeywell

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

• What are the Troubleshooting & Maintenance aspects of the

Integration?

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Universal Safety Interface Honeywell

Experion Station
Experion
Safety Station
Server

Safety Manager USI

FTE Universal Safety Interface

2 channel High Speed

Ethernet
C300 Control Processor1 Control Processor2
TÜV approved data-exchange
Fault Tolerant Redundant
Configuration

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Universal Safety Interface (IP Address) Honeywell
Experion Station
Experion
Safety Station
Server

FTE

IP address
IP address Control Processor
Control 2
Processor 1

C300 Control Processor1 Control Processor2

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Firewall (Optional) Honeywell
Experion Station
Experion
Safety Station
Server

FTE

CF-
CF-9 (Optional) CF-
CF-9 (Optional)

C300 Control Processor1 Control Processor2

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Overview Safety Manager Network Structure Honeywell

Redundant Safety Manager Controller

Safety Manager Cabinet

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Overview Safety Manager Control Processors Honeywell

Redundant Safety Manager Controller

Controller Processor 2
Controller Processor 1

Safety Manager Cabinet

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Overview Safety Manager COM Module Honeywell

Redundant Safety Manager Controller

USI HSE Channel A
CP1
USI HSE Channel A
CP2

Safety Manager Cabinet

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SM Channel A & B Interconnection With Westermo Honeywell

Redundant Safety Manager Controller

Westermo SDW-550 switches

Safety Manager Cabinet

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Honeywell FTE Network Structure Honeywell
• Redundant fault tolerant integration

Safety Manager Cabinet

Switches

Experion
Safety Server
Station C300
Controller

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

• What are the Troubleshooting & Maintenance aspects of the

Integration?

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Configuration Overview Honeywell
• Safety Manager configuration

– Create Physical & Logical Network

– Allocate Input points with PLC addresses

– Compile & Download application to Controller

• Create Point & Hardware definition files by using SM2XperionConverter
tool

• Import Point & Hardware definition files in Configuration studio

• Download Channel, Controllers & Points to the Experion Server

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Create Physical Network Honeywell

Configuration highlights:
Clock source allowed &
timeout;
SOE collection.

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
Baud Rate

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
IP Address

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
Clock Source Priority List

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
SOE Enable
Maximum SOE ID

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Create Logical Network Honeywell

Configuration highlights
Markers & Register Bytes

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Create Logical Network (Cont’d) Honeywell

Range PLC addresses:

DI & DO = 1 - 8192
AI, AO, BI & BO = 10001 - 18192

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Create Logical Network (Cont’d) Honeywell

Configuration Highlights:
Enable Timeout

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Allocate Points with PLC Addresses and SOE Enable Honeywell

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Create Point & Hardware Definition Files Honeywell
• Using the SM2XperionConverter tool

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Import Point & Hardware Definition Files Honeywell
• In Configuration studio

Configuration highlights
Select Build Channels

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Import Point & Hardware Definition Files (Cont’d) Honeywell
• In the Build channels section

Configuration
highlights
Select File / Import…

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Import Point & Hardware Definition Files (Cont’d) Honeywell
• Download Channel, Controllers & Points to the Experion Server

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

• What are the Troubleshooting & Maintenance aspects of the

Integration?

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Configuration Overview Honeywell
• Safety Manager configuration
– Create Physical & Logical Network
– Allocate points with PLC addresses
– Compile & Download application to Controller

• Process Controller configuration

– Create the Controller
– Create & configure a PCDI Master Block
– Create a Control Module
– Create Points

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Safety Manager Configuration Honeywell
• Create Process Controller

Configuration highlights
Device name is sufficient

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Create Physical Network Honeywell
• Create/re-use Physical Network

Configuration highlights
Baudrate

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
IP Address

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Create Physical Network (Cont’d) Honeywell

Configuration highlights
Device Address

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Create Logical Network Honeywell

Configuration highlights
Marker & Register bytes
PLC base in for markers &
needs to be different.

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Create Logical Network (Cont’d) Honeywell

Configuration highlights
Timeout

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C300 Configuration Honeywell
• Create the Controller

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Create the Controller Honeywell

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Create & configure a PCDI Master Block Honeywell

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Create & configure a PCDI Master Block (Cont’d) Honeywell

Configuration highlights
IP Address USI
Channels

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Create & configure a PCDI Master Block (Cont’d) Honeywell

Configuration highlights
Unit ID = Device
Address of Safety
Manager

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Create a Control Module Honeywell

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Create Points Honeywell

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Create Points (Cont’d) Honeywell

Configuration highlights
Device Address
Quantity of DI and DO’s

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Create Points (Cont’d) Honeywell

Configuration highlights
Add Points to the
Control Module

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

• What are the Troubleshooting & Maintenance aspects of the

Integration?

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Failed connection between Safety Manager & Exp Server Honeywell

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Establish a working link (Exp Server) – Important checks Honeywell

• IP Addresses in Safety Builder and Quick Builder should match

• Communication Address in Configuration Studio should be 4x the

Controller Node number

• Set Timeout in Safety Builder to a good value (30 sec. minimum)

• Baudrate of the Physical Network components should be equal

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Failed connection between Safety Manager & C300 Honeywell

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Establish a working link (C300) – Important checks Honeywell

• IP Addresses in Safety Builder and Quick Builder should match

• Device Address should be equal in Safety Builder and Control Builder

• Set Timeout in Safety Builder to a good value

• Baudrate of the Physical Network components should be equal

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Summary Honeywell
• What are the features and characteristics of the integration?
– Total Plant wide System Integration
– TÜV approved Data exchange
– Reduced Engineering
– Integration using the FTE infrastructure
– Peer to Peer connection to Process Controllers

• Which hardware is necessary for the Integration?

– USI’s
– Controller Back plane
– Westermo switches
– Routers

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Summary Honeywell
• How is a connection between Safety Manager and Experion Server
configured?
– Configure a Physical Network view
– Configure a Logical Network view
– Configure Experion using Quick Builder

• How is a connection between Safety Manager and Process Controller

configured?
– Configure Safety Manager
– Create a Controller
– Create & Configure PCDI Master block
– Create a Control Module
– Create Points

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Summary Honeywell
• What are the Troubleshooting & Maintenance aspects of the
Integration?
– Check IP Addresses
– Check Device Address (C300 only)
– Check Communication Address (Exp. Server only)
– Check Time out
– Check Baudrate settings

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Test Questions - Question 1 Honeywell
• Which communication medium is used for the Experion PKS
integration?

a) UCN Network

b) Fault Tolerant Ethernet

c) RS-232 Network

d) None of the above

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Test Questions - Question 2 Honeywell
• Where can it be defined how many signals can be transferred between
Safety Manager and Process Controller?

a) In the Quick Builder

b) In the Point Configurator

c) At the USI

d) At the Logical Network Properties of Network Configurator

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Test Questions - Question 3 Honeywell
• What is Quick Builder for?

a) To configure the Channel and download this to the Experion Server

b) To configure the Controllers and download this to the Experion Server

c) To configure the Points and download this to the Experion Server

d) A single builder tool allowing integrated application configuration

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Test Questions - Question 4 Honeywell
• Which tool can be used to convert the Safety Manager Database into
information which can be used in Configuration Studio?

a) The Network Configurator

b) Control Builder

c) The SM2XperionConverter

d) None of the above

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Test Questions - Question 5 Honeywell
• Where are the IP Addresses for the connection between Safety
Manager and C300 configured?

a) In the Physical Controller properties of the Network Configurator

b) In the Point Configurator

c) At the PCDI Master block in Control Builder

d) Answers a & c are both correct

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Conclusion Honeywell

Describe SM Experion PKS Integration

(SCADA)

Completion
Certificate

Proceed to the next lesson in your course material

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 Honeywell

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Topic: Safety Manager Experion PKS Integration (SCADA)
Contents
Experion PKS Integration - SCADA ................................................................................................. 3

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 Safety Manager Experion PKS Integration (SCADA)
Experion PKS Integration - SCADA

Experion PKS Integration - SCADA

Introduction
The objective of configuring connection between Safety Manager™ and Experion™ PKS is
met with this lab exercise.
Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed Experion training module.
• Knowledge of configuring a Safety Manager system
• Safety Builder installed on PC
• Safety Manager system, with Remote Universal Safe I/O modules connected and
the training application loaded
• Experion server connected to the Safety Manager system via Ethernet
• Quick Builder and Experion station installed on PC
• Ethernet connection between Safety Station and Safety Manager system
Description
In the lab procedure of Experion PKS the link between Safety Manager and the Experion
server will be configured. We will also configure some points that need to be transferred
from Safety Manager to Experion. First the training application of Safety Manager will be
modified and the system will be updated via the on line modification procedure. Then also
the Experion side will also be configured using Quick Builder.

Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

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Experion PKS Integration - SCADA

At some stages when executing the procedure, a window as shown in the figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as the
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

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Experion PKS Integration - SCADA

Experion PKS lab procedures

Practice

Step Action

Stage A: Preparing the On-Line Modification

A1 Make sure the application in the SM Controller and the Safety Station are identical.
To do so, perform steps A.1.a to A.1.f of the On-Line Modification procedure in the On-
line Modification Guide.

TIP
The On-line Modification Guide is located in the
category “Installation and Upgrades” of the Honeywell
Knowledge Builder

A2 Make a backup of the application files in your project folders.

To do so, perform steps A.2.a to A.2.c of the On-Line Modification procedure in the On-
line Modification Guide.

A3 Make sure the on-line modification option is activated.

To do so, perform steps A.3.a to A.3.f of the On-Line Modification procedure in the On-
line Modification Guide.

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Experion PKS Integration - SCADA

Stage B: Modifying the Application

Use the points as listed in the Table below for this lab procedure

Table Point list for modifying the application

Type Tag number PLC address

DI XX-HS-001 801

DI XX-HE-002 802

DI XX-PZA-003 803

DI XX-XEA-005 804

DI XX-LEA-006 805

DI XX-LEA-006_2 806

DI XX-LEA-008 807

DI XX-LEA-009 808

DI XX-LEA-010 809

AI XX-FE-001 11001

DO XX-SOV-001 810

DO XX-SOV-002 811

DO XX-P-003 812

DO XX-FEA-004 813

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Step Action

Stage B: Modifying the Application

B1 Make the required modifications to the application and verify

To do so perform steps B.1.a to B.1.h for the On-Line Modification procedure in the On-
line Modification Guide.
For the step B.1.b “modify the application”, perform the following steps:

B2 Open the Network Configurator and drag and drop an Experion server on the
Plant in the Physical view.

B3 Set the Experion Server properties as in the below screen shot:

Press OK when finished.

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Step Action

B4 The Experion Server will be connected via the same Ethernet network that is used
for the Safety Station. To create the Physical Network connection, drag and drop
the Physical Network from the explorer bar on the Experion Server.

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Step Action

B5 If the Physical Network is released the SM Controller is automatically connected.

If the + is clicked left from the Physical Network, the SM Controller will be visible.

TIP
The Physical Network Fault Tolerant Ethernet
was already configured in the “Network Configurator
lab exercises” on page 7.
The properties of the Physical Network and the SM
Controller therefore don’t need this adjustment.
This means that the same Ethernet port of the USI’s is
™
used for both Safety Station and Experion server.

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Step Action

B6 After the Physical Network is created, the Logical Network needs to be added.
Select the Logical View via the Logical View tab.

B7 Right-click the Controllers list and select Add Logical Connection from the pop-up
menu, or click the Add Logical Connection button in the button bar.

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Step Action

B8 Right-click the new logical connection row and select Properties from the pop-up menu.

B9 The Logical Network Properties dialog will appear.

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Step Action

B10 Set the properties for the logical network as shown in the below screenshot:

TIP
The Marker In and out size is set at 100. This
means 800 digital Inputs and Outputs can be
transferred via the link between Safety Manager
and Experion. The Register In and Out size is
set at 1000. This means 500 words can be transferred
via the link between Safety Manager and
Experion.

Press OK when finished.

The Logical Network View is now completed. The IP address of the USI
communication port was already set during the “Network Configurator lab exercises”.

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Step Action

B11 Set the Experion Server properties as in the below screen shot:

Press OK when finished.

B12 The next step is to allocate the points, which will be transferred from Safety Manager to
the Experion Server. First open the Point Configurator.

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Step Action

B13 Select the All points allocated to hardware View.

B14 Select first point from the Table Point list for modifying the application2 (XX-HS-001) and
double click it in the Point Configurator.

B15 Select Experion Server - MY SM controller at the Communication allocation part of the
Configure Point window. Double click the pull down menu to get other options.

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Step Action

B16 Finally select the designated PLC address for the point.

B17 Click OK.

The point is now allocated to the Experion connection. Repeat steps B11 to B17 for
other points from Table above.

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Step Action

B18 If all the points are allocated go back to the Physical View, right click the controller and
select properties.

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Step Action

B19 Click the Clock Sources tab and select the Experion Server as Clock source priority 1.

Press OK when finished.

Now continue with steps B.1.c to B.1.h of the OLM procedure.

Step Action

Stage C: Upgrading the SM Controller

C1 Check the SM Controller before upgrading

To do so perform steps C.1.a to C.1.d for the On-Line Modification procedure in the On-
line Modification Guide.
C2 Upgrading the SM Controller.
To do so perform steps C.2.a to C.1.w for the On-Line Modification procedure in the On-
line Modification Guide.
C3 Make a backup of the loaded application files.
To do so perform steps C.3.a to C.3.d for the On-Line Modification procedure in the On-
line Modification Guide.

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Programming the Experion Server using Quick Builder

Programming the Experion Server using Quick Builder consists of the following steps:

Step Action
Build a Channel

1 Start Quick Builder and open the Existing Project My SM projects.

TIP
The project should already be on your PC. If not, ask
your training instructor.

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Step Action
2 Select Channels by pressing the related button.

3 Now press the Add button to add a Channel.

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Step Action
4 The Add Items window will appear. In this window only the name of the channel needs
to be identified. This can be done at the Use Name field. Fill in the name MySMsys
™
expanded with the controller node number of your Safety Manager system. Press OK
after the name has been given.

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Step Action
5 After the name of the Channel is given, other information of the Channel needs to be
defined. At the Main tab a Description of the channel can be filled out. Safety
Manager system expanded with the Safety Manager Controller node number is an
appropriate description. At the bottom of the screen, the Channel number has to be
defined. Adding the Controller node number to CHN can do this. So in case of this lab
procedure, CHN01 is the appropriate Channel number.

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Step Action
6 Select the Port tab, and define the Port Type and Port Name as in the below screenshot.

7 Finally also modify the parameters of the Redundant Port tab according the following
screenshot.

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Step Action
™
8 Now download the Channel to the Experion server. To do so, select the Channel and
press the Download button.

9 In the Download window just press OK.

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Step Action
10 The Results window must now indicate the message: Download SUCCESSFUL

If errors are reported check the previous steps and try to download it again. If this doesn’t
help consult the training instructor.

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Step Action

Build the Controllers

1 Open the Controllers part of the Quick Builder and press the Add button.

2 The Add Items window will appear. In this window only the name of the Controller needs
to be identified. This can be done at the Use Name field. Fill in the name CoilsXX - where
XX is again replaced with the Controller node number.

Press OK after the name has been given.

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Step Action

3 After the Controller is added, the following information needs to be set:

• Description: Coils for MySMController_XX (XX = the Controller node number)

• Channel Name: MySMsysXX (XX = the Controller node number)
• Communication Address = 4 * XX (XX = the Controller node number)
• Data Table: Coils
• IP Address 1: IP of USI communication port 1.1A
• IP Address 2: IP of USI communication port 2.1A
• Uncheck the SOE enable check box
• Check the Sync Enable check box and fill in 5 Minutes.
• Item Number: RTU0XX (XX = the Controller node number).

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Step Action

4 After the Coils, the Registers also need to be added as a Controller. To do so, press the
Add button in the Controller section again.

5 The Add Items window will appear. In this window only the name of the Controller needs
to be identified. This can be done at the Use Name field. Fill in the name RegXX - where
XX is again replaced with the Controller node number. Press OK after the name has
been given.

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Step Action

6 After the Controller is added, the following information needs to be set:

• Description: Registers for MySMController_XX (XX = the Controller node

number)
• Channel Name: MySMsysXX (XX = the Controller node number)
• Communication Address = 4 * XX (XX = the Controller node number)
• Data Table: Registers
• IP Address 1: IP of USI communication port 1.1A
• IP Address 2: IP of USI communication port 2.1A
• Uncheck the SOE enable check box
• Check the Sync Enable check box and fill in 720 Minutes.
• Item Number: RTU0YY (YY = the Controller node number XX + 1).

7 Now download the Controllers to the Experion Server. To do so, select both the channels
and press the Download button.

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Step Action

8 Just press OK in the Download window.

9 The Results window must now indicate the message: Download SUCCESSFUL

If errors are reported check the previous steps and try to download it again. If this doesn’t
help consult the training instructor.

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Build Points
Table below shows the Point list to be used for this lab procedure

Table Points used for “Build points” procedure

1
Type Tag name Location

DI XX-HS-001 801

DI XX-HE-002 802

DI XX-PZA-003 803

DI XX-XEA-005 804

DI XX-LEA-006 805

DI XX-LEA-006_2 806

DI XX-LEA-008 807

DI XX-LEA-009 808

DI XX-LEA-010 809

AI XX-FE-001 11001

DO XX-SOV-001 810

DO XX-SOV-002 811

DO XX-P-003 812

DO XX-FEA-004 813

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Step Action
Build Points
™
1 First we will build the digital Inputs and Outputs. In Experion they are called the status
points.
Open the Point section by pressing the related button and press the Add button.

2 In the Add item(s) window select the Status Point and fill in the Tag name of the point.

Press OK after the Add Item(s) window is altered.

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Step Action
3 The next step is to identify the Location (PLC Address) of the Point. To do so, click the
button next to the PV Source Address field.

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Step Action
4 The Address Builder window appears. In this window set the Controller to Coils and fill
in the Location of the particular Point.

Press OK after the Point is altered.

5 The last mandatory step for building Status Points is setting the PV Scan Period to 1.

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Step Action
6 Repeat steps 1 until 5 for all digital Inputs and Outputs. If all points are had been built,
select them all and press the Download button.

7 The Download window should indicate that 13 items are going to be downloaded. If this
is the case press OK. If not, check the previous steps.

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Step Action
8 The Results window must now indicate the message: Download SUCCESSFUL

If errors are reported check the previous steps and try to download again. If this doesn’t
help consult the training instructor.

9 In the last part of this lab procedure we will build the analog input from the Table above
(XX-FE-001)
Press the Add button and adjust the Add Item(s) window as the following screenshot is
showing:

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Step Action
10 Click the button next to the PV Source Address field to define the Location from the
analog Input.

11 The Address Builder window appears. In this window set the Controller to Registers
and fill in the Location of the particular Point.
Because this point is analog point the code: FSC420MA has to be added to the Location.
After this is done press OK.

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Step Action
12 Finally select 1 for the PV Scan Period and fill in the Engineering Units; m3/HR.
In case of this analog input the 100% and 0% Range Value can stay at 100 and 0.

13 Now select the analog input and press the Download button.

14 In the Download window just press OK to download the analog Point to the Server.

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Step Action
15 The Results window must now indicate the message: Download SUCCESSFUL

If errors are reported check the previous steps and try to download again. If this doesn’t
help consult the training instructor.

16 The connection between Safety Manager and Experion is now configured.

The live connection can be viewed at the Experion Station.

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 Safety Manager Experion PKS Integration
(CDA)

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Introduction Honeywell
• Module Description:
– This module is part of the communication solutions section of the Safety
Manager training courses
– It will give an explanation of the Integration of Safety Manager in Experion
PKS using the CDA Protocol

• Job Importance:
– This module is important for everyone who is doing Planning & Design,
Engineering, Installation & Upgrades or Troubleshooting & Maintenance

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

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Honeywell Architecture Overview Honeywell

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Safety Manager is Part of Honeywell Network Honeywell

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SM Interfaces via FTE to the Experion Servers Honeywell

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SM Interfaces to Process Controllers (C300) via FTE Honeywell

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Safety Builder Engineering Tool Honeywell
• Safety Station can also be part of FTE

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Features and Characteristics Honeywell
• Total Plant wide System Integration:
– Detailed Safety Manager extended diagnostic information on Experion
Server
– Integrated Alarms & Sequence Of Events on Experion Server

• Approved Data exchange:

– TÜV approved
– Achilles level 1 certified
– ISA Secure Level 1 certified

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Approved Data Exchange Honeywell

Firewall

CDA

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Features and Characteristics Honeywell
• Total Plant wide System Integration:
– Detailed Safety Manager extended diagnostic information on Experion
Server
– Integrated Alarms & Sequence Of Events on Experion Server

• Approved Data exchange:

– TÜV approved
– Achilles level 1 certified
– ISA Secure Level 1 certified

• Reduced Engineering

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Reduced Engineering Honeywell

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Features and Characteristics Honeywell
• Total Plant wide System Integration:
– Detailed Safety Manager extended diagnostic information on Experion
Server
– Integrated Alarms & Sequence Of Events on Experion Server

• Approved Data exchange:

– TÜV approved
– Achilles level 1 certified
– ISA Secure Level 1 certified

• Reduced Engineering;

• Peer to Peer connection to Process Controllers

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Peer to Peer Connection to Process Controllers Honeywell

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

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Hardware Overview of the Integration Honeywell
Experion Station
Experion
Safety Station
Server

FTE
COM1 COM1

CHANNEL B CHANNEL B

COM1 COM1
CHANNEL A CHANNEL A
C300

Control Processor1 Control Processor2

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Universal Safety Interface Honeywell

Experion Station
Experion
Safety Station
Server

Safety Manager USI-0002

Universal Safety Interface
FTE

2 channel High
Speed Ethernet
TÜV approved
data-exchange.
C300 Control Processor1
Fault Tolerant
Control Processor2
Redundant
Configuration

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Universal Safety Interface (IP Address) Honeywell

Experion
Safety Station
Server

Experion Station

FTE

IP address
IP address Control Processor
Control 2
Processor 1

C300 Control Processor1 Control Processor2

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Overview Safety Manager Network Structure Honeywell

Redundant Safety Manager Controller

Safety Manager Cabinet

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Overview Safety Manager Control Processors Honeywell

Redundant Safety Manager Controller

Controller Processor 2 Controller Processor 1

Safety Manager Cabinet

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Overview Safety Manager COM Module Honeywell

Redundant Safety Manager Controller

USI HSE
COM 1 Module
USI HSE
Channel A & Channel B
COM 1 Module
CP1
Channel A & Channel B
CP1

Safety Manager Cabinet

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SM Channel A & B Interconnection With Westermo Honeywell

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Honeywell FTE Network Structure Honeywell
• Redundant fault tolerant integration

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and Process Controller

configured?

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Configuration Overview Honeywell
• Safety Manager configuration;
– Create Physical & Logical Network
– Allocate Input points with PLC addresses
– Verify the “Parent Asset” has been configured in configuration studio
– Compile & Download application to Controller (if Parent Asset has been
configured in Configuration Studio)

• Experion Server configuration;

– Create and configure Parent Asset
– Build your HMI
• Standardized HMI Components (Shapes, Faceplates, Detail displays)
available

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Configuration Overview Honeywell

To make System changes we

had chosen the Experion
System on the previous slide

Choose Configure Assets

for the System

Alarm Groups are also

Configured in the System
Task Box

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Safety Manager Control Builder Configuration Honeywell

Enter SM and
this will be the
asset name used

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Safety Manager Control Builder Configuration Honeywell

The User Defined

Identification Screen Name
The Default name
must be changed to
the user defined
name

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SM Control Builder Configuration (Asset Download) Honeywell

Download
Button

Down load
Screen
After
changes have
been made
they
must be
downloaded .

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Safety Manager Experion Server Properties Honeywell
• Create Physical Network
– Select Experion Server and then place it on the plant. Server properties will
pop up
– If there are large systems with multiple Experion servers, then add the
corresponding Host name or IP Address of the Primary Server on which the
points must be loaded

Host Name is the

name of the
primary server

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Safety Manager Physical Network Properties Honeywell

Drag a Physical Network on the

Experion Server

Select Fault Tolerant Ethernet

at the interface drop down box to
allow for CDA integration with
Experion devices

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SM IP Address Configuration for Physical Network Honeywell

Fill in the IP address

and Subnet Mask
which is supplied by
network administrator

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Safety Manager FTE Device Index Honeywell

COM module type only USI-0002 is

supported

The FTE Device Index is user

defined. The Device Index along
with the base IP address will be the
IP address of the Controller

Ex: 192.168.10.1 and 192.168.10.2

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Safety Manager Logical Connection Honeywell
• Create Logical Connection
– Change View to Logical Link.
– Choose Add Logical Link.
– Choose Node ID
– Choose Experion Server
– Choose Peer ID
– Choose SM Controller

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Safety Manager Logical Network Properties Honeywell

CDA
Protocol

Right Click on
Experion server
and choose
Logical Network
Properties

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Safety Manager Memory Space Allocation Honeywell
• Markers In: Reserve the memory space for DIs
on the communication module to the selected
controller
• Registers In: Reserve the memory space for
BIs on the communication module to the
selected controller
• Range PLC addresses: DI= 1 - 8192 BI
= 10001 – 18192
• Timeout: It is recommended that no timeout be
used
• Network Delay: Not used
• Note: No allocation is required for Markers/
Registers out buffers as read via CDA does
not require out allocation in the safety manager
Points

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SM Experion Server Properties SOE Collection Check Box Honeywell

Choose Experion
Server
Right Click and
Server Properties
will appear SOE can
be enabled
if required

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SM Controller Properties SOE Range Selection Honeywell

On the controller SOE must

be Enabled and the address
range Set. The first 16 are
reserved for the system

The number of points that can

Be assigned an SOE address
In this example is 1000 – 16
or 984 points

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Safety Manager and SOE Configuration in Experion Honeywell

Source of Event Description

Controller and of Event
FLD

Date and
Time of
Event Value and
Units
Status of
Event

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Safety Manager Point Configuration Honeywell

Main Configuration
Screen

Options
Configuration
Screen

Experion
Configuration
Screen

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Safety Manager Point Configuration Honeywell

Options
Configuration
Screen

SOE Enabled

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Safety Manager Point Configuration Honeywell
Experion
Configuration Screen

Block Name is
the Experion Alarm Reporting
Terminology for for Experion
a Tag Name

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Safety Manager Application Configuration Honeywell

Parent Asset: is
Configured in Experion
and must be available
before publishing. The
FLD will belong to this
Asset (SM)

Item Name: Identifies the

FLD defined in the
Parent Asset. In this
example the FLD sheet
was 10

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Safety Manager Application Configuration Honeywell

This property defines which display

file will be used in Experion to
display point details

This property defines which display

file will be used in Experion to
display Group details

This property defines which display

file will be used in Experion to
display associated details

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Safety Manager Publishing Honeywell
• Publishing is the method by which Safety Manager points are integrated
to Experion for CDA Communication (Control Data Access)
• The method below is when you are not loading yet but need to move the
points to Experion for Engineering reasons to continue to work until you
do a download
Second Step: Choose Publish
First Step: Choose Controller Configuration from the “File” Drop Down

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Safety Manager Publishing Honeywell
• After Publish has been selected a pop up box will appear

Do not use this without reviewing the

selection

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Safety Manager Publishing Honeywell
• Publish (Without any Options)
– Only the changes in the application with respect to SR are published

• Delete all unknown controllers

– Deletes unknown SM Controllers that was previously published in Experion but does
not exist in current plant database.
– Use this option to remove SM Controllers from Experion that were deleted in Safety
Builder

• Delete all Before Update

– Deletes all the points which are published as part of the selected controller and re-
publishes the points (application)
– Do not use without using all qualifications

• Force Update all

– Forcefully updates all the points even if they are not modified
– The Force All option is only recommended in case some changes that have been
published are not seen on Experion
– Do not use without meeting all qualifications

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Safety Manager Publishing Honeywell

This Method of Publishing will

occur automatically after OLMs,
after some offline loads and
after some failed loads that later
succeed

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Safety Manager Publishing Honeywell

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Topics Honeywell
• What are the features and characteristics of the integration?

• Which hardware is necessary for the Integration?

• How is a connection between Safety Manager and Experion Server

configured?

• How is a connection between Safety Manager and C300 configured?

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Configuration Overview Honeywell
• Safety Manager configuration
– Create Physical & Logical Network
– Allocate Input points with PLC addresses
– Verify the “Parent Asset” has been configured in configuration studio
– Compile & Download application to Controller (if Parent Asset has been
configured in Configuration Studio)
– Publish Points to Experion Server (after Parent Asset has been configured
in Configuration Studio)

• C300 Controller Configuration

– Create and configure Parent Asset
– Create and configure C300 block
– Create and configure C300 Control and Execution Environment block
– Configure the IO Links
– Create the Control Modules
– Download

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Safety Manager C300 Configuration Honeywell

• Select Process (Process) Controller and place on Plant. Properties will

appear but at this time it can only be named

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Safety Manager C300 Configuration (Physical Network) Honeywell

Choose the Fault Tolerant Ethernet

from Components and place it on
Process Controller

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SM C300 Logical Connection Properties Honeywell

Choose Add Logical

Connection Node ID
Connects to
Choose Process MySMController
Controller Via the Experion
CDA
Right click on Process
controller and choose
Logical Network
Properties

Timeout is used
It is only necessary
to detect a faliure
to configure memory
of the
space for DI’s and
communication
BI’s for CDA
link
communication

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C300 Control Builder Configuration Honeywell

Choose Control Strategy first

Then Choose the box

Control Strategies and
Configure Process
Control Strategy

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C300 Control Builder Configuration (Controller Selection) Honeywell

The first item to be built is the C300 Controller with 2IO Links. This is Hardware related

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C300 Control Builder Configuration (Controller Block) Honeywell

The Default
Screen for
SYSTEM:C300
Block

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C300 Control Builder Configuration (Contd’) Honeywell

These Boxes
Require Entry

After the
download of the
entered
information the
following items
appear in the
tree

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C300 Control Builder Configuration: Parameters Honeywell

Defines the
Execution and
scheduling
Environment in
which user
defined control
Modules and
Sequential
Control Modules
Execute the
Application

Enter the Tag

Name and Item
Name #

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C300 Control Builder Configuration: Control Module Honeywell

Next the Control

Modules require
configuration.
Navigate to Control
Module and select

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C300 Control Builder Configuration Honeywell

Use the connector that

allows a point to be Pull down appropriate
entered symbol from the library.
An AND Block is
chosen for this
example

The Format is: xx_FLD Number .Tag.

Parameter. The xx is user defined
name which is not required

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C300 Control Builder Configuration Honeywell
• Complete building the logics in the Control Modules

• Download

• Activate

• CDA Data Exchange should be initiated

• The On Line Environment will be explored in another training module.

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Safety Manager Control Builder Configuration Honeywell

This is the
tree structure
that has been
built. It will
correspond to
the tree in
Experion
Station which
will be seen
on next slide

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Safety Manager Control Builder Configuration Honeywell

In the preceding
slide, the tree is
shown from the
Configuration
Studio tool. This
Screen Shot is
after download to
Experion as seen
in the Experion
Station

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Summary Honeywell
• What are the features and characteristics of the integration?
– Total Plant Wide System Integration
– Approve/ Certified Data Exchange
– Reduced Engineering
– Integration using the FTE infrastructure
– Peer to Peer connection to Process Controllers

• Which Hardware is necessary for integration?

– USI’s
– Controller Back Plane
– Westermo Switches
– Routers

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Summary Honeywell
• How is connection between Safety Manager and Experion Server
Configured?
– Create Physical & Logical Network
– Allocate Input points with PLC addresses
– Verify the “Parent Asset” has been configured in configuration studio
– Compile & Download application to Controller (if Parent Asset has been
configured in Configuration Studio)
– Publish Points to Experion Server (after Parent Asset has been configured
in Configuration Studio)

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Summary Honeywell
• How is connection between Safety Manager and C300 Controller
Configured?
– Create Physical & Logical Network
– Allocate Input points with PLC addresses
– Verify the “Parent Asset” has been configured in configuration studio
– Compile & Download application to Controller (if Parent Asset has been
configured in Configuration Studio)
– Publish Points to Experion Server
– Create and Configure Asset
– Create and configure C300 block
– Create and configure C300 Control and Execution Environment block
– Create and Configure IOTA
– Configure the IO Links
– Create the Control Modules
– Download

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Test Questions - Question 1 Honeywell
• Which communication medium is used for the Experion PKS
integration?

a) UCN Network

b) Fault Tolerant Ethernet

c) RS-232 Network

d) None of the above

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Test Questions - Question 2 Honeywell
• Where can it be defined how many signals can be transferred between
Safety Manager and C300 Controller?

a) In the Quick Builder

b) In the Point Configurator

c) At the USI

d) At the Logical Network Properties of Network Configurator

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Test Questions - Question 3 Honeywell
• What is Control Builder for?

a) To configure the Channel and download this to the Experion Server

b) To configure the Controllers and download this to the Experion Server

c) To configure the Points and download this to the Experion Server

d) A single builder tool allowing integrated application configuration

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Test Questions - Question 4 Honeywell
• What Tool creates a Control Module?

a) The Network Configurator

b) Control Builder

c) The SM2XperionConverter

d) None of the above

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Test Questions - Question 5 Honeywell
• Control Execution Environment is

a) In the Physical Control Properties of Network Configuration

b) Where the Controller Executes the application

c) At the PCDI Master block in Control Builder

d) Answers a & b are both correct

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Conclusion Honeywell

Describe SM Experion PKS Integration (CDA)

Completion
Certificate

Proceed to the next lesson in your course material

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 Honeywell

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Topic: Safety Manager Experion PKS Integration (CDA)
Contents
Experion PKS Integration - CDA ...................................................................................................... 3

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 Safety Manager Experion PKS Integration (CDA)
Experion PKS Integration - CDA

Experion PKS Integration - CDA

Introduction
CDA (Control Data Access) is the communication backbone of Experion™ PKS system.
CDA Protocol allows:
• Experion to access data of Safety Manager
• HMI Graphics to display Safety Manager Points
• Peer to Peer communication
• To view Safety Manager system alarms in Experion
In this lab we will configure the connection between Safety Manager™ and Experion™
PKS, configure process points in Safety Manager™ and publish these process points on
Experion™ PKS.

Prerequisites
To qualify for these exercises the trainee should meet the following prerequisites:
• Viewed training module Experion Integration (CDA)
• Knowledge of how to configure a Safety Manager system
• Safety Builder installed on PC
• Safety Manager system with Remote Universal Safe I/O modules connected and the
training application loaded
• Experion server connected to the Safety Manager system via Fault Tolerant Ethernet
• Configuration Studio and Experion station available
• Ethernet connection between Safety Station and Safety Manager system
Description
In the lab procedure of Experion PKS - CDA, the integration of Safety Manager in the
Experion environment will be configured. We will configure the points and FLD’s to be
published from Safety Station to Experion. First the training application of the Safety
Manager will be modified and the system will be updated via the on line modification
procedure. After the OLM, all the information will be published to the Experion Server.
Then a second modification will be implemented in the same fashion where a digital input
will be configured to implement a reset signal coming from the Experion Server.
Audit trail

TIP
Audit Trail is an integrated tool, which logs
all the changes that are made to the
application.

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At some stages when executing the procedure, a window as shown in the figure below will
appear.

Audit trail event justification

This is the Audit Trail window. It is a common practice to enter a brief description as
justification (a reference to the documentation is useful) and fill in your initials when the
windows user account is used by multiple persons.
Check the checkbox for ‘Accept future changes with this justification’ to log all work with
the same justification. After this is done just press OK.

Attention

It is necessary to install “Safety Manager R152.1

“Experion Components.msi” during Safety Manager
CDA integration.
This installer package allows us to view the Safety
Manager system alarms on the Experion Station

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Experion PKS lab procedures

Practice

Step Action

Stage A: Preparing the On Line Modification

A1 Make sure the application in the SM Controller and the Safety Station are
identical.
To do so, perform steps A.1.a to A.1.f of the On-Line Modification procedure in the On-
line Modification Guide.

TIP
The On-line Modification Guide is located in the
category “Installation and Upgrades” of the Honeywell
Knowledge Builder.

A2 Make a backup of the application files in your project folders.

To do so, perform steps A.2.a to A.2.c of the On-Line Modification procedure in the On-
line Modification Guide.

A3 Make sure the on-line modification option is activated.

To do so, perform steps A.3.a to A.3.f of the On-Line Modification procedure in the On-
line Modification Guide.

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Stage B: Modifying the Application

The following FLD sheets will be used in the lab procedure

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Step Action

Stage B: Modifying the Application

B1 Make the required modifications to the application and verify.

To do so perform steps B.1.a to B.1.h for the On-Line Modification procedure in the On-
line Modification Guide.
For step B.1.b “modify the application”, perform the following steps:

Attention

CDA protocol will only be configured when

QPP-0002 and USI-0002 are selected in Hardware
Configurator

B2 Open the Network Configurator, and drag and drop an Experion server on the Plant in
the Physical view.

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Step Action

B3 Set the Experion Server properties as in the below screen shot:

If there are multiple Experion Clusters present then to Publish the application on desired
Experion Server the correct Experion Server Properties must be entered in Safety Builder.
Add the corresponding Host name or IP Address of the Primary Server in Experion Server
Properties

The trainer will provide the correct Host name to use.

Press OK when finished.

Attention

Ensure that correct Host name is added to publish

the application on desired Experion Server

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Step Action

B4 The Experion Server will be connected via the same Ethernet network that is used for
the Safety Station. To create the Physical Network connection, drag and drop the
Physical Network from the explorer bar on the Experion Server.

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Step Action

B5 If the Physical Network is released, the SM Controller is automatically connected.

If the + sign is clicked left from the Physical Network, the SM Controller will be visible.

TIP
The Physical Network Fault Tolerant Ethernet was
configured as Ethernet in the “Network Configurator
lab exercises”.
The properties of the Physical Network and the
SM Controller therefore need adjustment for the
CDA Integration. The same Ethernet port of the
™
USI’s is used for both Safety Station and Experion
server.

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Step Action

B6 For the CDA Integration, the Physical Network Fault Tolerant Ethernet needs to be
configured as Fault Tolerant Ethernet in the Physical Network Properties.
Set the Physical Network properties as in the below screen shot:

IP address:
• This field is only applicable when FTE is selected
• This field represents the Base IP address of FTE Network (Network IP address)
• The FTE Device index configured in SM Controller properties in combination with
Network IP address is used for calculating the IP address for Safety Manager
• The actual IP address is obtained directly from Bootp Server

Attention

This is not the IP address assigned to Safety

Manger.
IP address configured here must be equal to the
Base IP address configured in System Preferences
option in Control Builder

Press OK when finished.

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Step Action

B7 Set the Safety Manager Controller properties as in the below screen shot:

The trainer will provide the correct FTE device index to use.
Press OK when finished.

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Step Action

B8 After the Physical Network is correctly configured, the Logical Network for the Experion
Server needs to be added.
Select the Logical View via the Logical View tab.

B9 Right-click the Controllers list and select Add Logical Connection from the pop-up
menu, or click the Add Logical Connection button in the button bar.

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Step Action

B10 Right-click the new logical connection row and select Properties from the pop-up menu.

B11 The Logical Network Properties dialog will appear.

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Step Action

B12 Set the properties for the logical network as shown in the below screenshot:

TIP
The Marker In size is set at 100. This means 800
Digital Inputs can be transferred from the Experion
Server to Safety Manager via the link. The
Register In size is set at 1000. This means 500
words can be transferred as Binary Inputs via the
link between the Safety Manager and Experion.
Press OK when finished.
The Logical Network View is now completed.

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Step Action

B13 Enable the Experion Server SOE collection as shown in the below screen shot:

Press OK when finished.

B14 Enable the Safety Manager System SOE generation (In SM Controller Properties)
and set the SOE ID range as in the below screen shot:

Press OK when finished.

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Step Action

B15 The next step is to set the alarming and SOE reporting for the points. First open the Point
Configurator.

B16 Make sure that the View All points sorted on Type and Tag is selected.

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Step Action

B17 Create a Point by clicking the Point Type select button.

The new AI is now added to the point list. The Tag number Analog Input is used. The user
can alter the point details as desired.

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Step Action

B18 Modify the Point details of the created Analog input by using the Point Database table

Table: Point Database

Type Tag number Location Description SOE Alarm Normal State/

Enable Priority Limit

AI AI-FLD-Float FLD AI-FLD-Float No Journal Not Applicable

AO AO-FLD-Float FLD AO-FLD-Float No Journal Not Applicable

BI BI_COM_Byte COM BI_COM_Byte No Journal Not Applicable

BO BO_COM_Byte COM BO_COM_Byte No Journal Not Applicable

DI DI_FLD_Alr_High FLD DI_FLD_Alr_High Yes High NORMALSPEED

DO DO_FLD_Alr_High FLD DO_FLD_Alr_High Yes High RUNTURBINE

DI DI_COM_Alr_High COM DI_COM_Alr_High Yes High NORMALSPEED

DO DO_COM_Alr_High COM DO_COM_Alr_High Yes High RUNTURBINE

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Step Action

B19 Fill in the details as shown in Point Database table

Attention

Hardware allocation and communication allocation

details will be provided by trainer

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Step Action

B20 Now for Options and Experion tab fill in the details as show below

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Step Action

B21 Repeat Steps B17 to B 20 to add all the points from Point Database table
AO_FLD_Float:

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Step Action

B22 BI_COM_Byte:

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Step Action

B23 Similarly Create BO_COM_Byte

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Step Action

B24 DI_FLD_Alr_High:

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Step Action

B25 DO_FLD_Alr_High:
Fill in the properties for DO_FLD_Alr_High as in Point Database table

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Step Action

B26 Refer to the point Database table and fill in the properties for rest of the points
DI_COM_Alr_High

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Step Action

B27 DO_COM_Alr_High

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Step Action

B28 The next step is to create the FLD mentioned above.

To do so, refer steps of Create FLD 10 procedure in the Application editor Lab

B29 Select the first FLD from the table above (FLD 0001), go to Application Editor and select
FLD Properties.

Refer the below table FLD Experion Properties to fill in the FLD Properties details

Table: FLD Experion Properties

FLD FLD Title Parent Asset Item Name

1 ECIREG_FLD0001 ECI ECIREG_FLD0001

2 ECIREG_FLD0002 ECI ECIREG_FLD0002

53 ECIREG_FLD0053 ECI ECIREG_FLD0053

54 ECIREG_FLD0054 ECI ECIREG_FLD0054

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Step Action

B30 In the FLD Properties dialog set the designated Parent Asset and the Item Name for the
FLD on the Experion Tab.

Click OK.

B31 Repeat steps B22 and 23 for other FLD’s from the table above.

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Step Action

Stage C: Control Builder Configuration

C1 Open Configuration Studio.

Connect to System.
Click on Configure Assets for this system.

C2 Click on Files and Select New ASSET…

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Step Action

C3 Enter the Asset Name and

Item Name in Main Tab

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Step Action

C4 Click on the Identification tab.

Enter the Name same as Asset Name.

C5 Close the window. Click on the Download Icon.

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Step Action

C6 Download screen appears.

Click OK.

C7 Once downloading is complete the following screen appears.

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Step Action

Stage D: Upgrading the SM Controller

D1 Check the SM Controller before upgrading.

To do so perform steps C.1.a to C.1.d for the On-Line Modification procedure in the On-
line Modification Guide.
D2 Upgrade the SM Controller.
To do so perform steps C.2.a to C.2.w for the On-Line Modification procedure in the On-
line Modification Guide.

D3 Make a backup of the loaded application files.

To do so perform steps C.3.a to C.3.d for the On-Line Modification procedure in the On-
line Modification Guide.

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Step Action

Stage E: Publishing the SM points to Experion

E1 Select the controller.

Choose Publish Configuration from the File.

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Step Action

E2 Click on Publish.

Attention
Do not use checkboxes without reviewing the
requirements.

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Step Action

Stage F: Viewing the SM points on HMI Screen

F1 Open a HMI Web Display Builder from Configuration Studio.

Select Display and click on Create new Normal Display.
Or
You can browse to HMI Web Display Builder from Start Menu.

F2 Click Textbox component from the tool-bar to the Display page.

F3 Enter Text as Forced

We will configure two parameters for point AL_FLD_Float, one status one Analog
Status- Forced
Analog- PV
In the following steps we will show Status tag which Indicate the tag is forced or not

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Step Action

F4 Format the Textbox as shown

F5 Click Alphanumeric component from the tool-bar to the Display page.

F6 Double click on the Alphanumeric to open the Properties

Click on the Data Tab

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Step Action

F7 Click on the Point Browser Symbol

It opens the browser window which shows all the Points which you have configured as the
FLDs in Safety Builder.

Attention

FLDs configured in Safety Builder for CDA protocol

are considered as points in HMI Web Builder and
the points configured in FLD are Parameters for the
corresponding tag

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Step Action

F8 Select ECIREG_0001 then.

Click on the Parameter Drop Down.
It shows all the parameter types of SM Points configured in the FLD ECIREG_0001.

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Step Action

F9 Select AI_FLD_Float.Forced from the Parameter drop-down.

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Step Action

F10 Click on the Details tab.

Select State descriptor from the dropdown for the field Display as.

Close the Window.

F11 Rearrange the Textbox and Alphanumeric

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Step Action

F12 Similarly Add Textbox for PV

In the following steps we will show Analog tag which displays PV Value

F13 Add Alphanumeric and configure following details in Data tab and in Parameter

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Step Action

F14 Click on the Details tab.

Select Numeric from the dropdown for the field Display as

F15 Add a textbox (AI_FLD_Float) which will Indicate point that is configured in Safety Builder
Point Configurator and FLD

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Step Action

F16 Again Insert a textbox as “Forced” which will indicate the forced status for Digital Input
tag

F17 Click Alphanumeric component from the tool-bar to the Display page and open the
properties.
Assign the properties in Data tab as shown below

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Step Action

F18 Select State Descriptor in Details tab and close the window

F19 Now insert a textbox as “PV”

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Step Action

F20 Click on Alphanumeric component from the tool-bar to the Display page and open the
properties to assign the properties in Data tab and Details tab as shown below

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Step Action

F21 Insert a text box and enter a tag name for DI tag

F22 Save the Display.

Under following Path
C:\ProgramData\Honeywell\Experion PKS\Client\Abstract
File Name as - CDA_Test

F23 Browse and connect to Station from Start Menu> All program>Honeywell Experion
PKS>Server>Station

F24 Call the Display in the station by Typing the CDA_Test in Command window and Press
Enter

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Step Action

F25 Observe the Forced status for configured tags

F26 Open the SM application in Online Environment in application viewer Mode.

Force AI Tag.

F27 Also force a DI tag to view the stats on station

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Step Action

F28 Observe the value on the Station.

F29 Click on the Alarm to view Alarm Summary

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Step Action

F30 You will observe all the alarms for the tags configured in SM which come under the asset
ECI in the alarm summary.

F31 Now click on System to view system status and alarms

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Step Action

F32 Double Click on MySMController_XX to view Safety Manager controller detail display

F33 Similarly double click on each SM hardware component to view its detail displays

F34 BKM Status

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Step Action

F35 CP Status Display

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Step Action

F36 IO Bus Status

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