Cdweb Control For Proflow: System Manual

CDWeb Control
for ProFlow
System Manual
6510020139
CDWeb
Control System Manual
for ProFlow
Revised November 2003

Confidentiality Statement
This manual is a product of Honeywell. It is intended for use only by Honeywell and customer personnel in
connection with Honeywell products. It is strictly prohibited to copy this manual or any part thereof or to
transfer this manual or any part thereof to any non-Honeywell person or entity, except customer personnel
for use in connection with Honeywell products. Persons employed by a third-party service company shall
not have access to this manual.
Notice
All information and specifications contained in this manual have been carefully researched and prepared
according to the best efforts of Honeywell, and are believed to be true and correct as of the time of this
printing. However, due to continued efforts in product improvement, we reserve the right to make changes
at any time without notice.
To order additional or revised copies of this publication, contact Honeywell, 500 Brooksbank Ave, North
Vancouver, B.C., Canada V7J 3S4. Telephone (604) 980-3421.
Trademarks
AutoSlice, ProCoat, ProSlice, ProFlow, CDWeb, CDConnect and CDWeb Manager are registered trademarks
of Honeywell. All other product names are mentioned for identification purposes only and may be
trademarks of their respective companies.
Copyright
© 2003 Honeywell
500 Brooksbank Ave, North Vancouver, BC, Canada V7J 3S4.
All rights reserved. No part of this publication may be reproduced or translated, stored in a database or
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of Honeywell.
Printed in Canada.
Contents
Table of Contents
Contents ..................................................................................................................................................... i
Table of Contents................................................................................................................................. i
List of Figures ..................................................................................................................................viii
List of Tables ...................................................................................................................................... ix
Preface ....................................................................................................................................................... x
About This Manual ............................................................................................................................ x
Related Reading................................................................................................................................. xi
Conventions ....................................................................................................................................... xi
Honeywell Part Numbers ..............................................................................................................xiii
Chapter 1. CDWeb System Overview ................................................................................................ 1

Introduction ........................................................................................................................................ 1
LonWorks Introduction................................................................................................................... 3
Neuron Chip ................................................................................................................................. 3
LONTALK Protocol ..................................................................................................................... 3
LONTALK Addressing ......................................................................................................... 4
Channel.............................................................................................................................. 4
Domain .............................................................................................................................. 4
Subnet ................................................................................................................................ 4
Group ................................................................................................................................. 4
Network Topology................................................................................................................. 5
Network Components ........................................................................................................... 5
Transceivers ...................................................................................................................... 5
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Contents CDWeb Control System Manual
Routers................................................................................................................................6
Network Variable Messages..................................................................................................6
Chapter 2. CDWeb Manager.................................................................................................................7

Overview..............................................................................................................................................7
Power Conversion and Distribution ................................................................................................9
Protocol Conversion ...........................................................................................................................9
Supervisory Control System Communication Interface .......................................................10
Actuator Communication Interface .........................................................................................11
Rack Configuration...........................................................................................................................11
CDWeb Processor .......................................................................................................................11
General Description..............................................................................................................11
EPC-8A VMEbus Controller................................................................................................12
Specifications .........................................................................................................................13
Hardware Configuration .....................................................................................................13
Lithium Battery .....................................................................................................................15
BIOS Configuration ..............................................................................................................15
EXM-LTNI LonWorks Network Interface Card.....................................................................16
General Description..............................................................................................................16
Hardware Configuration .....................................................................................................16
Backplane (EXP-BP2)..................................................................................................................18
Software..............................................................................................................................................18
The File System ...........................................................................................................................18
Lon Task .......................................................................................................................................21
Longate task.................................................................................................................................21
ODX Task .....................................................................................................................................21
SCL Task.......................................................................................................................................22
RTU Task......................................................................................................................................23
Actuator Task ..............................................................................................................................24
Diagnostic Task ...........................................................................................................................26
Monitor Task................................................................................................................................27
Console Task................................................................................................................................28
File Transfer Task........................................................................................................................29
Additional Notes.........................................................................................................................29
Chapter 3. Host Communications......................................................................................................31

ODX ....................................................................................................................................................31
CDWeb Manager Network Communication Specification ..................................................31
Introduction ...........................................................................................................................31
Read Number of Actuator Zones .................................................................................33
Write LAN Alarm Word ................................................................................................33
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CDWeb Control System Manual Contents
Write System Status ....................................................................................................... 33

Read Setpoint and Position Scaling ............................................................................. 34
Read Actuator Setpoints................................................................................................ 35
Write Actuator Positions and Status ........................................................................... 35
Read Mode Flag.............................................................................................................. 36
Read/Write Actuator Enable Array ............................................................................ 36
Read Actuator Reset Array ........................................................................................... 37
Write Communications Active..................................................................................... 37
Write ProTrim Positions................................................................................................ 37
SCL ..................................................................................................................................................... 40
CDWeb Manager Serial Communication Specification........................................................ 40
Transmission Control Characters ............................................................................................ 41
Message Format.......................................................................................................................... 41
Establishment and termination of link.................................................................................... 42
Functions ..................................................................................................................................... 43
Function type 00: System commands and related messages ......................................... 43
Subfunction type 00: System status read .................................................................... 43
Subfunction type 02: Reset Link................................................................................... 43
Subfunction type 03: Clear alarms............................................................................... 44
Function type 01: Error notification messages ................................................................. 44
Subfunction type 01: Illegal function........................................................................... 44
Subfunction type 02: Illegal subfunction .................................................................... 44
Subfunction type 03: Illegal destination address....................................................... 45
Subfunction type 05: Inconsistent data ....................................................................... 45
Subfunction type 06: Unsuccessful transmission ...................................................... 45
Function type 02: Single data write message ................................................................... 45
Subfunction type 00: Set operating mode................................................................... 45
Subfunction type 01: Write number of zones............................................................. 46
Function type 03: Write sequential arrays ........................................................................ 46
Subfunction type 01: Write setpoints .......................................................................... 46
Function type 04: Write random arrays ............................................................................ 47
Function type 05: Single data read message..................................................................... 48
Subfunction type 00: Read operating mode ............................................................... 48
Subfunction type 01: Read number of zones.............................................................. 48
Function type 06: Read sequential arrays ......................................................................... 48
Subfunction type 00: Read zone status ....................................................................... 49
Subfunction type 01: Read actuator setpoint or position ......................................... 50
Function type 07: Read random arrays ............................................................................. 50
Function type 08: Write ASCII string ................................................................................ 50
Function type 20: Direct PLC memory access.................................................................. 51
Subfunction type 00: Write to PLC memory. ............................................................. 51
Subfunction type 01: Read from PLC memory .......................................................... 52
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Supported Functions and Setup for SCL Link........................................................................52

Data Link................................................................................................................................52
Application Messages ..........................................................................................................53
Function 0 - System Commands ...................................................................................53
Function 1 - Message Error Status ................................................................................53
Function 2 - Write Single Data ......................................................................................53
Function 3 - Write Sequential Arrays...........................................................................53
Function 4 - Write Random Arrays ..............................................................................53
Function 5 - Read Single Data .......................................................................................53
Function 6 - Read Sequential Arrays............................................................................54
Function 7 - Read Random Arrays ...............................................................................54
Function 8 - Write ASCII String ....................................................................................54
Function 20 - Direct Memory Access ...........................................................................54
Data Scaling ...........................................................................................................................54
Data Range.......................................................................................................................54
Scale Factor ......................................................................................................................54
Miscellaneous ........................................................................................................................54
RTU .....................................................................................................................................................56
CDWeb Manager Serial Communication Specification ........................................................56
Introduction ...........................................................................................................................56
Message Types ......................................................................................................................57
Message Fields.......................................................................................................................57
Station Address ...............................................................................................................58
Function Code .................................................................................................................58
Information Field ............................................................................................................59
Error Check Field ............................................................................................................59
Message Termination ...........................................................................................................59
Timeout Usage ......................................................................................................................59
Message Descriptions...........................................................................................................60
Function 03: Read Registers ..........................................................................................60
Function 16: Preset Multiple Registers ........................................................................61
Communication Errors.........................................................................................................62
Invalid Query Message ..................................................................................................62
Serial Link Timeout ..............................................................................................................63
Invalid Transaction...............................................................................................................64
MXOpen Protocol Extensions ...................................................................................................64
Actuator Status......................................................................................................................64
Actuator Reset .......................................................................................................................66
CDWeb Manager Registers .......................................................................................................67
Number of Actuators Register ............................................................................................67
System Status Registers........................................................................................................68
Actuator Type Register ........................................................................................................68
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Host Setpoint Registers ....................................................................................................... 68

Actuator Position Registers ................................................................................................ 68
Actuator Status Registers .................................................................................................... 69
Zone Enable/Disable Registers.......................................................................................... 70
Zone Reset Registers ............................................................................................................ 70
Actuator Status Flag Registers ........................................................................................... 70
Reset All Register ................................................................................................................. 70
Data Link ..................................................................................................................................... 70
Chapter 4. CDConnect Assembly...................................................................................................... 71

Hardware........................................................................................................................................... 71
Control Software .............................................................................................................................. 73
Actuator Configuration Values ................................................................................................ 74
Actuator Type ....................................................................................................................... 74
Maximum Status Send Rate................................................................................................ 75
Status Send on Delta Value................................................................................................. 75
Runaway Protection Enable................................................................................................ 75
Feedback Enable / Feedback Mode .................................................................................. 76
Version 1.00 ..................................................................................................................... 76
Check AC Zero Cross Enable (Version 1.00 only) ........................................................... 76
Hz Flag................................................................................................................................... 77
Version 1.00 to 1.01......................................................................................................... 77
Version 1.02 & greater ................................................................................................... 77
A/D Conversion Rate.......................................................................................................... 77
Startup Delay ........................................................................................................................ 78
DC Power Supply Error ...................................................................................................... 78
Status Startup Delay ............................................................................................................ 78
Communications Randomization Flag ............................................................................. 79
Reverse Direction Flag......................................................................................................... 79
Actuator Tuning Values ............................................................................................................ 79
Setpoint Upper Limit ........................................................................................................... 80
Setpoint Lower Limit ........................................................................................................... 80
Minimum Actuator Rate ..................................................................................................... 80
Feedback Sensor Filter Factor............................................................................................. 81
Minimum Control Cycles.................................................................................................... 81
Versions 1.00 to 1.01....................................................................................................... 81
Versions 1.02 & greater.................................................................................................. 81
Movement Failure Limit ..................................................................................................... 82
Runaway Limit ..................................................................................................................... 82
Position Deadband............................................................................................................... 83
Actuator Stop to Stop range................................................................................................ 83
Valve operating range ......................................................................................................... 83
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Crack Open to Low Flow.....................................................................................................83

Crack Open to High Flow....................................................................................................84
Feedback Sensor Low Alarm Limit....................................................................................84
Feedback Sensor High Alarm Limit...................................................................................84
Feedback Alarm Hysteresis.................................................................................................85
Modifying Configuration and Tuning Values........................................................................85
Actuator Commands ........................................................................................................................85
Function: 1 Change actuator mode. ......................................................................................86
Function: 2 Reset Actuator. ....................................................................................................88
Function: 3 Self test. .................................................................................................................88
Function: 4 Flush actuator. .....................................................................................................88
Function: 101 Define position (calibrate sensor) .................................................................88
Function: 102 Calibrate the A/D (position & millivolts) ...................................................89
Function: 104 change the open loop gain (ver. 1.02 and greater) .....................................90
Function: 105 change the startup cycles ...............................................................................90
Calibration .........................................................................................................................................91
Background..................................................................................................................................91
Actuator Scaling ................................................................................................................................92
Actuator Alarms................................................................................................................................93
Chapter 5. Utilities................................................................................................................................95
Overview............................................................................................................................................95
LonMaker ...........................................................................................................................................96
Hardware requirements.......................................................................................................96
Installing the SLTA driver ...................................................................................................97
Installing LonMaker .............................................................................................................98
Using LonMaker with Windows 95 ...................................................................................98
Starting LonMaker ..............................................................................................................100
Basic LonMaker Tasks........................................................................................................100
Node Installation...........................................................................................................100
Node Replacement........................................................................................................102
Troubleshooting LonMaker...............................................................................................103
Export .........................................................................................................................................104
TERM/Term95 ................................................................................................................................105
TERM and PC/TCP..................................................................................................................105
Term95 Installation and Setup ................................................................................................106
Running TERM and Term95 ...................................................................................................109
Using TERM...............................................................................................................................109
Using Term95 ............................................................................................................................112
CDWeb Explorer .............................................................................................................................114
Installing CDWeb Explorer .....................................................................................................115
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Using CDWeb Explorer........................................................................................................... 115
Chapter 6. How to ….......................................................................................................................... 117

Introduction .................................................................................................................................... 117
ProFlow Installation Box ................................................................................................... 117
Configure, Tune, and Calibrate Actuators ................................................................................. 118
Configuring actuators.............................................................................................................. 119
TERM/Term95 method..................................................................................................... 119
CDWeb Explorer method.................................................................................................. 120
Tuning an actuator ................................................................................................................... 121
TERM/Term95 method..................................................................................................... 121
Calibrating actuators with default values ............................................................................ 122
TERM/Term95 method..................................................................................................... 122
Calibrating an actuator manually/Two-point calibration ................................................. 124
Defining the current position of actuators............................................................................ 126
Replace a Failed CDConnect controller ...................................................................................... 128
LonMaker method.............................................................................................................. 128
Replace a Failed LonWorks Router ........................................................................................... 130
LonMaker method.............................................................................................................. 130
Replace a Failed CDWeb Processor............................................................................................. 131
LonMaker and TERM/Term95 method.......................................................................... 131
Install and Bind New CDConnects.............................................................................................. 133
LonMaker method.............................................................................................................. 133
Install and Bind a New LonWorks Router ............................................................................... 136
Install and Bind the CDWeb Processor ....................................................................................... 137
Create and Transfer an EXPORT.CSV File ................................................................................. 137
LonMaker and TERM/Term95 method.......................................................................... 138
CDConnect Maintenance using LonMaker ................................................................................ 139
Actuator Calibration ................................................................................................................ 140
A/D Calibration (Voltage):..................................................................................................... 142
Two-point: (only in versions 1.02 and greater) .............................................................. 142
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Manual Calibration:..................................................................................................................142
A/D Calibration (Position):.....................................................................................................142
Two-point Automated: ......................................................................................................142
Two-point: (only in versions 1.02 and greater)...............................................................143
Manual Calibration:............................................................................................................143
A/D Calibration (Voltage and Position): ..............................................................................144
Two-point: (only in versions 1.02 and greater)...............................................................144
Redefining Current Position for a Single Actuator (Crack Open) .....................................144
Changing the IP address of a CDWeb Manager ........................................................................145
TERM/Term95 method .....................................................................................................145
CDWeb Explorer method ..................................................................................................147
Appendix A. Installation Requirements ........................................................................................149

CDWeb Environmental Specification ..........................................................................................149
Mill Power Requirements ..............................................................................................................149
Voltage, Current and Frequency Ratings ..............................................................................150
Installation of distribution Circuits ........................................................................................150
CDWeb Manager Installation Details ..........................................................................................150
Enclosure Installation ...............................................................................................................150
Cable Installation ......................................................................................................................151
Storage Instructions ........................................................................................................................152
List of Figures
Figure 1-1. CDWeb System Schematic (AutoSlice) .............................................................................2
Figure 1-2. Network Topology...............................................................................................................5
Figure 2-1. CDWeb Manager Panel Layout .........................................................................................8
Figure 2-2. Jumper Configuration .......................................................................................................14
Figure 2-3. EXM-LTNI Configuration.................................................................................................17
Figure 2-4. Switch S1 configuration ....................................................................................................17
Figure 4-1. CDConnect Assembly for ProFlow .................................................................................72
Figure 4-2. CDConnect calibration curves ..........................................................................................91
Figure 4-3. ProFlow scaling relationships ...........................................................................................93
Figure 5-1 LonMaker Setup for Windows 95......................................................................................98
Figure 5-2 Windows 95 Memory Assignments for LonMaker.........................................................99
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Figure 5-3 Network Settings Dialog Box in Windows95................................................................ 107

Figure 5-4 TCP/IP Settings in Windows95 ...................................................................................... 108
Figure 6-1. RJ-45 cable connections .................................................................................................. 148
List of Tables
Table 1-1. Transceiver Specifications.................................................................................................... 6
Table 2-1. CDWeb Processor Specifications ...................................................................................... 13
Table 2-2. CDWeb Manager computer directory structure ............................................................. 19
Table 2-3. CDWeb Manager file names, locations and types........................................................... 20
Table 2-4. Lon Task Configuration Options ....................................................................................... 21
Table 2-5. Scl Task Configuration Options ......................................................................................... 23
Table 2-6. Rtu Task Configuration Options........................................................................................ 24
Table 2-7. Actuator Task Configuration Options .............................................................................. 25
Table 2-8. Monitor Task Configuration Options................................................................................ 28
Table 3-1. Application Manager Symbol Names ............................................................................... 38
Table 3-2. Actuator Zone Status Words .............................................................................................. 39
Table 3-3. SCL Actuator Status Alarms............................................................................................... 55
Table 3-4. RTU Functions ..................................................................................................................... 58
Table 3-5. RTU Error Codes ................................................................................................................. 62
Table 3-6. MXOpen RTU Actuator Status Fields .............................................................................. 64
Table 3-7. RTU Registers - CMM Mode ............................................................................................. 67
Table 3-8. RTU Registers - PCM Mode .............................................................................................. 67
Table 3-9. RTU Actuator Types ........................................................................................................... 68
Table 3-10. RTU Actuator Status Word.............................................................................................. 69
Table 4-1. Actuator commands functions .......................................................................................... 86
Table 4-2. Actuator Alarms................................................................................................................... 94
Table 5-1. CDWeb Explorer tasks versus port used....................................................................... 114
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Preface
About This Manual

The following manual has been written to support the installation,
commissioning and on-going maintenance of a CDWeb System.
Within this document exists a detailed description of the workings of the

CDWeb System, including the CDWeb Manager and the
AutoSlice/ProSlice/ProCoat CDConnect Assembly.
Both hardware and software aspects of the system are discussed.
This manual contains 6 chapters and an appendix.
Chapter 1, CDWeb System Overview, contains a brief discussion about

the CDWeb System and its major components.
Chapter 2, CDWeb Manager, describes the equipment and software

found in the CDWeb Manager.
Chapter 3, Host Communications, provides details about the

communications protocols between the CDWeb Manager and the host
control system.
Chapter 4, CDConnect Assembly, talks about the actuator controllers,

including the configuration and tuning parameters used during
installation and maintenance.
Chapter 5, Utilities, goes over the software tools and techniques used
when working with a CDWeb System.
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CDWeb Control System Manual Preface
Chapter 6, How To…, gives step-by-step procedures for working with a

CDWeb system.
Appendix A, Installation Requirements, provides necessary information

to install the ProFlow CDWeb Manager.
Related Reading
The following documents contain related reading material.
Honeywell P/N Document Title / Description
65 1002 0134 Installation Requirements for Conformance to

Standards
Conventions
The following conventions are used in this manual.
NOTE: Unless otherwise specified, you may type all text in uppercase or
lowercase.
Boldface Boldface characters in this special type indicate your input.

Special Type Characters in this special type that are not boldfaced indicate system
prompts, responses, messages, or characters that appear on displays,
keypads, or as menu selections.
Italics In a command line or error message, words and numbers shown in

italics represent filenames, words, or numbers that can vary; for
example, filename represents any filename.
In text, words shown in italics are manual titles, key terms, notes,
cautions, or warnings.
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Preface CDWeb Control System Manual
Boldface Boldface characters in this special type indicate button names, button
menus, fields on a display, parameters, or commands that must be
entered exactly as they appear.
lowercase In an error message, words in lowercase are filenames or words that

can vary. In a command line, words in lowercase indicate variable
input.
Type Type means to type the text on a keypad or keyboard.
Press Press means to press a key or a button.

[ENTER] [ENTER] is the key you press to enter characters or commands into the
or [RETURN] system, or to accept a default option. In a command line, square
brackets are included; for example:
SXDEF 1 [ENTER]
[CTRL] [CTRL] is the key you press simultaneously with another key. This
key is called different names on different systems; for example,
[CONTROL], or [CTL].
[KEY-1]-KEY-2 Connected keys indicate that you must press the keys simultaneously;
for example,
[CTRL]-C.
Click Click means to position the mouse pointer on an item, then quickly
depress and release the mouse button. This action highlights or
“selects,” the item clicked.
Double-click Double-click means to position the mouse pointer on an item, then

click the item twice in rapid succession. This action selects the item
“double-clicked.”
Drag X Drag X means to move the mouse pointer to X, then press the mouse
button and hold it down, while keeping the button down, move the
mouse pointer.
Press X Press X means to move the mouse pointer to the X button, then press
the mouse button and hold it down.
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CDWeb Control System Manual Preface
Honeywell Part Numbers

Honeywell assigns a part number to every manual. The part number
appears on every page in the footer. Sample part numbers are as follows:
P/N 6510020004
P/N 6510020048
The first two digits of the part number are the same for all Honeywell
division products. The next four digits identify part type. Technical
publications are designated by type numbers 1002.
The next four digits identify the manual. These digits remain the same for
all rewrites and revision packages of the manual for a particular product.
P/N 6510020139 - Rev. 02 98/11/09 xiii

Chapter 1. CDWeb System Overview
Introduction
The Honeywell CDWeb system is a distributed actuator control system
that holds many advantages over a conventional PLC-based control
system. These advantages include:
• Reduced floor space required for interface cabinets;
• Improved installation costs by using a bus topology that reduces the

cabling requirements between the actuators and the control system;
• Better performance by replacing a centralized PLC-based controller

with small, microprocessor-based modules controlling individual
actuators (see Figure 1-1).
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Chapter 1. CDWeb System Overview CDWeb Control System Manual
Profile Link Host

Control
System
Ethernet
CDWeb
Scanner System Manager
Power and Communications Bus
Actuator
CDConnect Assembly
Figure 1-1. CDWeb System Schematic (AutoSlice)
The main components of the CDWeb System are:
• CDWeb Manager: The CDWeb Manager contains an industrial

computer referred to as a CDWeb processor. This device acts as a
protocol converter between the Supervisory Control System and the
CDWeb system. The CDWeb Manager also distributes power and
communication signals to the CDConnect assemblies.
• CDConnect assemblies: the function of these devices depends upon

the type of actuator that it must interface with. For weight control
actuators (AutoSlice, ProSlice, ProCoat, ProFlow), these devices act as
actuator controllers, monitoring actuator status and controlling to set
point positions.
• Power and Communications Bus: the bus supplies power and

communications to the actuators from the CDWeb Manager.
• Actuators: each actuator (or in the case of the ProFlow, every four
actuators) is controlled by a CDConnect control assembly. The
CDConnect assembly communicates with the CDWeb processor,
exchanging status and control information.
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CDWeb Control System Manual Chapter 1. CDWeb System Overview
LonWorks Introduction
The CDWeb architecture is based on Echelon Corporation’s LonWorks
technology. At the core of the LonWorks technology is a micro-controller
dubbed the NEURON CHIP. This micro-controller is currently
manufactured by both Motorola and Toshiba.
Neuron Chip
The NEURON CHIP implements a 7-layer networking protocol (modeled
after the ISO OSI reference model) using two of the three built-in
processors. The third processor executes your application-specific code.
Some features of the NEURON CHIP are:
• A communications port that will interface to a variety of media

interfaces, including twisted pair, RF, infrared, coaxial and fiber
optic.
• Eleven I/O pins to interface to application-specific external

hardware. The programming model allows the designer to declare
one or more pins as an I/O object. An object could be a simple
binary input or output, or a more complicated object such as a dual-
slope A/D input, a serial input/output, or a triac output.
• Internal RAM and EEPROM for data or program storage.
• Internal or external ROM for program storage.
LONTALK Protocol
The LONTALK protocol is a complete networking protocol that follows
the ISO OSI reference model. This includes support for multiple
communication channels, network routers, and network management.
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LONTALK Addressing
Channel
A channel is a physical transport medium for data packets. A LonWorks

network is comprised of one or more channels. The physical form of the
channel depends on the medium used.
Twisted-pair channels are physically limited to 64 nodes per channel.
For CDWeb applications, the number of nodes that can reside on a single
channel will depend on the application, and the network message
requirements.
Domain
A domain is a logical collection of nodes on one or more channels.

Communications can only take place among nodes configured in a
common domain. A node can be configured to belong to a maximum of
two domains.
For CDWeb applications, all LonWorks nodes of a similar type will

belong to a common domain.
Subnet
A subnet is a logical collection of up to 127 nodes in a domain. Up to 255

subnets can exist in a single domain. All nodes in a subnet must be on the
same segment (A segment may be one or more physical channels linked
together by bridges or repeaters). Subnets cannot span across intelligent
routers (to be discussed).
Group
A group is a logical collection of nodes within a domain. Unlike a subnet,

nodes are grouped together regardless of the physical location of the node
within a domain. A node can be a member of up to 15 groups. Groups
are useful when it is required to communicate common information (a
message) to several nodes. By communicating a message from one node
to many nodes, network bandwidth is used efficiently.
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CDWeb Control System Manual Chapter 1. CDWeb System Overview
Network Topology
The following topology is a typical CDWeb implementation. Note that for
this example, a maximum of 64 nodes exist within a single subnet.
All nodes are common to a single domain.
Domain 1
Channel 1
Router 1
Network
Channel 4 Nodes 1-64 Terminator
Subnet 1
CDWeb Router 2
Channel 2
Manager
Nodes 65-128 Network
Terminator
Subnet 2
Channel 3
Router 3
Network
Nodes 129-196 Terminator
Subnet 3
Figure 1-2. Network Topology
Note that the channel 4 media may or may not be different from the media
used in channels 1-3.
Network Components
Transceivers
Twisted pair transceivers are currently used for CDWeb actuator

applications.
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The transceivers supported include; the transformer-coupled twisted pair

transceivers TP/XF-78 and TP/XF-1250, the free topology TP/FT-10.
The following specifications exist for each of these transceivers:
Table 1-1. Transceiver Specifications
Performance TP/XF-78 TP/XF-1250 TP/FT-10

Specification
Transmission Speed 78 kbps 1.25 Mbps 78 kbps

Nodes per Channel 64 (0 to 70 °C) 64 (0 to 70 °C) 64 (-40 to 85 °C)
Network Bus Wiring UL Level IV, 22 AWG (0.65 mm) twisted 22 to 16 AWG,
pair see user’s guide
for qualified types
Network Stub Wiring UL Level IV, 22 or 24 AWG (0.50 mm)
twisted pair
Network Bus Length
- typical 2000 m 500 m 500 m
- worst case 1330 m 125 m
Maximum Stub 3m 0.3 m (0 to 70 °C) 3m
Length 0.6 m (-40 to 85 °C)
Routers
A message transmitted from the CDWeb processor is destined for a single

node. All routers receive the message. Each router will check the
destination address of the message with its internal routing tables. Only
one router (therefore only one channel) will forward the packet. In this
way, the bandwidth of the channel is used more efficiently.
The routing table is defined by a Network Management Tool. Configured

routers can be configured to selectively forward group packets.
Network Variable Messages

Messages between the CDWeb processor and the actuators have
predefined formats. Each message contains a network variable are
described in Appendix A for reference purposes only.
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Chapter 2. CDWeb Manager
Overview
The CDWeb Manager consists of:
• a protective enclosure;
• an industrial PC;
• power conversion devices (transformers, DC power supplies) ;
• protection devices (circuit breakers, fuses);
• communications devices (routers, Ethernet converters, RS-485
converters);
• digital I/O for interlock control (where applicable); and
• analog inputs for ProTrim sensor support (where applicable).
The primary functions of the CDWeb Manager are:
• protocol conversion between the Supervisory Control System and the

actuators;
• power and communications distribution to the actuators;
• power conversion between the site supplied power and the devices
comprising the system; and
• maintenance of system interlocks.
The following figure is an example panel layout for the CDWeb Manager:
P/N 6510020139 - Rev. 02 98/11/09 7 - 151

Chapter 2. CDWeb Manager CDWeb Control System Manual
Card Rack Line Filter

(Standard) (Standard)
LF-1
Router #1
(Standard)
ROUTER #1
0 1 2 3 4 5 Router #2 (Required if system
is greater than 64 zones)
P/S1 Power Supply #1
RACK No. 0 ROUTER #2 (Standard)
TS11 Terminal Strips 2, 3, 11

(Standard)
TS2 Terminal Strips 1, 4

(Standard)
TS3
TS4 Terminal strips 7, 8

(Standard)
TS12
erminal Strip 12
TS7 TS8
Power Supply #2
(Standard)
TS1
Terminal Strip 13
P/S2 TS13 (Required if Communications to
CDWeb Manager is via a serial link)
Transformer
(Not required if an AutoSlice system
and supplied voltage is 110VAC)
TS6 Terminal Strips 6, 9

(Standard)
TS9
Terminal Strip 10 (Required if
system is greater than 64 zones)
TS10
TR-1
Figure 2-1. CDWeb Manager Panel Layout
Power supply P/S1 supplies 12 VDC to the router(s) located in the top
right corner of the CDWeb Manager.
Power supply P/S2 supplies 24 VDC to the CDConnect assemblies

associated with the actuators. The 24 VDC powers the CDConnect
electronics as well as the actuator position sensor. This power supply also
has remote sense inputs that can be used to compensate for a voltage drop
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CDWeb Control System Manual Chapter 2. CDWeb Manager
across long cable runs between the CDWeb Manager and the junction box
or actuators.
The card rack contains a VME backplane and houses the cards necessary
for the protocol conversion, system interlock maintenance, and ProTrim
sensor support. All CDWeb Managers have a power supply and at least
one EPC-8A industrial computer for the protocol conversion in the rack.
Digital I/O cards are present only in those systems with interlocks.
Analog input cards are present only in systems with ProTrim sensors.
Power Conversion and Distribution

For weight control actuator systems, the actuators receive power from the
CDWeb Manager. Depending upon the type of actuator and the
installation site, a transformer may be required to convert the site-
supplied AC voltage to the actuator required voltage. AC supply
frequency (50 or 60 Hz) is accommodated through the use of different
phase-shift components on each CDConnect circuit board.
A 24 VDC power supply provides power to the electronics in the

CDConnect assemblies. Circuit breakers and fuses within the CDWeb
Manager distribute power and protect the various devices being powered
by the CDWeb Manager.
Protocol Conversion
The CDWeb Manager receives messages from the Supervisory Control
System, then interprets, converts, and distributes this information to the
actuators.
The CDWeb Manager also receives information from the actuators, such
as actuator position and status. It must then present this data in a suitable
format to the Control System for use in the CD Control algorithm or
operator display.
Depending on the system configuration, the CDWeb Manager may also

receive interlock information or ProTrim sensor information through
digital and analog inputs. This information is also presented to the Control
System.
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Supervisory Control System Communication Interface

A Supervisory Control System typically receives the paper measurements
(e.g. weight, moisture, caliper) from a scanner system and calculates a new
actuator setpoint using a control algorithm. The Supervisory Control
System must transmit this desired setpoint to the actuator controller.
Additional information such as individual actuator position and status,
actuator tuning and configuration, and system status (interlocks) are also
communicated between the Supervisory Control System and the
controller.
Historically, the actuator controller has been a centralized controller (such

as a PLC) that has been linked to the Supervisory Control System via a
serial communication interface (point-to-point or some form of
Master/Slave arrangement), or via a Local Area Network (LAN). With the
CDWeb system, the CDConnects attached to individual or small groups of
actuators perform the control, and the CDWeb Manager serves as a
communications interface between the CDConnects and the Supervisory
Control System.
The CDWeb Manager supports a number of different communications

protocols for communications with Supervisory Control Systems. The
Open Data Exchange (ODX) interface is a Honeywell-developed interface
that operates on top of an Ethernet local area network using TCP/IP as a
transport protocol. This is the standard protocol used in Honeywell
systems. The CDWeb Manager also supports two serial protocols: RTU
Modbus (with or without Honeywell extensions) and SCL. These
protocols are provided for compatibility with older products.
As a convenience, ProTrim sensor support is also available in CDWeb

Managers running a software revision level of 1.53 or above. The ProTrim
sensor signals can be brought into the CDWeb Manager cabinet and
transmitted to the Control System. This option is mostly used in
conjunction with the WebTrak option available in Honeywell control
systems.
NOTE: ProTrim sensor support requires additional hardware - a PLC CPU, at

least one analog input card, and an SNP link cable.
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Actuator Communication Interface

The CDConnect assemblies associated with the actuators contain Neuron
processors that send and receive data in the form of network variables
using the LonWorks protocol over a local operating network, or LON. The
CDWeb Manager interface to the LON consists of software within the
EPC-8A, a network interface communications card, and one or more
network routers.
The LON in a CDWeb system consists of several segments. The first

segment is internal to the CDWeb Manager cabinet and is a 1.25 Mbps
channel that runs between the EPC-8A and the routers. Each router
provides a connection between this high-speed segment and one slower
actuator segment. The actuator segments run from the router to a bank of
at most 64 actuators and operates at 78 kbps. These segments are also
called free-topology channels.
Rack Configuration
The GE Fanuc 5-slot PLC rack is home to the CDWeb processor. In some
systems, there may also be additional PLC components in the rack to
support system interlocks, ProTrim sensors, or non-CDWeb related
functions.
CDWeb Processor
General Description
The CDWeb Processor consists of a PC-compatible computer designed for
use in the VMEbus environment, a LonWorks interface expansion card,
and a 2 slot EXM expansion backplane to interface expansion cards to the
PC-compatible computer.
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EPC-8A VMEbus Controller

The PC-compatible computer is an EPC-8A computer developed by
Radisys Corporation. It has the following features:
• Intel 486 DX2-66 MHz processor
• 8 MB DRAM
• Standard PC peripheral interfaces including an RS-232 serial port

(COM1), an RS-422/485 serial port (COM2), a bi-directional parallel
port, a PS/2 style keyboard port, and a VGA monitor connection
• A Radisys EXM expansion interface for adding peripherals or

interfaces
• 10-Base-T Ethernet interface
• A watchdog timer. This device is configured to generate a VMEbus

SYSFAIL signal and reset the processor.
• 2 MB Flash-EPROM memory containing the operating system and

the application software.
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Specifications
The following are the relevant environmental and electrical specifications
for the EPC-8A:
Table 2-1. CDWeb Processor Specifications
Environmental
Characteristic Value
Temperature Operating 0°C to +65°C
Storage -40°C to +85°C
Humidity Operating 5% to 95% non-condensing
Storage 5% to 95% non-condensing
Altitude Operating 0 to 10,000 ft (3000 m)
Storage 0 to 40,000 ft (12,000 m)
Airflow 6 Litres/second (12.7 cfm). for the two
slot module
Electrical
Characteristic Value
Current @5V 4.0A typical
@+12V 0.2A typical
@-12V 0.2A typical
Hardware Configuration
The Radisys EPC-8A has a number of jumpers that can be configured.
Slot-1 Jumper
In cases where the CDWeb Processor is installed on the VMEbus along

with another VME processor (i.e. GE-Fanuc 90/70 PLC) that is the bus
master, the Slot-1 jumper must be removed. This is the default
configuration.
In cases where the CDWeb Processor is the only VME card installed on the
bus, the Slot-1 jumper may be installed or removed, although the default
configuration is for the jumper to be removed.
JP2 Jumper (Loop)
Reserved for use by Radisys and should not be installed
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JP3 Jumper (Alive)
Reserved for use by Radisys and should not be installed
JP4 Jumper (BIOS)
Enables the BIOS Flash memory for writing. This should not be installed
unless you are attempting to upgrade the BIOS.
JP5 Jumper (Flash)
Enables the resident Flash memory for writing. This jumper is installed to
allow for site software upgrades.
Slot-1 Jumper
JP3
Lithium Battery
JP5
JP4
JP2 JP6
Installed
Removed
Figure 2-2. Jumper Configuration
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Lithium Battery
A 3.0 V battery powers the CMOS RAM (i.e. BIOS Configuration) and the
Time of Day (TOD) clock when system power is not present. In a system
that is powered on most of the time, the battery should have an estimated
life of 10 years.
Removing the battery will invalidate the CMOS setup parameters if you
do not put the new battery into the empty socket within 60 seconds. It is
recommended that all setup parameters be documented while the battery
is still good.
BIOS Configuration
The BIOS can be configured by attaching a keyboard and monitor to the
appropriate ports on the EPC-8A. Pressing the reset button on the EPC-8A
and holding the F2 key on the keyboard enters the BIOS setup program.
The BIOS settings are grouped into 4 categories: Main, Advanced, EXM,
and VME. These categories appear in a row along the top of the screen.
The category can be selected using the left and right arrow keys.
Under the Main category the standard settings are:

Diskette A: Not installed
Diskette B: Not installed
IDE Adapter 0 Master: None
IDE Adapter 0 Slave: None
Video System: EGA/VGA
Boot Sequence: C: then A:
Numlock: Auto
Selecting the IDE Adapter 0 Master and pressing the Enter key brings up a
sub-menu which is used to set the hard-drive type. On this sub-menu the
standard setting is None for Type.
The Boot Sequence option also brings up a sub-menu with the following
standard settings:
Boot Delay: 0
Boot Sequence: C: then A:
Setup Prompt: Enabled
POST Errors: Disabled
Floppy Check: Enabled
Summary Screen: Enabled
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Use the ESC key to return from a sub-menu to the main menu.
The Advanced category has the following standard settings:

Halt on watchdog timer Disabled
Flash ROMdisk C800-CBFF
VME ROMdisk Not Installed
VME Scan Range 00000000-FFF00000h A32SD
The Integrated Peripherals sub-menu is normally configured as follows:

COM 1: 3F8, IRQ4
COM 2: 2F8, IRQ3
LPT 1: 378, IRQ7
ECP Disabled
The EXM category should have the following settings:

EXM Slot 31: FD, 01, 0
EXM Slot 0: 67, 25, 40
All others: FF, 00, 00
The VME category settings are not used.
Press ESC and Save Settings and Exit to make changes permanent. The
EPC-8A will automatically reboot when the changes have been written.
EXM-LTNI LonWorks Network Interface Card

General Description
The EXM-LTNI LonWorks interface card developed by Engenuity Systems
Inc. is connected to the EPC-8A via the 2-slot expansion bus.
Hardware Configuration
This card has a number of jumpers and dip switches that can be
configured. Depending on the manufacturing date of the card in a
particular system, it may or may not resemble the following diagram:
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Oscillator Eprom in socket
JP14
1 JP13
2 JP12
3
S1 4
JP11
5
JP8 JP10
6
7 JP9
P2 JP1 JP2
8
JP4
JP3 JP7
P3
JP6
JP5
Note:
if Oscillator is 10.0000, JP1 is not jumpered Installed
if Oscillator is 20.0000, JP1 is jumpered Removed
Figure 2-3. EXM-LTNI Configuration
Switch S1 should be configured as follows:
OFF ON
1
2
3
4
S1 5
6
7
8
Figure 2-4. Switch S1 configuration
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Backplane (EXP-BP2)
The backplane is a printed circuit board with connectors on both sides.
The backplane provides the following functions:
• Acts as the PC/AT bus to enable interfacing peripheral cards to the

controller
• Provides power from the VMEbus backplane to the EPC-8A and any
expansion modules (e.g. the EXM-LTNI interface card)
The EXP-BP2 backplane provides one connector to interface to the EPC-

8A, and two connectors for expansion boards.
The EXM-LTNI LonWorks interface card must be inserted into slot 0

(bottom). If the EXM-LTNI is inserted into slot 1 (top), then the EPC-8A
BIOS configuration must be changed.
Software
The CDWeb Processor uses the QNX operating system. QNX is very
much like UNIX, but is specially designed for embedded applications
running on Intel processors. Anyone who is familiar with UNIX will find
this version of QNX very familiar.
The functions of the CDWeb Manager are handled by several QNX

programs, or tasks, which all run simultaneously. The primary tasks are
the lon task, the host communications task, and the actuator task. There
are secondary tasks that are not essential to the operation of the CDWeb
Manager, but make using it easier and more convenient. These include the
console task, the diagnostic task, and the file transfer task.
The File System

As mentioned previously, the CDWeb Manager processor contains 2MB of
special memory called flash memory. This memory is different from
normal computer RAM in that it maintains its contents even when the
computer is turned off, much like a computer disk holds its contents even
without power. In fact, the flash memory in the computer is formatted to
look just like a disk. As far as QNX or any of the tasks are concerned, there
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is a small disk attached to the computer. This flash disk can be used just
like any other disk (with a few exceptions).
The flash disk is formatted with a QNX file system. This file system has a
directory hierarchy just like in UNIX, DOS, or Windows. Files placed in
the file system are located within some directory or sub-directory and are
located by specifying a path to the file. One difference worth mentioning
is that in DOS or Windows paths are specified using the ‘\’ character,
while in QNX, like UNIX, paths are specified using the ‘/’ character.
For example, in DOS the full path to a file might be:

\dir\subdir\file
In QNX, the path to the same file would be specified as:

/dir/subdir/file
The file system in the CDWeb Manager computer has the following
directory structure:
Table 2-2. CDWeb Manager computer directory structure
Directory Description
/ the file system root
/bin operating system files
/etc QNX, TCP configuration files (i.e. hosts)
/etc/config QNX startup files (i.e. sysinit)
/dev QNX device drivers
/pipe QNX pipe files
/cdwebman CDWeb Manager tasks and configuration files
Most of the files on the flash disk are files required by QNX and are not
specific to the CDWeb Manager. Files specific to proper CDWeb Manager
operation are:
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Table 2-3. CDWeb Manager file names, locations and types
File Location and Name Description File Type

/etc/config/sysinit System start up file Text
/bin/ft File transfer task Binary
/etc/hosts IP address database Text
/cdwebman/lon Lon task Binary
/cdwebman/longate Longate task (version 1.52 and above) Binary
/cdwebman/act Actuator task Binary
/cdwebman/odx ODX communication task Binary
/cdwebman/scl SCL communication task Binary
/cdwebman/taskmon Task monitor Binary
/cdwebman/taskmon.log Task monitor log file Text
/cdwebman/console Remote console task Binary
/cdwebman/debug Remote diagnostic task Binary
/cdwebman/term Local diagnostic task Binary
/cdwebman/export.csv Lon network database Text
/cdwebman/webstart Shell script which starts up all of the Text
necessary CDWeb Manager tasks
/cdwebman/cdweb.ini For CDWeb Manager versions 1.07 and Text
greater, this file configures the other tasks
/bin/ffsinfo Displays information on the flash file Binary
system
For the most part, the only files that may need modification are in the
/cdwebman directory. In particular the export.csv file may need to be
updated if the LON database is modified, or if any software upgrades are
issued for any of the CDWeb Manager tasks.
The one exception to this is the hosts file in the /etc directory. This file
defines the IP address of the CDWeb Manager and possibly the IP address
of the host if the CDWeb Manager is communicating using the ODX
protocol. This file must be located in the /etc directory in order for QNX
to find it. Also, the names in the file should not be changed as the
operating system looks specifically for those names when starting up the
TCP/IP drivers. The IP addresses in the file can be modified, however.
Prior to version 1.07, configuration options for the tasks were specified in
the /cdwebman/webstart file using switches. These switches were hard
to understand and use, so starting with version 1.07, the software uses the
newer /cdwebman/cdweb.ini configuration file. This file uses text
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descriptions that are easier to modify and understand. The older switches
are still supported for compatibility.
Lon Task
The lon task is a protocol task. That means it understands a communi-
cations protocol (the LON protocol in this case), and it provides other
tasks with a convenient mechanism for using this protocol. This task is
started automatically by the webstart script. Options to the lon task are
specified with switches or, in version 1.07 or greater, in cdweb.ini.
Table 2-4. Lon Task Configuration Options
Switch cdweb.ini setting Description (default value)
-d name database = name a fully qualified pathname for the LON database
-i id task id = id a task ID which uniquely identifies this lon task (1)
-s slot engenuity slot = slot the EXM slot where the LTNI card is located (search)
-b address engenuity base = address the base address in hexadecimal where the LTNI card data
structures are located (D0000)
-m name node name = name the name of the CDWeb Manager in the Lon database
(cdweb_proc_1)
Notes: When the lon task starts up, it attaches a name to itself. This name is /devron/loni where i is the same as
above. The name can be seen by typing sin name at the QNX shell. By default, it reads the [lon] section
in the cdweb.ini configuration file.
Longate task
The longate task allows the CDWeb Manager to act as a gateway for other
LON-based devices that need to communicate directly with the actuators
but do not have a direct connection to the actuator LON. This feature is
used primarily in conjunction with CDWeb Explorer. It allows CDWeb
Explorer (version 1.60 and above) to support and maintain the CDWeb
system over an ethernet network.
ODX Task
The odx task is the host communications task that understands the ODX
protocol. It enables communications over a TCP/IP link to an ODX
server. This task is only present in systems which communicate to the
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control system using the ODX protocol. This task is started automatically
by the webstart script with the parameters defined during the system
build.
The odx task has no configuration options.
NOTE: The odx task name is /devron/host. When running, the ODX task
spawns several other tasks which help it run. Executing the QNX
command ps (for process status) at the QNX terminal shows all
currently executing tasks. If the odx task is running correctly the ps
command should show three instances of /cdwebman/odx running.
SCL Task
The scl task is identical to the odx task except it speaks the SCL protocol
over a serial link. This task is only present in systems which communicate
to the control system using the SCL protocol. This task is started
automatically by the webstart script with the parameters defined when
the system was built.
NOTE: The scl task name is /devron/host. As with an ODX system, executing
the QNX command ps at the QNX command prompt should show three
instances of /cdwebman/scl running. By default, it reads the [scl]
section in the cdweb.ini configuration file.
With the new cdweb.ini configuration file, the scl task can actually be
configured in two ways: by reading the [scl] section and by reading the
section with the same name as the host name option for the act task. This
allows possible support for multiple, simultaneous SCL links.
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Table 2-5. Scl Task Configuration Options
-t type actuator type = type the actuator type

-n number number of actuators = number the number of actuators
-p port port = port the serial port to use (1)
-b rate data rate = rate the serial port speed (2400)
-[8 | 7][E | N | O][1 | 2] data bits = {8 | 7} the serial port parameters - data bits, parity, and
parity = {E | N | O} stop bits (8N1)
stop bits = {1 | 2}
message time-out = time the maximum time in seconds to wait for a message
to complete before restarting the link (30)
RTU Task
The rtu task is similar to the scl task in that it speaks the RTU protocol
over a serial link. This task is only present in systems which communicate
to the control system using the RTU protocol. This task is started
automatically by the webstart script with the parameters defined when
the system was built.
NOTE: The rtu task name is /devron/host. As with an ODX system, executing
the QNX command ps at the QNX command prompt should show three
instances of /cdwebman/rtu running. By default, it reads the [rtu]
section in the cdweb.ini configuration file.
With the new cdweb.ini configuration file, the rtu task can actually be
configured in two ways: by reading the [rtu] section and by reading the
section with the same name as the host name option for the act task. This
allows possible support for multiple, simultaneous RTU links.
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Table 2-6. Rtu Task Configuration Options

-a address station address = address the RTU station address
-{c|x} emulation = {CMM|PCM} use Modbus or Honeywell RTU
-p port port = port the serial port to use (1)
-b rate data rate = rate the serial port speed (2400)
-[8 | 7][E | N | O][1 | 2] data bits = {8 | 7} the serial port parameters - data bits, parity, and
parity = {E | N | O} stop bits (8N1)
stop bits = {1 | 2}
base register = register the base register of the per actuator information
(400 in CMM mode, 401 in PCM mode)
register block = size the number of registers to use for each per
actuator information block (200)
Actuator Task
The actuator task is the meat in the CDWeb Manager sandwich (where the
lon and odx, scl, or rtu tasks are the bread). It receives information, such as
setpoints, from the control system (via the odx, scl or rtu task), reformats
the information, and retransmits it to the actuators (via the lon task).
Similarly it receives information from the actuators, such as position,
reformats it and sends it to the control system.
In a system with interlocks or ProTrim sensors, the actuator task also

reads the relevant information from the PLC CPU for formatting and
transmission to the control system.The actuator task is automatically
started by the webstart script when the system starts.
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Table 2-7. Actuator Task Configuration Options

-b id beam id = id the beam id (1)
-t id lon task id = id the id of the lon task (1)
-a number actuators per node = number the number of actuators controlled by each node (1)
-h name host name = name the name of the host
-g gauge host gauge = gauge the gauge of the host (1)
-l lpn host lpn = lpn the LPN of the host (1)
-c timeout actuator timeout = timeout the time in seconds to wait for a status message before
considering an actuator failed
-m file actuator map file = file the file to use for configuring the mapping between zone,
controller, and output
host capabilities mask = mask this mask allows selective enabling and disabling of certain
CDWeb Manager options (0xFFFFFFFF - all features
enabled)
flush cycles = number the number of times to cycle an actuator during a flush
operation (3) - ProFlow only
snp port = port flush link communication parameters (2, 19200, 8, N, 1) and
snp data rate = rate refresh rate (5 seconds)
snp data bits = {8 | 7}
snp parity = {E | N | O}
snp stop bits = {1 | 2}
snp link rate = rate
protrim enable = {0 | 1} ProTrim sensor configuration (0, 8, 120 ie. ProTrim disabled,
protrim read segment = seg ProTrim data in %R121 and %R122 in the PLC)
protrim read register = reg
Note: When the actuator task starts up the name it attaches to itself is /devron/typebt where type, b, and t are as
shown above (eg. autoslice11).
The host gauge option specifies the symbol names to use for the host link,
for example, P1CWP1_ASP for setpoints, where WP1 is the gauge. This
option can take two forms: it can be either a single-digit number or a three
character identifier. In the first case, the default characters for the actuator
type are used (WP for all weight actuators). In the second case, the entire
string can be replaced (eg. CP1) if the actuators are being controlled by a
non-weight optimizer.
The actuator map file option is used in cases where the relationship
between zone number and controller/output is not trivial. In most cases
zone 1 is actuator 1, zone 2 is actuator 2, etc. Often with the ProFlow, this
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simple relationship is not adequate because a single controller runs several

actuators which may not be contiguous. For example, controller 5 may run
actuators 17, 32, 34, and 60.
Other actuators may also use a map file if some actuators are not being
controlled by the Supervisory Control System. For example, perhaps only
the 7 actuators on either edge of a 47 actuator beam are being controlled.
In this case, the CDWeb Manager is only talking to 14 actuators, but they
are configured as actuators 1 through 7 and 41 through 47.
The map file describes these relationships. It has one line per actuator. The
line can contain either a single number - the zone number, or the zone
number followed by the controller number followed by the output letter.
For the previous ProFlow example, the map file would contain the lines:
17 5 A
32 5 B
34 5 C
60 5 D
And the second example would be:

1
2
3
4
5
6
7
41
42
43
44
45
46
47
Diagnostic Task
Each CDWeb Manager task must be able to run with no screen output or
keyboard input because under normal circumstances they run in a cabinet
with no monitor or keyboard attached. Yet, there are circumstances in
which knowing the state of the various tasks can greatly simplify any
troubleshooting. The diagnostic task serves this function.
The diagnostic task acts as a virtual monitor for the other CDWeb
Manager tasks. These other tasks can write messages to the diagnostic
console. Using the appropriate software it is possible to view this virtual
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console on any computer that is attached to the same Ethernet network as

the CDWeb Manager.
In addition to writing messages to the diagnostic console, the other tasks

also send a message severity level. The severity level is a numeric value
between one and seven which is an indicator of the seriousness of the
message. A computer that is viewing the diagnostic console can filter
messages based on the severity level.
In general, the various tasks running in the CDWeb Manager will send
messages with severity level one only under dire circumstances which will
result in the immediate termination of the task. Severity level two means
the task has encountered an error which, while not fatal, is very serious.
Levels three through seven are used for informational messages. These
messages do not represent errors but allow an operator to view the
operations of the tasks with a varying degree of detail.
The diagnostic task has no options.
Monitor Task
The monitor task is a last line of defense. This task simply watches the
other tasks. In the event that one of the other tasks fails, the monitor task
issues a hardware reset. This signal resets the computer and restarts the
system.
The monitor task generates a log file called taskmon.log. Every time the
monitor starts up and whenever it detects a problem, it adds an entry in
the log file.
NOTE: The tasks to monitor are identified by name (not command line).
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Table 2-8. Monitor Task Configuration Options
switch cdweb.ini setting description (default value)
taskname the name(s) of the task(s) to watch

watchdog fail limit = the number of times a task can fail to respond before it is
number considered failed(15)
monitor period = time the period in seconds for checking tasks (2)
startup delay = time the time to allow tasks to start up (30)
priority increase = number the task priority increase (1)
Console Task
Since the CDWeb Manager computer normally runs in a box with no
keyboard or monitor attached, the various tasks do not use the keyboard
and monitor for user input and output. As mentioned previously, the
diagnostic task provides a virtual console for monitoring the state of all of
the CDWeb Manager tasks. The console task provides a similar function. It
allows user interaction with the other CDWeb Manager tasks.
The console task is designed for user input and output over the Ethernet.
The user can invoke the console task over the network and use the
keyboard and monitor on another computer to interact with the various
tasks on the CDWeb Manager computer.
Once attached the user can get a menu of functions supported by the task
by pressing the space bar. Currently the actuator, lon, scl, rtu, and odx
tasks support user interaction via the console task.
Command Line:
console task_name
where:
task_name is the name of the task to serve (sin name to view all task
names)
NOTE: When connecting to a named task, the /devron/ prefix can be omitted.
Once connected, pressing the space bar will display a menu specific to
the task.
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For example, the command to attach to an actuator task that is controlling

a ProCoat is:
console procoat11
File Transfer Task

The file transfer task allows file transfers to and from the CDWeb Manager
computer to take place over the Ethernet network. This facility is the only
means of updating and retrieving files since the CDWeb Manager
computer has no floppy disk drive. The file transfer task implicitly
assumes that any files transferred are to and from the /cdwebman
directory, although it is possible to override this behavior.
The file transfer task has no options.
NOTE: This task is located in the /bin directory and is started by the QNX
system script sysinit unlike the other CDWeb Manager tasks which
are located in the /cdwebman directory and are started by the webstart
script. This task is different from the other CDWeb Manager tasks
because with out the file transfer task, the CDWeb Manager computer
has no means of updating files. This weakness is guarded by the
implicit file location mentioned previously. The ft task can not be
accidentally overwritten because it is not located in the implicit
directory. Also, a corrupt webstart file will not prevent the task from
being started.
Additional Notes
The question of whether computer viruses can affect the CDWeb
Processor or any other part of the CDWeb system sometimes comes up in
troubleshooting sessions or during training class discussions. Although
the CDWeb Processor is an Intel-processor based computer, much like
most office or home computers, it is first and foremost an industrial
computer. The operating system used, QNX, is very dissimilar from MS-
DOS. The link between the CDWeb Processor and any maintenance
computer is via a proprietary file transfer task. Due to the different file
systems and different operating systems, a DOS-based computer virus
cannot be transmitted to the CDWeb Processor simply by connecting to it
P/N 6510020139 - Rev. 02 98/11/09 29 - 151

using TERM/Term95 or CDWeb Explorer. Nor can a DOS-based

computer virus on a maintenance computer affect the files on the CDWeb
Processor directly. However, a computer virus can affect the ability of the
maintenance computer to function properly, or can corrupt the data on the
maintenance computer’s hard disk to the point where programs are lost.
If one of these programs happens to be TERM/Term95 or CDWeb
Explorer, then the maintenance computer will no longer be able to run
them to connect to the CDWeb Processor. It is considered good practice to
use virus-scanning and shielding software on any computer where
multiple users have access, and where data is constantly transferred on
floppy disk or via e-mail attachments. In short, while the CDWeb
Processor is relatively immune from computer viruses that strike PCs, the
maintenance computer can be affected.
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Chapter 3. Host Communications
ODX
CDWeb Manager Network Communication Specification

This specification assumes that the CDWeb Manager contains client
software for ODX communication. The CDWeb Manager is responsible
for initiating all network communications between itself and the
Supervisory Control System. The content of all messages adheres to the
ODX Functional Specification. If a discrepancy exists between this
document and the ODX Functional Specification, this document should be
used.
Introduction
In a CDWeb Manager there are two tasks which participate in a given
ODX session: the actuator task and the odx task. The actuator task defines
the content of the communication while the odx task formats the
information according to the ODX protocol. The pair together can be
considered a single ODX client.
The ODX client initiates all communications between the CDWeb

Manager and the ODX server running on the AM. The communications
between the client and server consists of symbols, which contain numeric
or character data, ordinals which are boolean flags, and events which may
be scheduled thereby causing some action to happen on the AM. As far as
the ODX server is concerned, read requests may be on-demand, periodic,
or triggered off an ordinal change on the AM, while write requests are
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Chapter 3. Host Communications CDWeb Control System Manual
always on-demand and have the option of specifying an event to be

scheduled on the AM after the write is complete. Each read or write
request may contain multiple symbols and any given symbol may be
associated with multiple read or write requests. Before any read or write
request is attempted, all necessary symbols and ordinals are looked-up
through the ODX server to determine the data type and array size on the
AM. It should be noted that the ODX server sends and expects a value for
each element in an array, regardless of whether or not the full array is
valid from an application point of view.
The actuator task has hard-coded read and write request templates which
contain required symbol, ordinal, and event names. All actuator specific
symbols and ordinal names used for communication by a given CDWeb
Manager are prefixed by a common 6 character actuator identifier. This
actuator id has the form PxCyyy, where x represents the process number,
and yyy represents the actuator type and gauge number, e.g. WP1 for the
first weight control actuator. The process number and the gauge number
can be specified to the actuator task on startup or default values are used.
The actuator task builds symbol names based on this information and the
hard-coded templates.
The remainder of the symbol name (e.g. ASP) identifies the parameter
type. Some small amount of information about the symbol can be
extracted by examining the character(s) which separate the actuator and
parameter identifiers. An underscore ( _ ) indicates an array and a period
( . ) indicates an ordinal. An ordinal array is therefore indicated by a
period followed by an underscore ( ._ ). In general, the actuator task does
not use ordinal arrays. Instead, individual boolean flags are compacted
into 16-bit status words which are transmitted to the AM as unsigned
integers. It is the responsibility of the application software on the AM to
break these unsigned integers out into the appropriate ordinal arrays for
alarm and status reporting.
Event names are of the form LPNz\EVTnnn, where z represents the LPN
number of the master AM, and nnn represents the event number. In
general, all status changes for all possible LAN based CDWeb Managers
are funneled through a single event, EVT586. For this reason, each write
request made by the client that requires a status update on the AM also
sets a corresponding control ordinal prior to scheduling the Status Change
event. In this way the chain which runs off the Status Change event can
decipher which data needs to be updated. All symbol, control ordinal,
and event names required for a single ODX client are listed in Table 3-1.
Application Manager Symbol Names at the end of this section.
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CDWeb Control System Manual Chapter 3. Host Communications
The ODX client logs into the AM with a user name of IDS and a password
of RESULTS. These are hard-coded into the ODX client software. The
client ID for the ODX protocol is Webyyy where yyy is the actuator gauge
described previously.
If the odx task detects that communications have been lost it resets itself to
a startup condition. When communications are re-established all data that
is specified to be transferred on a startup condition is transferred.
Read Number of Actuator Zones
The ODX client reads the number of actuator zones from the AM
(PxCyyyNUMACT) once upon startup. This value is compared against the
number of actuator zones in the actuator task configuration. If a
discrepancy is found the client sets the corresponding bit in the LAN
alarm word (see below) and attempts to write this word to the AM.
Write LAN Alarm Word
The ODX client writes the LAN alarm word PxCyyyLALM to the AM to
identify possible problems with the LAN configuration. Currently there
are only 2 bits defined in the status word as follows:
• bit 0: a symbol lookup failure occurred
• bit 1: a mismatch was found in the number of configured zones
This word is written once after the symbol lookup and the comparison of
actuator zones has been completed. This write either clears or sets the
corresponding alarm states on the AM. As with all status words, the
associated status change ordinal PxCyyy.LALM is set and the status
change event LPNz\EVT586 is scheduled by this write request.
Write System Status
The ODX client writes the four system status words PxCyyy_SST on a
periodic basis. The four system status words are defined as Major System
Alarms, Minor System Alarms, Major PLC Alarms, and Minor PLC
Alarms to correspond with older systems. At the present time, neither of
the System Alarm words are used in CDWeb systems.
In certain CDWeb systems a PLC or similar device is present for the

management of interlocks or other digital inputs. When such a device is
present but not communicating, the ODX client sets the PLC Not Ready
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For Control alarm (bit 2) in the Major PLC Alarm word. When such a
device is communicating, the alarm words are read directly from the
device and the ODX client acts simply as a pass through.
In versions 2.0 and above of the CDWeb Manager software, the PLC Not
Ready For Control is set upon link establishment. The CDWeb Manager
clears the alarm once it has received status messages from all of the
actuators or the communications time out interval has elapsed, whichever
comes first. This enables the CDWeb Manager to start up a link without
complete information from all the actuators and still force the AM to
perform a bumpless transfer once the position information becomes
available.
In systems prior to version 2.0, the CDWeb Manager starts up with all
actuators flagged with communication time out alarms and the PLC Not
Ready For Control alarm clear.
As with all status words, the associated status change ordinal PxCyyy.SST
is set and the status change event LPNz\EVT586 is scheduled by this write
request.
Read Setpoint and Position Scaling
The scaling information consists of the slope (slope (PxCyyyACTSLP) and

offset (PxCyyyACTOFF). These values are used to convert between the
position and setpoint scales used on the AM and the position and setpoint
scales used by the actuators. These values are read whenever a connection
is established with the AM.
A potential problem exists for any ODX client which reads these values.
The AM stores these values in the ISR data. When the AM is starting up
after a shutdown or reset, the ODX server is initialized before the ISR data
is loaded. Consequently it is possible for a client to log in and read these
values before they have been properly loaded. The fix for this problem is
to change not only the ISR values, but the symbol default values using
BlocBuilder.
This problem has been more completely documented in Honeywell

Software Bulletin 3 dated May 4, 1995. A step-by-step procedure for fixing
the problem is also provided.
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Read Actuator Setpoints
The ODX client reads actuator setpoint information on a periodic basis.

The setpoint information consists of the actual setpoint array
(PxCyyy_ASP). The time period between reads is hard-coded at 5 seconds.
The setpoint array always contains floating point values. The slope and
offset required to go from the AM to the actuator setpoint format is also
read from the AM as indicated above. The actuator task scales the
setpoints appropriately before forwarding them to the actuators. The ODX
client assumes that the actuators ignore setpoints when disabled.
Due to the asynchronous nature of the communication between the

actuators and the CDWeb Manager and between the CDWeb Manager
and the AM, setpoints can become corrupted when performing a
bumpless transfer. When the AM performs a bumpless transfer, it copies
its position array into its setpoint array. Similarly, upon receiving a reset,
an actuator copies its position into its control setpoint. However, there is
no guarantee that the entry in the AM’s position array corresponds to the
current actuator position because of the time lag in communication
between the actuator and the AM. The CDWeb Manager guards against
this situation by discarding setpoints for any actuator which has not
reported its position within a time limit defined in the actuator task
configuration. Setpoints continue to be discarded until the position has
been successfully reported to the AM and the AM has acknowledged the
new position by sending a reset. This acknowledgment normally involves
an operator invoking a “Reset Failed Actuator” or a “Reset All Actuators”
command.
Write Actuator Positions and Status
The ODX client writes actuator positions, PxCyyy_APOS, and status,

PxCyyy_ASTAT, to the AM on a periodic basis. As with all status words,
the associated status change ordinal PxCyyy.ASTAT is set and the status
change event LPNz\EVT586 is scheduled by each write request. The time
period between transmissions is hard-coded at 5 seconds.
The position array always contains floating point values which are in the
same units as the setpoint array. As with the setpoint array, the CDWeb
Manager scales the positions appropriately before writing them to the
AM. Positions are written to the AM regardless of the state of the AM
Auto/Manual ordinal to facilitate bumpless transfer between modes.
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The zone by zone actuator status words are actuator dependent and are
outlined in Table 3-2. Actuator Zone Status Words.
Read Mode Flag
The mode flag is an ordinal value which is 1 if the actuators should obey,
if possible, the setpoints in the setpoint array and 0 if the actuators should
cease all control. This flag is read immediately upon startup and thereafter
a triggered read request causes the information to be transmitted to the
CDWeb Manager whenever the flag changes state. The flag is expected in
the symbol PxCyyy.LODON.
Read/Write Actuator Enable Array
The Actuator Enable array is an array of integers which are set to 1 or 0 to

indicate if a given zone is enabled or disabled, respectively. The actuator
enable array is read from the AM immediately upon startup in order to
synchronize the AM and the actuators. Once the 2 copies of the array
match, the client issues a triggered read request which reads the
PxCyyy_AED array from the AM whenever the PxCyyy.AED ordinal on
the AM changes state. Note that the actual data from this request is
transmitted asynchronous to the request. The client, therefore, constantly
checks for a new response to this request and transmits the information as
necessary to the actuators.
This exchange suffers from a problem similar to the problem noted under
Read Setpoint and Position Scaling. Unlike the previous case, the problem
does not arise from a time lag between the startup of the ODX Server and
the load of the ISR data, but from incorrect initialization of the Enable
Array by the AM. The AM assumes that all actuators are enabled and does
not ever initialize this array until a change is made in the array.
Consequently, until a change is made in the array, it contains whatever
default values it had at startup. If any of the default values are 0, then the
corresponding actuators is disabled when the CDWeb Manager reads the
symbol, even though the actuator is regarded as enabled by the AM.
As in previous case, the problem is fixed by changing the default values

for the array to the desired startup values (usually 1 in this case).
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Read Actuator Reset Array
The Actuator Reset array is an array of integers which are set to 1 or 0 to

indicate if a given zone should be reset or left in a failed condition,
respectively.
Upon startup, the ODX client issues a triggered read request to read the
PxCyyy_ARST array from the AM whenever the PxCyyy.ARST ordinal on
the AM changes state. Note that the actual data from this request is
transmitted asynchronous to the request. The client, therefore, constantly
checks for a new response to this request and transmits the information as
required to the affected actuators.
Write Communications Active
Since the ODX client initiates all communications with the server, a
heartbeat which allows the AM application software to detect a LAN
network failure has been implemented. This heartbeat is in the form of an
integer value, PxCyyyACOM, which is incremented by the ODX client on
a periodic basis. The heartbeat is set to 0 upon startup through an ODX
write request and increments up to 32767 before wrapping back to -32768.
The AM application software is responsible for checking the heartbeat
every 10 seconds. A non changing symbol indicates communications have
stopped. The time period between successive symbol writes is hard-
coded at 2 seconds.
Write ProTrim Positions
The ProTrim positions are transmitted to the AM on a periodic rate if

ProTrim support is enabled and the link between the CDWeb Processor
and the PLC CPU is active. This position information is the raw sensor
data as read from the PLC. It is the responsibility of the AM to scale the
data to the desired system of units. The low and high positions are written
to the symbols PxCLEDTRM and PxCHEDTRM respectively.
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Table 3-1. Application Manager Symbol Names
Description Direction AM Ordinal AM Symbol AM Event
Number of Zones Read N/A PxCyyyNUMACT N/A

Communications Active Write N/A PxCyyyACOM N/A
AM On Control Read PxCyyy.LODON N/A N/A
Actuator Setpoints Read N/A PxCyyy_ASP N/A
Setpoint Scaling Slope Read N/A PxCyyyACTSLP N/A
Setpoint Scaling Offset Read N/A PxCyyyACTOFF N/A
Actuator Positions Write N/A PxCyyy_APOS N/A
Actuator Status Write PxCyyy.ASTAT PxCyyy_ASTAT LPNz\EVT586
(Actuator Dependent Bit Pattern)
PLC System Status Write PxCyyy.SST PxCyyy_SST LPNz\EVT586
(Actuator Dependent Bit Pattern)
LAN Alarm Status Write PxCyyy.LALM PxCyyyLALM LPNz\EVT586
bit 0: symbol_lookup
bit 1: num_zones
Reset Actuators Read PxCyyy.ARST PxCyyy_ARST N/A
Enable/Disable Actuators Read / Write PxCyyy.AED PxCyyy_AED N/A
ProTrim Sensor Positions Write N/A PxCLEDTRM LPNz\EVT586
PxCHEDTRM
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Table 3-2. Actuator Zone Status Words
Status Word Actuator Family Bits Alarm Description
0 Actuator Disabled
1 Actuator Failed
2 Position sensor undervoltage
3 Position sensor overvoltage
4 Actuator moving too slow
5 Actuator Moving in Wrong Direction
6 Actuator Running Away
Zone Status Slice family 7 Invalid Calibration
8 Actuator Locked
9 Actuator at Upper Limit
10 Actuator at Lower Limit
11 Actuator at Bend Limit
12 Invalid Configuration
13 Invalid Tuning
14 Unused
15 Lost communications
0 Actuator Disabled
1 Actuator Failed
ProFlow 7 Invalid Calibration
8 Unused
11 Unused
13 Invalid Tuning
14 Unused
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SCL
CDWeb Manager Serial Communication Specification

software for SCL communication. The Supervisory Control System is
responsible for initiating all communications between itself and the
CDWeb Manager.
The Standard Communication Link (SCL) allows both Honeywell and

non-Honeywell systems to communicate setpoint and status information
to and from a CDWeb Manager. The Supervisory Computer System
(Host) communicates with the CDWeb Manager through a serial port on
the CDWeb processor. A software task called scl running on the CDWeb
processor handles all communications and reads or writes the required
information directly into a memory map. This implementation emulates a
Profile Manager’s Programmable Co-processor Module (PCM). All
references to PCM in this document should be understood as referring to
this software emulation. The memory map emulates the standard Profile
Manager PLC memory layout.
Configuration data is given at the end of this section.
The SCL link is an implementation of the MN332200 Honeywell protocol.

For more detailed information on MN332200, see the SCL User's Manual
supplied with Honeywell supervisory systems, Honeywell part number
46000001.
NOTE: The bit positions referred to in this document start at 0 for the first bit
as is standard practice in the computer world.
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Transmission Control Characters

The characters which are used for control of the link are:
Start of text STX 2

End of text ETX 3
End of transmission EOT 4
Enquire ENQ 5
Acknowledge ACK 6
Negative acknowledge NAK 21
Message Format
Any message transmitted has the following format:
<STX> -------- TEXT -------- <ETX><BCC>
The content of the TEXT field depends on the information being

transferred but always contains the Destination, Source, Function,
Subfunction and Message Type fields. All information is transmitted as
ASCII characters in hexadecimal format. The block check character (BCC)
is used to detect errors in transmission.
Messages are divided into functional categories with each category given
a number or 'function'. Within each category there are sub-categories or
'subfunctions' which determine a specific action. A list of supported
functions and subfunctions is given at the end of this section, along with a
detailed explanation of their use.
The format of a complete message is:

STX
Destination
Source
Function Type
Subfunction Type
Message Type
DATA
ETX
BCC
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Destination A two character code identifying to which station

this message is directed.
Source: A two character code identifying the message
sender.
Function Type: A two character code defining the category of this
message.
Subfunction Type: A two character code defining the sub-category of
this message.
Message Type: A one character code specifying whether the
message is a request or a response.. Request = 0,
Response = 1.
DATA: Function dependent data field.
The complete message has the form:
<STX>[Dest][Source][Func][Subfunc][Msgtype][...DATA...]<ETX><BCC>
NOTE: In CDWeb systems, the address fields are essentially ignored since the
SCL specification states that the protocol only supports point-to-point
links. As such, the addressing is redundant. The CDWeb Manager
simply exchanges the source and destination addresses in its replies.
Establishment and termination of link

To establish communications between the Host and CDWeb Manager, the
Host must first send an ENQ character. If the CDWeb Manager is ready to
communicate, it responds with an ACK; if not, it responds with a NAK. If
any messages are sent to the CDWeb Manager without first sending an
ENQ, they are ignored. Once the link is established there is no need to
send another ENQ.
The link can be terminated at any time by the Host by sending an EOT
character. If an EOT is sent to the CDWeb Manager, an ENQ must be sent
to re-establish communication. During a link session the Host may
request a retransmission of a message by sending an ENQ to the CDWeb
Manager. This use of ENQ is handled differently from the link
establishment ENQ.
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Functions
The following section details the messages and information transfer that
are implemented in the system. For example messages the address of the
CDWeb Manager is assumed to be 01 and the address of the Host 02.
Function type 00: System commands and related messages

These messages are sent to the CDWeb Manager by the Host.
Subfunctions:
00 System status read
01 Self test (Not implemented)
02 Reset Link
03 Clear alarms (Not used in CDWeb systems)
04 Clear zone alarms (Not implemented)
06 Simulation (Not implemented)
Subfunction type 00: System status read
This message requests that the CDWeb Manager transmit the system
status, consisting of 4 words. The four system status words are defined as
Major System Alarms, Minor System Alarms, Major PLC Alarms, and
Minor PLC Alarms to correspond with older systems. At the present time,
neither of the System Alarm words are used directly in CDWeb systems.

present but not communicating, the CDWeb Manager sets the PLC Not
Ready For Control alarm (bit 2) in the Major PLC Alarm word. When such
a device is communicating, the alarm words are read directly from the
device and the CDWeb Manager acts simply as a pass through.
Subfunction type 02: Reset Link
This message tells the CDWeb Manager to attempt to clear any actuator
alarms. This resets any failed or disabled actuators.
The request message has no DATA field and the following format:
<STX> 01 02 00 02 0 <ETX> <BCC>
The response to this message is an ACK.
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Subfunction type 03: Clear alarms
This message indicates that system status alarms should be cleared. As

there are currently no system status alarms in CDWeb systems, this
message is not used.
Function type 01: Error notification messages

These messages are sent to the Host from the CDWeb Manager when
errors in transmission are detected.
Subfunctions:
01 Illegal function
02 Illegal Subfunction
03 Illegal destination address
04 Invalid string (not implemented)
05 Inconsistent data
06 Unsuccessful transmission
07 Defective actuator (not implemented)
Subfunction type 01: Illegal function
This message notifies the Host that the message received by the CDWeb
Manager contains a function which is not supported by this system. The
message from the CDWeb Manager has a DATA field which contains the
value of the function in question. If, for example, a function of 09 is
transmitted, the message from the CDWeb Manager has the following
format:
<STX> 02 01 01 01 0 09 <ETX> <BCC>
The expected response to this message is either a new message or an ACK.
Subfunction type 02: Illegal subfunction
Manager contains a subfunction which is not supported by this system.
The message from the CDWeb Manager has a DATA field which contains
the value of the subfunction in question. If, for example, a function of 00
and subfunction of 07 is transmitted to the CDWeb Manager, the response
has the following format:
<STX> 02 01 01 02 0 07 <ETX> <BCC>
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The expected response to this message is either a new message or an ACK.
Subfunction type 03: Illegal destination address
Manager contains a destination address which is not correct for this link.
As the CDWeb Manager merely reflects the addresses used in the original
message, this message is never used.
Subfunction type 05: Inconsistent data
Manager contains data which is not consistent with the message. The
message from the CDWeb Manager has a DATA field which contains the
function, subfunction and DATA field of the message in question.
Assume for the moment that the Host wants to download the number of
actuator zones to the CDWeb Manager. See function 02, subfunction 01
for details. The maximum number of allowable zones is 127 (7F hex).
Assume also that the Host attempts to set the number of zones at 128 (80
hex). The message to the CDWeb Manager would be:
<STX> 01 02 02 01 0 80 <ETX> <BCC>
The CDWeb Manager would detect an error and respond with:

<STX> 02 01 01 05 0 02 01 80 <ETX> <BCC>
Subfunction type 06: Unsuccessful transmission
This message notifies the Host that the link session has been terminated by
the CDWeb Manager. The CDWeb Manager does not use this message.
Function type 02: Single data write message

Subfunctions:
00 Set operating mode
01 Write number of zones
Subfunction type 00: Set operating mode
This message requests that the CDWeb Manager set its operating mode to
that specified. The DATA field is four characters in length and contains a
value relating to the required mode.
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0000 = Manual 0001 = Computer
In manual mode the CDWeb Manager ignores setpoints over the link.
If, for example, the Host is setting the CDWeb Manager mode to manual,
the transmitted message has the following format:
<STX> 01 02 02 00 0 0000 <ETX> <BCC>
Subfunction type 01: Write number of zones
This message is defined in the SCL specification to allow the Host to

download the number of actuator zones to the CDWeb Manager. The
DATA field is two characters in length and contains a hexadecimal value
of the required number of zones.
The CDWeb Manager responds to these messages, but does not alter its
configuration. The number of actuators for CDWeb systems is set in the
actuator task configuration and the scl task configuration.
Function type 03: Write sequential arrays

Subfunctions:
01 Write setpoints
03 Referencing (not implemented)
Subfunction type 01: Write setpoints
This message allows the Host to send setpoints to the CDWeb Manager.
The DATA field consists of the starting and ending zone numbers and the
setpoints required. The zone numbers are two characters in length and
the setpoints are four characters in length. Both the zone numbers and
setpoints are given in hexadecimal values. The setpoints transmitted on
the link are the required setpoints multiplied by a scale factor. If the
CDWeb Manager has been set to manual mode by the Host all setpoints
are ignored. Even if the setpoints have been ignored, the CDWeb
Manager responds with an ACK.
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Negative values are expressed in twos complement form. For example if

the required setpoint is -1396 microns and the scale factor is 1, the
transmitted value would be calculated as follows:
1396 * 1 = 1396 = 0574 (hex) = 0000 0101 0111 0100 (binary)
ones complement = 1111 1010 1000 1011
twos complement = 1111 1010 1000 1100
transmitted setpoint = FA8C (hex)
If the required setpoint is 74.2 percent and the scale factor is 10, the
transmitted value would be:
74.2 * 10 = 742 = 02E6 (hex)
If the Host was to send the setpoints 35.7, 43.1, 84.9 and 27.6 to zones 26,
27, 28 and 29 respectively and the link factor was 10, the message would
be formulated as follows:
setpoints: 35.7 Æ 357 Æ 0165 (hex)
43.1 Æ 431Æ 01AF (hex)
84.9 Æ 849 Æ 0351 (hex)
27.6 Æ 276 Æ 0114 (hex)
zones: 26 Æ 1A (hex)
29 Æ 1D (hex)
Message from Host to CDWeb Manager:

<STX> 01 02 03 01 0 1A 1D 0165 01AF 0351 0114 <ETX> <BCC>
Function type 04: Write random arrays

Subfunctions:
01 Write setpoints (not implemented)
03 Referencing (not implemented)
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Function type 05: Single data read message

Subfunctions:
00 Read operating mode
01 Read number of zones
Subfunction type 00: Read operating mode
This message requests that the CDWeb Manager return the value of its
operating mode. The request message has no DATA field and the
following format:
<STX> 01 02 05 00 0 <ETX> <BCC>
The response to this message is:
<STX> 02 01 05 00 1 dddd <ETX> <BCC>
Where dddd is 0000 for manual mode and 0001 for computer mode.
Subfunction type 01: Read number of zones
This message requests that the CDWeb Manager return its configured
number of zones. The request message has no DATA field and the
following format:
<STX> 01 02 05 01 0 <ETX> <BCC>
The response to this message is:

<STX> 02 01 05 01 1 dd <ETX> <BCC>
Where dd is the hexadecimal value of the number of zones.
Function type 06: Read sequential arrays

Subfunctions:
00 Read zone status
01 Read actuator setpoint
03 Read reference value (not implemented)
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Subfunction type 00: Read zone status
This message requests the status word (16 bits) for a given number of
actuators. The DATA field consists of the starting and ending zone
numbers of the required actuators. If, for example, the status of actuators
26, 27, 28 and 29 is required, the Host would transmit the following
message:
<STX> 01 02 06 00 0 1A 1D <ETX> <BCC>
The response to this message would be:
<STX> 02 01 06 00 1 dddd dddd dddd dddd <ETX> <BCC>
The returned status words (dddd) are four hexadecimal characters whose
bit pattern define the status of each actuator.
If for example the returned status words from an AutoSlice were 2001,
0008, 0020, and 0800 the following would be indicated:
2001 (hex) is equal to 0010 0000 0000 0001 (binary)
This shows that bits 0 and 13 are set and therefore indicates that the
actuator is disabled and has invalid tuning.
0008 (hex) is equal to 0000 0000 0000 1000 (binary) and shows that the
actuator sensor has exceeded its maximum permissible voltage.
actuator failed due to movement in the wrong direction.
actuator is at its bend limit.
See Table 3-3. SCL Actuator Status Alarms for a complete description of
the possible alarms.
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Subfunction type 01: Read actuator setpoint or position
This message requests the setpoints or positions for a given number of

actuators. Whether the reply message contains positions or setpoints
depends on the actuator type. At present, the AutoSlice, ProSlice, ProCoat
and ProFlow actuators all return positions. The DATA field consists of the
starting and ending zone numbers of the required actuators. If, for
example, the positions of actuators 26, 27, 28 and 29 are required, the Host
would transmit the following message:
<STX> 01 02 06 01 0 1A 1D <ETX> <BCC>
The response to this message would be:

<STX> 02 01 06 01 1 dddd dddd dddd dddd <ETX> <BCC>
The returned values (dddd) are four hexadecimal characters which give
the actuator setpoint or position. Negative values are returned in twos
complement form. If the CDWeb Manager had returned the message:
<STX> 02 01 06 01 1 0165 01AF 0351 0114 <ETX> <BCC>
and the link setpoint factor was 10 then the requested values of zones 26 to
29 would be 35.7, 43.1, 84.9 and 27.6 respectively. See Function type 03:
Write sequential arrays - Subfunction type 01: Write setpoints for an
explanation on how these values were derived.
Function type 07: Read random arrays

Subfunctions:
00 Read zone status (not implemented)
01 Read actuator setpoint (not implemented)
03 Read reference value (not implemented)
Function type 08: Write ASCII string

Subfunctions:
00 Send ASCII string (not implemented)
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Function type 20: Direct PLC memory access

This function is a non-standard function which allows the Host computer
to read or write any memory location within the memory map.
NOTE: This function is implemented in the CDWeb Manager, but it should

only be used for testing purposes. Proper use requires a detailed
knowledge of the memory map . Incorrect use could cause the system to
crash.
Subfunctions:
00 Write to PLC memory
01 Read from PLC memory
Subfunction type 00: Write to PLC memory.
This message directs the CDWeb Manager to write data values directly
into specified memory locations. No check is done on the location or the
value deposited.
The DATA field of this message includes the number of registers to be

written, the location of the base register and the values to be written. Both
the number of registers and values are given in hexadecimal format. The
base register is given in base 10 and must be five characters in length. The
message has the following format:
<STX> 01 02 20 00 0 [#regs] [base reg] [values] <ETX> <BCC>
If for example the Host wishes to write the values 175A, 28D3, FE3D, and
731C into the four registers starting at %R12. The message would be
transmitted to the CDWeb Manager as follows:
<STX> 01 02 20 00 0 04 R0012 175A 28D3 FE3D 731C <ETX> <BCC>
The CDWeb Manager responds with an ACK.
If the Host attempts to read or write registers which do not exist the
CDWeb Manager returns an error response (function 01 subfunction 05)
which includes the illegal register in the data field.
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Subfunction type 01: Read from PLC memory
This message directs the CDWeb Manager to return the values in specified
memory locations within the memory map. The DATA field of this
message includes the number of registers to be read and the location of the
base register. The number of registers is given in hexadecimal format.
The base register is given in base 10 and must be five characters in length.
The message has the following format:
<STX> 01 02 20 01 0 [#regs] [base reg] <ETX> <BCC>
If for example the Host wishes to read three values starting at %R16. The
message would be transmitted to the CDWeb Manager as follows:
<STX> 01 02 20 01 0 03 R0016 <ETX> <BCC>
The CDWeb Manager would respond with:
<STX> 02 01 20 01 1 dddd dddd dddd <ETX> <BCC>
where each group of dddd is four hexadecimal characters representing the

value in that memory location. Negative numbers are given in twos
complement form.
Supported Functions and Setup for SCL Link

Data Link
Baud rate: 300, 1200, 2400, 9600, 19200
Data bits: 7, 8
Parity: NONE, ODD, EVEN
Start bits: 1
Stop bits: 1, 2
ACK/NAK time-out: configurable (3 sec.)
Message response time-out: configurable (3 sec.)
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Application Messages
Supported 9
Function 0 - System Commands
Subfunction 0 System status read

Subfunction 1 Self test
Subfunction 2 Reset 9
Subfunction 3 Clear alarms
Subfunction 4 Clear zone alarms
Subfunction 6 Simulation
Function 1 - Message Error Status
Subfunction 1 Illegal function 9

Subfunction 2 Illegal subfunction 9
Subfunction 3 Illegal destination 9
Subfunction 4 Invalid string
Subfunction 5 Inconsistent data 9
Subfunction 6 Unsuccessful trans. 9
Subfunction 7 Defective actuator
Function 2 - Write Single Data
Subfunction 0 Set operating mode 9

Subfunction 1 Write no. of zones 9
Function 3 - Write Sequential Arrays
Subfunction 1 Write setpoints 9

Subfunction 3 Referencing
Function 4 - Write Random Arrays
Subfunction 1 Write setpoints

Subfunction 3 Referencing
Function 5 - Read Single Data
Subfunction 0 Read operating mode 9

Subfunction 1 Read no. of zones 9
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Function 6 - Read Sequential Arrays
Subfunction 0 Read zone status 9

Subfunction 1 Read setpoints 9
Subfunction 3 Read reference values
Function 7 - Read Random Arrays
Subfunction 0 Read zone status

Subfunction 1 Read setpoints
Subfunction 3 Read reference values
Function 8 - Write ASCII String
Subfunction 0 Send ASCII string
Function 20 - Direct Memory Access
Subfunction 0 Write data to memory 9

Subfunction 1 Read data from memory 9
Data Scaling
Data Range
AutoSlice, ProCoat, ProSlice: -6000 to +6000 microns

All Others: 0 to 100%
Scale Factor
AutoSlice, ProCoat, ProSlice: x1

All Others: x10
Miscellaneous
Setpoints Absolute
First Slice/Zone 1
Station Number any
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Table 3-3. SCL Actuator Status Alarms

0 Actuator Disabled
1 Actuator Failed
8 Actuator Locked
13 Invalid Tuning
14 Unused
0 Actuator Disabled
1 Actuator Failed
8 Unused
11 Unused
13 Invalid Tuning
14 Unused
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RTU
CDWeb Manager Serial Communication Specification

software for RTU communication. The Supervisory Control System is
responsible for initiating all communications between itself and the
CDWeb Manager. The content of all messages should adhere to the RTU
Modbus Protocol Specification as defined by GE Fanuc in Series 90TM PLC
Serial Communications User’s Manual. If a discrepancy exists between this
document and the RTU Protocol Specification, this document should be
used.
Introduction
The RTU protocol is a query-response protocol used for communication
between the RTU device and a supervisory computer (Host). The Host is
defined as the master device and it transmits a query to the slave, which
then responds. The slave cannot query the Host, it can only respond to
queries from the Host.
The CDWeb Manager supports two different types of the RTU protocol.
The first mode emulates a GE Fanuc Series 90-70 Communications
Coprocessor Module (CMM - note this is not called a CCM to distinguish
it from GE Fanuc CCM protocol). In this mode the CDWeb Manager
supports only functions 03 and 16 of the standard RTU protocol. The
second mode emulates a GE Fanuc Series 90-70 Programmable
Coprocessor Module (PCM). In this mode the CDWeb Manager supports
a subset of the standard RTU protocol functions but also provides some
extensions specifically for use with MXOpen. The functional differences
are discussed in this document.
NOTE: One major difference between the two modes is in the specification of
register addresses. In CMM mode, the first register has an address of 0,
while in PCM mode, the first register has address 1. It is the
responsibility of the Host to transmit addresses appropriate to the mode
in use.
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In normal operation information is transferred between the CDWeb

Manager system and the Host by sending commands which read and
write memory locations called registers using the RTU protocol. The data
transferred consists of 8 bit binary characters with an optional parity bit.
No control characters are added to the data block, however there is an
error check (Cyclic Redundancy Check (CRC)) included as the final field
of each query and response to ensure accurate transmission of data.
For more information on RTU protocol refer to GE Fanuc Series 90 PLC

Serial Communications, User's Manual, GFK-0582.
Message Types
The RTU protocol has four message types defined. These are: query,
normal response, error response and broadcast and are explained below.
Query The master sends a message addressed to a single

slave.
Normal response After the addressed slave performs the function

requested, it sends back a normal response for that
function. This indicates that the request was
successful.
Error response The slave receives the query but for some reason it
cannot perform the requested function. The slave
sends back an error response which indicates the
reason the request could not be processed. No error
message is sent for certain types of errors.
Broadcast The master sends a message addressed to all slaves

by using address 0. All slaves that receive the
broadcast message perform the requested function.
No response is returned.
Message Fields
The message fields for a typical message are shown below.
| <----------------------------------- FRAME ------------------------------------> |

Station Address Function Code Information Error Check
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Station Address
The station address is the address of the slave station selected for this data
transfer. It is one byte in length and has a value from 0 to 255 inclusive.
An address of 0 selects all slave stations, and indicates that this is a
broadcast message. The station address used by a CDWeb Manager is
specified in rtu task configuration.
Function Code
The function code identifies the command being issued to the station. It is
one byte in length and is defined for the values 0 to 255 as follows:
Table 3-4. RTU Functions
Function Code Description
0 Illegal Function
1 Read Output Table
2 Read Input Table
3 Read Registers
4 Read Analog Input
5 Force Single Output
6 Preset Single Register
7 Read Exception Status
8 Loopback Maintenance
9 to 14 Unsupported Function
15 Force Multiple Outputs
16 Preset Multiple Registers
17 Report Device Type
67 Read Scratchpad Memory
128 to 255 Reserved for Exception Responses
NOTE: For standard operation with CDWeb Managers, the Host reads from and
writes to a series of predefined registers. To do this only functions 03
and 16 are used and supported. The other functions are listed for
information only.
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Information Field
The information field contains all of the other information required to

further specify or respond to a requested function. Detailed specification
of the contents of the information field for each message type is found in
the Message Descriptions section.
Error Check Field
The error check field is two bytes in length and contains a cyclic
redundancy check (CRC) code. Its value is a function of the station
address, function code, and information field.
Message Termination
Each station monitors the time between characters. When a period of
three character times elapses without the reception of a character, the end
of a message is assumed. The reception of the next character is assumed
to be the beginning of a new message.
The timers used in the CDWeb Manager implementation of RTU limited

to a minimum of 100 milliseconds. If the standard of three character times
is less than 100 milliseconds, then a 100 millisecond delay is used as the
message delimiter.
Timeout Usage
Timeouts are used on the serial link for error detection, error recovery and
to prevent the missing the end of messages. After sending a query
message, the master should wait approximately 500 milliseconds before
assuming that the slave is not responding to its request.
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Message Descriptions
The following pages explain the format for each RTU message. "MSB" and
"LSB" indicate most significant (high order) and least significant (low
order) bytes respectively.
Function 03: Read Registers
QUERY
Address Function (03) Starting Number of Error
Reg. No. Registers Check
M L M L L M
S S S S S S
B B B B B B
NORMAL RESPONSE
Address Function (03) Byte Count Data Error Check
1st Register
M L ......... M L L M
S S S S S S
B B B B B B
QUERY:
An address of 0 is not allowed as this request cannot be a broadcast

request. The function code is 3.
The starting register number is two bytes in length. The starting register
number may be any value less than the highest register number available
in the CDWeb Manager.
NOTE: The register numbers vary depending on the emulation mode in use.
The number of registers value is two bytes in length. It must contain a

value from 1 to 125 inclusive. The sum of the starting register value and
the number of registers value must be less than or equal to the highest
register number available in the CDWeb Manager.
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RESPONSE:
The byte count is a value from 2 to 250 inclusive. It is the number of bytes
in the normal response following the byte count and preceding the error
check. Note that the byte count is equal to two times the number of
registers returned in the response. A maximum of 250 bytes (125
registers) is allowed.
The registers are returned in ascending order with the lowest numbered
register in the first two bytes of the data field.
Function 16: Preset Multiple Registers
QUERY
Address Function Starting Number of Byte Data Error
(16) Reg. No. Registers Count Check
M L M L M L .......... M L L M
S S S S S S S S S S
B B B B B B B B B B
NORMAL RESPONSE
Address Function (16) Starting Number of Error Check
Reg. No. Registers
M L M L L M
S S S S S S
B B B B B B
QUERY:
An address of 0 indicates a broadcast request. All slave stations process a

broadcast request and no response is sent. The function code is 16.
The starting register number is two bytes in length. The starting register
number may be any value less than the highest register number available
in the CDWeb Manager.
NOTE: The register numbers vary depending on the emulation mode in use.
The number of registers field is two bytes in length. It must contain a

value from 1 to 125 inclusive. The sum of the starting register value and
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the number of registers value must be less than or equal to the highest
register number available in the CDWeb Manager.
The byte count is one byte in length. It is a value from 2 to 250 inclusive.
It is equal to the number of bytes in the data field (twice the number of
registers).
The values of the registers to be preset are given in the data field.
RESPONSE:
The description of the fields returned in the response message are covered
in the QUERY section above.
Communication Errors
The serial link communication errors are divided into three groups:
• Invalid Query Message
• Serial Link Timeouts
• Invalid Transaction
Invalid Query Message
When the CDWeb Manager receives a query addressed to itself, but

cannot process the query it sends one of the following error responses:
Table 3-5. RTU Error Codes
Error Response Subcode Value
Invalid Function Code 1

Invalid Address Field 2
Invalid Data Field 3
Query Processing Failure (CMM mode only) 4
Backplane Error (PCM mode only) 5
The format for an error response is as follows:

Address Exception Function Error Subcode Error Check
L M
S S
B B
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An address of 0 is not allowed as an error response is never a broadcast

message. The exception function code is 128 plus the value of the function
code of the query that caused the exception.
Invalid Function Code (Subcode 1)
This subcode indicates that the CDWeb Manager has received a function
code which is not supported.
Invalid Address (Subcode 2)
This error response is sent if the starting register number and number of
register fields specify registers that are not available.
Invalid Data (Subcode 3)
This error response is sent if the data length specified is longer than the
data received.
Query Processing Failure (Subcode 4)
This error response is sent if data for the original request is not available.
This message is used in CMM mode only.
Backplane Error (Subcode 5)
This error response is sent if data for the original request is not available.
This message is used in PCM mode only.
Serial Link Timeout

The only cause for a device timeout is if an interruption of the data stream
of three character times occurs while a message is being received. If this
occurs the message is considered to have terminated and no response is
sent to the Host. After sending a query message the Host should wait
approximately 500 milliseconds before assuming that the CDWeb
Manager is not responding to its request.
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Invalid Transaction
If an error occurs during transmission that does not fall into the category
of an invalid query message or a serial link timeout, it is known as an
invalid transaction. Types of errors causing this are:
• Bad CRC
• The data length specified is greater than that received
• Framing or overrun errors
• Parity errors
If an error in this category occurs when a message is received by the

CDWeb Manager, it does not return an error message.
MXOpen Protocol Extensions

MXOpen Protocol Extensions are available only in PCM emulation mode.
This mode may also be referred to as MXRTU. CMM mode (RTU
Modbus) does not support these protocol extensions.
Actuator Status
The status of individual actuators is normally accessed by reading the
registers starting at %R801. Each actuator has an associated 16 bit register
whose bits indicate operational status. For use with MXOpen a maximum
of four actuator statuses are allowed. These are defined below.
Table 3-6. MXOpen RTU Actuator Status Fields
STATUS AutoSlice, ProSlice, ProCoat ProFlow
1 Failed Failed
2 Limited Limited
3 Locked N/A
4 Runaway Runaway
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To access these status values use function 01, Read Output Table, to read
the following registers.
• Registers 5001 to 5016 contain the STATUS1 value for up to 256

actuators
• Registers 5017 to 5032 contain the STATUS2 value
Each register contains 16 bits of status, one bit per actuator, with the
lowest number actuator at the least significant bit position. The format of
these messages are shown below.
NOTE: The returned status words are transmitted LSB first not MSB first as
with standard RTU protocol.
QUERY
Address Function (01) Starting Number of Error
Reg. No. Actuators Check
M L M L L M
S S S S S S
B B B B B B
NORMAL RESPONSE
Address Function (01) Byte Count Data Error Check
1st Register
L M ......... L M L M
S S S S S S
B B B B B B
Example:
The STATUS2 (LIMITED) value for 32 actuators is requested starting at
actuator 17.
Method:
The starting register for STATUS2 for actuator 17 is 5018 (139A hex). The
requested number of statuses is 32 (20 hex).
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QUERY:
01 01 139A 0020 5889
RESPONSE:
01 01 04 42B5 C190 5103
Decoding:
The contents of the first register requested is 42B5. Rearranging with MSB
first gives B542 or 1011010101000010 (binary). Therefore actuators
18,23,25,27,29,30 and 32 are limited.
The contents of the second register requested is C190. Rearranging with

MSB first gives 90C1 or 1001000011000001 (binary). Therefore actuators
33,39,40,45 and 48 are limited.
Actuator Reset
When an actuator fails it may need to be "reset" before it can be controlled.
Registers %R1401 to %R1600 are used for this purpose. Writing a one (1)
into the correct register resets that specific actuator. For the MXOpen
implementation (PCM mode) writing a one into register 6000 (1770 hex)
resets all actuators. Functions 06 or 16 can be used for this purpose. In the
example below, function 06 (Preset Single Register) is used for this
purpose. The normal response to a function 06 query is identical to the
query.
QUERY and NORMAL RESPONSE

Address Function (06) Register Data Error
Number Check
M L M L L M
S S S S S S
B B B B B B
Example:
QUERY:
01 06 1770 0001 4C65
RESPONSE:
01 06 1770 0001 4C65
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CDWeb Manager Registers

The following tables of registers are applicable for all Honeywell
actuators. With either the CMM or PCM mode it is permissible for the
Host, using standard RTU protocol, to read from any of these registers or
write to those indicated.
Table 3-7. RTU Registers - CMM Mode
%R Address Range Number of Words Data Description Host Read/Write
0 1 Number of actuators Read

100-103 4 System Status Read
109 1 Actuator Type Read
400-599 200 Host Setpoints Read/Write
600-799 200 Actuator Position Read
800-999 200 Actuator Status Read
1000-1199 200 Zone Enable/Disable Write
1400-1599 200 Zone Reset Write
Table 3-8. RTU Registers - PCM Mode
%R Address Range Number of Words Data Description Host Read/Write
1 1 Number of actuators Read

101-104 4 System Status Read
110 1 Actuator Type Read
401-600 200 Host Setpoints Read/Write
601-800 200 Actuator Position Read
1001-1200 200 Zone Enable/Disable Write
1401-1600 200 Zone Reset Write
6000 1 Reset All Write
Number of Actuators Register

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

These four words contain the CDWeb Manager system status. The four
system status words are defined as Major System Alarms, Minor System
Alarms, Major PLC Alarms, and Minor PLC Alarms to correspond with
older systems. At the present time, neither of the System Alarm words are
used directly in CDWeb systems.

present but not communicating, the CDWeb Manager sets the PLC Not
Ready For Control alarm (bit 2) in the Major PLC Alarm word. When such
a device is communicating, the alarm words are read directly from the
device and the CDWeb Manager acts simply as a pass through.
Actuator Type Register

This word contains a value indicating the type of actuator the CDWeb
Manager is controlling. Possible values are indicated below.
Table 3-9. RTU Actuator Types
Value Actuator Type
1 AutoSlice
2 ProCoat
3 ProSlice
13 Rotary ProFlow
14 Linear ProFlow
Host Setpoint Registers

These words contain the setpoints for the actuators. For slice actuators
(AutoSlice, ProSlice, or ProCoat) the values are in microns. For ProFlow
actuators, the values are in tenths of a percent.
Actuator Position Registers

These words contain the current actuator position. The units are the same
as the units for the setpoint registers.
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Actuator Status Registers

These registers contain one 16-bit word for each actuator. Each word is a
bitmap which indicates the actuator status as indicated below.
Table 3-10. RTU Actuator Status Word

0 Actuator Disabled
1 Actuator Failed
8 Actuator Locked
13 Invalid Tuning
14 Unused
0 Actuator Disabled
1 Actuator Failed
8 Unused
11 Unused
13 Invalid Tuning
14 Unused
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Zone Enable/Disable Registers

These registers are used by the Host system to selectively enable and
disable individual actuators. Writing a one to a register enables the
corresponding actuator and writing a zero disables the actuator. Initially
all actuators are enabled.
Zone Reset Registers

These registers allow the host to reset individual actuators. Writing a one
to a reset register causes a reset of the corresponding actuator.
Actuator Status Flag Registers

These registers are described under MXOpen Protocol Extensions.
Reset All Register

This register is described under MXOpen Protocol Extensions.
Data Link
Baud rate: 300, 1200, 2400, 9600, 19200
Data bits: 7, 8
Parity: NONE, ODD, EVEN
Start bits: 1
Stop bits: 1, 2
Message delimiter: maximum of 0.1 seconds or 3 character times
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Chapter 4. CDConnect Assembly
Hardware
The ProFlow CDConnect controller assembly is responsible for managing
the motor control, feedback, and diagnostics of up to four ProFlow
actuators. Up to four controller assemblies can be installed in a
CDConnect box, meaning that each box can control up to sixteen ProFlow
actuators. CDConnect boxes are connected to each other and to the
CDWeb Manager through specialized cabling that carry communications
and power signals to the controller assemblies.
The CDConnect Assembly for the ProFlow, consists of a controller PCB

assembly in an environmental enclosure, along with the necessary
connections and fittings to interface to the actuator, power and signal bus.
The CDConnect Assembly is mounted separate from the actuator body
due to space and hardware considerations.
The controller PCB assembly consists of two printed circuit boards. The
smaller of the two boards is a TP/FT10 Control Module (Honeywell P/N
6561520033) manufactured by Echelon Corp. This control module
contains a micro-controller, an EPROM, clock crystal and a
communications transceiver to interface to the communications network.
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Chapter 4. CDConnect Assembly CDWeb Control System Manual
The larger of the two printed circuit boards contains:
• a 5 VDC switching power supply to power the electronic circuitry

onboard and the control module;
• the AC switching circuitry and a phase shift network to drive the

actuator motor; and
• an A/D converter to process the analog signal from the actuator

position sensor and monitor the DC power supply voltage.
An example of a typical ProFlow CDConnect Assembly is shown in the

next figure. Note that in the case of the ProFlow, the CDConnect
Distribution Box houses four controller units, each unit in turn controlling
up to four individual actuators. This means that each ProFlow
CDConnect Distribution Box is capable of controlling up to sixteen
individual ProFlow actuators.
Figure 4-1. CDConnect Assembly for ProFlow
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CDWeb Control System Manual Chapter 4. CDConnect Assembly
Control Software
The CDConnect is responsible for actuator position control. Whenever a
new setpoint is received by the CDConnect, it performs several steps:
• first, the new setpoint is compared to the current position to

determine the position error, if any;
• the number of cycles required to move the actuator to within the

position deadband of the new position is calculated based on the
position error;
• AC power is applied to the actuator for the calculated number of

cycles;
• for actuators with feedback enabled, the new actuator position is

again compared to the desired setpoint to check if the actuator is
truly within the position deadband of the desired setpoint.
During operation, the CDConnect also monitors several items to detect

actuator failure. These include sensor voltage, actuator movement, and
sensor calibration. If the actuator is not behaving properly, the logic must
resolve the cause of the problem to one of the following:
• Position Sensor Undervoltage
• Position Sensor Overvoltage
• Actuator Moving Too Slow
• Actuator Moving in Wrong Direction
• Actuator Runaway
• Invalid Calibration
Maximum and minimum position sensor voltage values are set as tuning
values during installation. If the CDConnect detects that the actual sensor
voltage is outside of the range defined by the maximum and minimum
values, it will set an alarm indicating high or low voltage, and disable the
actuator.
“Moving Too Slow” and “Moving in Wrong Direction” are detected in

similar ways. Whenever AC power is applied to an actuator to change its
position, the CDConnect monitors the rate of change in the feedback. This
rate of change is compared to the minimum movement rate set during
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installation as a tuning parameter. If this minimum movement is not

detected, then the failure count is incremented. If the actuator does not
meet this minimum movement rate for a number of consecutive seconds
(again, the number of seconds to failure is set as a tuning parameter), then
the CDConnect compares the current position error to the previous
position error: if the error is less than before, then the actuator is moving
too slow; if the error is greater, then the actuator is moving in the wrong
direction.
If an actuator has been failed by the control software for moving too slow
or moving in the wrong direction, it is monitored to detect if it starts to
move on its own. If a failed actuator moves beyond the runaway dead-
band from its last control position, the CDConnect will alarm this zone as
a runaway, and the onboard miniature relay will be de-energized to
totally remove AC power to the motor drive circuitry. Note that all four
zones controlled by the failed controlled will lose the A/C power as there
is only one relay per controller. At this point the problem must be
rectified and a reset command must be issued via the Supervisory Control
System to restore control. If an actuator fails due to runaway two
consecutive times, do not restore control again until the cause of the
problem has been determined, or else there may be permanent damage
done to other components.
Actuator Configuration Values

The following is a description of the Configuration parameters supported
by the CDConnect Assembly for the AutoSlice, ProSlice, ProCoat:
Actuator Type
Each Honeywell actuator type is identified by a unique identifier.
Valid Range
Rotational ProFlow = 13
Linear ProFlow = 14 (Ver 1.02 and greater)
Default Value
The default value is factory configured.
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Maximum Status Send Rate

This parameter defines the maximum elapsed time between transmitting
actuator status messages to the Gateway. This does not prevent an
actuator status message from being sent at a faster rate than defined by
this parameter (to be discussed later in this section).
Valid Range
0 - 255 seconds. A value of 0 indicates that no status message will be sent.
Note it is not recommended that the send rate be set to zero in standard
operation, as the CDWeb Manger will send an alarm to the host indicating
the lack of communications from an actuator if the time out period is
exceeded. Note that the lowest status send rate of the four actuators being
controlled by the controller will be used as the send rate.
Default Value
The default value is 5 seconds.
Status Send on Delta Value

This configuration parameter is used to determine the amount by which
the actuator position must change before an actuator status message is
transmitted. The data type must be the same as that defined for the
actuator setpoint or actuator position.
Valid Range
1 to 1000 (.1% flow).
Default Value
200 (.1%flow)
Runaway Protection Enable

This configuration parameter is used to determine whether the application
will monitor the actuator position and detect movement of the actuator
when no control actions are being performed on the actuator (i.e. moving
too slow, moving in wrong direction). When enabled, and the application
detects movement when the actuator should not be moving, an onboard
relay will shut off AC power to the motor control circuitry. Note that this
will turn off the power for all four actuators controlled by the controller.
When disabled, no checking for an actuator runaway is performed.
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Valid Range
1 = Runaway Protection Enable
0 = Runaway Protection Disable
Default Value
The default value is Enabled (1).
Feedback Enable / Feedback Mode
Version 1.00
This configuration parameter is used to determine whether the application

will perform closed-loop actuator control or not. When enabled, the
application will use the position sensor measurement to position the
actuator to the setpoint. When disabled, positioning of the actuator is
based on a known rate of movement, and an internal, software maintained
actuator position.
Valid Range
1 = Feedback Enable
0 = Feedback Disable
Default Value
The default value is Enabled (1).
Check AC Zero Cross Enable (Version 1.00 only)

This parameter will enable the use of zero cross signals for use in run time
calculations. If disabled an internal timer will be used to determine the
run time instead.
Valid Range
1 = Enabled
0 = Disabled
Default Value
Disabled (0)
In Version 1.02 and greater this is a spare value.
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Hz Flag
Version 1.00 to 1.01
This parameter is used to determine the time that the zero cross timer
should be set to if the zero cross detect is disabled or has failed. If the flag
is on (50 Hz) the timer will be set to 20 ms. If the flag is off (60 Hz) the
timer will be set to 17 ms.
Version 1.02 & greater
This parameter is used in the runtime calculation to adjust for the different
rotational speeds at 50 Hz and 60 Hz.
Valid Range
1 = 50 Hz
0 = 60 Hz
Default Value
0 (60 Hz)
A/D Conversion Rate

This parameter will determine the rate at which the A/D converter will
sample the analog data.
Valid Range
50 - 2000 ms
Default Value
100 ms (this will allow 10 samples per control action)
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Startup Delay
This parameter determines the amount of time that the actuator will delay
control actions after a hardware reset or a power-up. During this time the
actuator will read the A/D, and calculate its position.
Valid Range
2 - 100 seconds
Default Value
10 seconds
DC Power Supply Error

This parameter is used to determine if the supply voltage is within range.
If the supply voltage drifts out of range a power supply alarm will be set.
As the input supply is used to power the LVDT a variation in the supply
can indicate that the current measured position of the actuator may be
incorrect.
Valid Range
5 - 100 %
Default Value
10 %
Status Startup Delay

This parameter is used on power-up to stagger the time at which the
controller will communicate to the CDWeb Manager. This is done by
multiplying this value by its node number. The value can be determined
by taking the status send rate (in milliseconds) and dividing it by the
number of zones or 64 whichever is less.
Valid Range
0 - 255 ms
Default Value
Status send rate divided by lesser of number of zones or 64
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Communications Randomization Flag

This parameter determines whether or not a delay time should be used
before the next status message is sent. If the flag is on and a
communications failure has occurred a random amount of time between 0
- 255 ms will be added to the status send rate before the next message is
transmitted. This is done to minimize burst communications.
Valid Range
1 = Enabled
0 = Disabled
Default Value
Enabled (1)
Reverse Direction Flag

This parameter determines which direction the actuator sees as the open
direction, and affects how the feedback from the position sensor is
converted into unitized values. When this parameter is set to 1, the
ProFlow actuator will reverse its operating direction.
Valid Range
1 = Enabled
0 = Disabled
Default Value
Disabled (0)
Actuator Tuning Values

The CDConnect control logic contains a number of parameters that can be
tuned depending upon each installation. In most cases the default tuning
values will suffice, but some values may vary from one installation to
another.
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Setpoint Upper Limit

Defines the maximum allowable setpoint that the logic will control to.
Valid Range
± 1500 (.1% flow)
Default Value
1000
Setpoint Lower Limit

Defines the minimum allowable setpoint that the logic will control to.
Valid Range
± 1500 (.1% flow)
Default Value
0
Minimum Actuator Rate

Used for determining actuator failures. The actuator will check to ensure
that the actuator is moving at a minimum rate (e.g. 3 (.1 % flow)/sec) as
defined by the minimum actuator rate. If the actuator does not move at
this rate, the actuator failure count is incremented.
Valid Range
1 - 30 (.1% flow /sec)
Default Value
3 (.1% flow / sec)
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Feedback Sensor Filter Factor

Defines the amount of first order exponential filtering to be performed on
the analog LVDT values. A value of 1000 indicates no filtering is
performed. A value of 10 indicates that the LVDT values are heavily
filtered. The amount of filtering is dependent upon the noise levels
induced in the analog signals. This will vary from installation to
installation.
Valid Range
10 - 1000
Default Value
800 80 % of the current value and 20% of the last
Minimum Control Cycles
Versions 1.00 to 1.01
This parameter defines the minimum number of A/C cycles that the
actuator will use. If the calculated number of cycles is less than this
amount then no control will be performed on the actuator.
Valid Range
1 - 10 A/C cycles
Default Value
4 A/C cycles
Versions 1.02 & greater
This parameter defines the minimum number of cycles that the actuator
will use. If the calculated number of cycles is less than this amount then
no control will be performed on the actuator. Note that cycles are 1.638
ms for a 5Mhz control module and .819 ms for a 10Mhz control module.
Valid Range
1 - 1000 cycles
Default Value
4 cycles
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Movement Failure Limit

Defines the number of successive seconds in which an actuator has not
successfully attained a minimum movement. Values too low could result
in nuisance alarms (i.e. alarms occurring, but the actuator is not faulty).
Valid Range
1 - 100 Seconds
Default Value
5 seconds
Runaway Limit
Only applies after an actuator has failed due to moving too slow or in the
wrong direction. If the actuator is determined to have failed, no more
control actions will be performed. The actuator will continue to monitor
the position of the actuator. If the position moves in excess of the
runaway deadband from the position at the time of failure, the actuator is
determined to be a "runaway". If a "runaway" actuator occurs, the AC
contactor relay in the CDConnect controller assembly is turned off, and
power is removed from that actuator and any other actuator controlled
by that controller assembly. This check is to protect against an actuator
failing in such a way that it cannot stop its movement (e.g. a triac located
in the CDConnect fails in a shorted condition).
Valid Range
10 - 1000 (.1% flow)
Default Value
50 (.1% flow)
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Position Deadband
Defines a deadband around the actuator setpoint. If the actuator position
is within this deadband (e.g. ±5 .1% flow), no control actions will be
performed on the actuator.
Valid Range
1 - 200 (.1% flow)
Default Value
5 (.1% flow)
Actuator Stop to Stop range

Value in tenths of degrees of actuator range of travel from high stop to
low stop. Used in scaling calculations to relate actuator movement to
desired flow.
Valid Range
100 - 2000 (0.1°)
Default Value
970 (0.1°)
Valve operating range

Value in tenths of degrees for the amount of the actuator range of travel
used in actual operation (from crack-open to full flow).
Valid Range
100 - 2000 (0.1°)
Default Value
770 (0.1°)
Crack Open to Low Flow

Value in percentage of flow offsetting the lowest operating flow setpoint
(0%) from the crack open position. This assumes that the maximum
allowable setpoint range is from zero to one hundred percent, and that
this corresponds to crack open position to full open position. The crack
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open to low flow value is the unscaled actual percentage value,

corresponding to the unscaled actual setpoint between crack open and full
open, that is scaled to an operating setpoint of zero percent.
Valid Range
0 - 1200 (0.1% valve operating range)
Default Value
100 (0.1% valve operating range)
Crack Open to High Flow

Value in percentage of flow offsetting the highest operating flow setpoint
(100%) from the crack open position. This assumes that the maximum
allowable setpoint range is from zero to one hundred percent, and that
this corresponds to crack open position to full open position. The crack
open to high flow value is the unscaled actual percentage value,
corresponding to the unscaled actual setpoint between crack open and full
open, that is scaled to an operating setpoint of one hundred percent.
Valid Range
0 - 1200 (0.1% valve operating range)
Default Value
0 (0.1% valve operating range)
Feedback Sensor Low Alarm Limit

This parameter sets the minimum voltage that the sensor can get to before
stopping all control actions and indicating this with a low limit alarm.
Valid Range
0-5000 mV
Default Value
75 mV
Feedback Sensor High Alarm Limit

This parameter sets the maximum voltage that the sensor can get to before
stopping all control actions and indicating this with a high limit alarm.
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Valid Range
0-5000 mV
Default Value
5000 mV
Feedback Alarm Hysteresis

This parameter determines the amount that the actuator feedback must
come back into range once a low or high limit alarm has been set in order
to clear the alarm. If a low or high limit alarm is triggered by the feedback
signal going beyond the alarm limits, the alarm will only be cleared after
the feedback signal has come back within the limit by the amount set with
this tuning parameter (e.g. if the hysteresis value is set to 50 mV and the
high limit is at 4900 mV, then when the feedback signal goes beyond 4900
mV, triggering the alarm, the signal must drop to 4850 mV or less to clear
the alarm).
Valid Range
0 - 500 mV
Default Value
50 mV
Modifying Configuration and Tuning Values

Configuration and tuning values can be modified using either the
maintenance software provided with the system. This will be either
CDWeb Explorer, the remote login shell feature of TERM/Term95 utility,
or the LonMaker software. Changing values for more than one actuator is
best accomplished using CDWeb Explorer or the TERM/Term95 utility.
Refer to the How To… section for step-by-step instructions.
Actuator Commands
The CDConnect has a number of actuator commands which are used to
change values or modes of an actuator that are not in configuration or
tuning. Normally, these commands are accessible through CDWeb
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Explorer or TERM/Term95 as menu commands. However, there may be

times when it is necessary to issue the command directly. This section
shows what the various command function numbers and parameters
mean. Commands can be issued through the use of the generic command
menu item in CDWeb Explorer, or through the remote login shell
provided by TERM/Term95 (see How To… section for further details).
The commands are formatted in the following way.
Function: the actuator function to be done
Param_1: the first parameter (action)
Param_2: the second parameter (data)
Param_3: the third parameter (data)
Param_4: the fourth parameter (data)
The following commands are available:
Table 4-1. Actuator commands functions
Function Description Parameter 1 Parameter 2 Parameter 3 Parameter 4
1 Change mode mode - - -

2 Reset actuator - - - -
3 Self test - - - -
4 Flush flush action cycle times final position -
101 Define position - - - -
102 Clibration calibrate action - - -
104 Change open loop gain gain - - -
105 Change startup cycle startup cycles - - -
Function: 1 Change actuator mode.

This function is used to change the mode of the actuator. The mode of an
actuator is defined by the data located in parameter 1. The modes that the
actuator can be placed in are:
Manual mode 0
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Auto mode 1
Quiet mode 4
There are other modes that the actuator may place itself in. These are as
follows:
Self test 2
wink 3
Manual mode
The actuator will not make any control actions and will make its position
equal to its measured value.
Auto mode
The actuator will control to a setpoint change and will set alarms as
required.
Quiet mode
The actuator will no longer send out messages on the network, this mode
should only be used during installation if the network is noisy.
Self Test mode
The actuator is currently in a self-test, and is not available for control.

This mode is only used in the factory.
Wink mode
The actuator has received a “wink” command from another node on the
operating network (typically the installation tool node, when requested to
do so by LonMaker or CDWeb Explorer). Once the “wink” response has
been completed, the actuator will return to its previous mode.
Example:
function = 1 (change mode)
Param_1 = 1 (change the mode to auto)
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Function: 2 Reset Actuator.

This function does not require any additional parameters to be sent. It
will cause the actuator to clear all its alarms and do a bumpless transfer to
the current measured position.
Function: 3 Self test.

This function will initiate a self test of the zone and is intended for factory
use only.
Function: 4 Flush actuator.

This function is used to control the actuator during a flush sequence.
There are a number of functions that the actuator can initiate:
Action Param # 1 Description

Open 0 Will send the actuator to its open
position
Close 1 Will send the actuator to its closed
position
Cycle 2 Will cycle the actuator to its limits a
specified number of times and end at
a specified open or closed position
End 3 Will end the flush sequence and place
the actuator into its previous mode
Stop 4 Will stop the actuator in the middle of
whatever action it was doing
Resume 5 Will resume from its stopped state
and continue its last action
With the cycle action there are two parameters that need to be sent, the
number of cycles to perform and the final position of the actuator after the
cycles are complete.
Function: 101 Define position (calibrate sensor)

This function will define the position that the actuator is currently located
at as the crack open position. It will adjust the intercept of the actuator
position calibration curve to make the calculated actuator position equal
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to the specified position. In order for this calibration to work correctly the
actuator must have a valid position slope in its memory.
param_1 = 0 (don’t care)
param_3 = 0
Function: 102 Calibrate the A/D (position & millivolts)

This function is used to define the slopes and intercepts for the A/D
converter. Depending on the action (param_1) the actuator will perform a
two point calibration and calculate a slope and intercept or a slope and
intercept can be entered directly, for each of the position and voltage
conversions.
param_1 = action, depending on function:
0 - Store initial data, for a two point calibration.
1 - Calibrate for mV (second point in a two point calibration) this will

calculate a slope and an intercept based on the differential of the
A/D counts.
2 - Calibrate for valve position (second point in a two point

calibration) this will calculate a slope and an intercept based on the
differential of the A/D counts.
3 - Calibrate for both mV and valve position this will calculate a slope
and an intercept based on the differential of the A/D counts.
4 - Send a slope and intercept directly for mV.
5 - Send a slope and intercept directly for valve position.
6 - Auto calibrate to valve position using hard stops as the two points.
param_2 = data
In action 0,1,3 this parameter is the value in mV.
In action 4,5 this parameter is the slope
param_3 = data
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In action 0,2,3 this parameter is the value in valve position.
In action 4,5 this parameter is the intercept value.
param_4 =not used
Example:
In order to manually send the slope and intercept for calibration to

millivolts you would type the following
function_number = 102
param_1 = 4 (manual calibration to millivolts)
param_2 = 4883 (default slope)
param_3 = 0 (default voltage intercept)
For further examples of calibration please see the how to section.
Function: 104 change the open loop gain (ver. 1.02 and
greater)
This function will change the open loop gain of the actuator. Note that
this value is set in the factory and should not need to be changed. The
value is in terms of cycles per 10 microns, and is defaulted to 240. Each
cycle = 1.638 ms for a 5 MHz processor and .819 ms for a 10 MHz
processor.
Example:
function = 104 (change the open loop gain)
param_1 = 240 (default gain)
Function: 105 change the startup cycles

This function will change the number of cycles that get added to a run
time in order to compensate for motor startup delays. This value is set in
the factory and should not be changed.
Example:
function = 105 (change the startup cycles)
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param_1 = 20 (default number of cycles)
Calibration
Background
The purpose of calibrating is to define to the CDConnect controller a point
in space and associate this point with an analog signal. The controller can
then accurately move the actuator to new locations (as determined by the
Supervisory Control System) by using the analog feedback signal. The
ProFlow uses a potentiometer for its feedback. The response of a
CDConnect is depicted in Figure 4-2.
2000
1500
1000
0.1 % flow
flow (rotational)
flow (linear)
500
0
1040
160
240
320
400
480
560
640
720
800
880
960
80
0
-500
A/D counts
Figure 4-2. CDConnect calibration curves
The calibration of an actuator is done by using actuator commands. There

are two ways of calibrating an actuator:
• directly assign a slope and intercept value; or
• collect data from two known points and have the CDConnect
calculate the slope and intercept itself.
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Either one of these methods may require more than one command to
complete the calibration. More information on the exact commands and
the order to send them are located in the How To… section of this manual.
Note that there are five channels on the A/D converter. One measures the
supply to the measuring device, while the other four measure the
feedback from the measuring device. Thus there are two calibrations
needed in a CDConnect:
• Calibration to voltage (used in feedback and supply measurements.
• Calibration of the feedback in 0.1% flow.
A two point calibration is recommended when calibrating the ProFlow.
Note that the calibration to millivolts is not used in any calculations for
actuator position. These calibration values are only used for setting the
position sensor undervoltage & overvoltage alarms, as well as for display
purposes.
Actuator Scaling
In the ProFlow position control is done to a scaled value representing
flow. This scaled value is determined in the following manner. The first
step is to calibrate the actuator using the automated two point calibration.
This will find the low and high stop A/D counts. These two points
represent the stop to stop range entered as a tuning parameter in units of
0.1 degrees. The next item that needs to be known is the rotational range
of the valve where the valve is actually open. This value is entered as the
valve range in the tuning parameters. Another value needed is the point at
which the valve is just starting to open (crack open). The valve must be
placed in this position, and an actuator command issued to define the
position (this will store the A/D counts for the crack open position). At
this point we have enough information to calculate the calculated valve
opening, in units of 0.1% valve opening. Using the calculated valve
opening and knowing that the flow is close to linear from 10% to 90% of
the valve opening, we can define the low and high flow tuning values in
0.1% units of valve opening (L and U in the figure). This will then give us
the ability to send a setpoint between 0% and 100% representing the total
flow range of the valve.
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Figure 4-3. ProFlow scaling relationships
Actuator Alarms
An alarm is indicated when a bit is set (1). No alarms exist if all bits are
reset (0).
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Table 4-2. Actuator Alarms
0 Actuator Disabled
1 Actuator Failed
2 Position Sensor Undervoltage
3 Position Sensor Overvoltage
4 Actuator Moving Too Slow
Zone Status Slice/Flow family 7 Invalid Calibration
8
11
13 Invalid Tuning
14
15 Lost Communications
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Chapter 5. Utilities
Overview
The CDWeb Manager is shipped with all control software pre-loaded in
the EPC-8A processor, and the CDConnect control logic is embedded in
the hardware of each assembly. During system installation and
maintenance, it may be necessary to change some of the configuration or
tuning values used by the system, or to replace components of the CDWeb
system. Several software utilities are provided to assist in this. The
various steps involved in installing and maintaining a CDWeb system are:
• installing or replacing nodes (CDConnect assemblies, routers,

CDWeb processors);
• creating the EXPORT.CSV file required by the CDWeb processor;
• transferring the EXPORT.CSV file to the CDWeb processor;
• performing actuator configuration, tuning, and calibration.
Depending on when a particular system shipped, different software tools

are used. If a system is supplied with LonMaker and TERM/Term95,
refer to those parts of this chapter. System users with CDWeb Explorer, a
Windows95/WindowsNT application, should refer to that portion of this
chapter.
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Chapter 5. Utilities CDWeb Control System Manual
LonMaker
Echelon’s LonManager LonMaker Installation Tool is used during the
installation and repair of nodes on the LON. This program works with the
database built for each system during manufacturing. The database for
each system is shipped on distribution disks, and should be copied from
those distribution disks to the PC where LonMaker and the rest of the
CDWeb tools are installed.
The database contains all of the information necessary to construct and

define the LON. Each CDConnect node, along with the router(s) and the
CDWeb processor, is installed into the database, and all bindings between
nodes on the LON are defined.
Hardware requirements
In order to run LonMaker, it must first be installed onto a PC. Detailed
instructions are provided in the software documentation provided by
Echelon with LonMaker. Minimum hardware requirements are:
• IBM PC-compatible computer equipped with at least an Intel 80386-

25MHz,
• 640 KB conventional RAM, with 580 KB free for LonMaker,
• 2 MB of expanded or extended memory,
• 1.1 MB free hard disk space for the LonMaker software, plus at least
375 KB free hard disk space for the parts database and the
installation database,
• 3.5” 1.44 MB floppy disk drive,
• a free serial port (COM1 or COM2),
• VGA display,
• MS-DOS 3.2 or higher. For Windows 95 use, see “Using LonMaker

with Windows 95”.
A mouse is helpful; all commands are also available through the

keyboard.
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CDWeb Control System Manual Chapter 5. Utilities
In order to communicate with the nodes on the LON, the PC must be

connected to the LON as a node itself. This is accomplished using a Serial
LonTalk Adapter (SLTA), one of which is provided with the system. The
SLTA is a battery-powered device that allows a PC to be connected as a
node on the LON via a serial port (COM1 or COM2). A 9-pin to 9-pin
serial cable is also provided to connect the SLTA to the PC containing the
LonMaker software. If the only free serial port is a 25-pin one, then it will
be necessary to obtain a 25-pin to 9-pin converter. Such devices are
readily available from any computer-equipment dealer.
Installing the SLTA driver

The first step in installing LonMaker is to install the SLTA driver. The
SLTA driver, called LDVSLTA.SYS, can be found on the LonMaker
installation disks in the \DRIVERS subdirectory. In order to use this
driver, it must be copied from the installation disk to the hard drive of the
PC, and a device= line must be added to the CONFIG.SYS file:
device=<drive>:\<path><driver-filename> [options]
where:
<drive> is the drive letter of the drive where the driver is stored
<path> is the complete path to the location of the driver
<driver-filename> is the name of the driver, LDVSLTA.SYS
[options] a combination of the following:
/A use automatic baud rate detection
/Bnnnn set baud rate to nnnn, not to be used in conjunction with

the /A option
/Pn set serial port used to COMn
/Dn set driver name to “LONn”, default name is “LON1”
Note that LonMaker defaults to selecting the driver named “LON1”, so

the /Dn parameter should be omitted unless absolutely necessary.
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Installing LonMaker
The LonMaker distribution disks include an installation program,
INSTALL. Run this program to install LonMaker onto the PC. This
installation program will default to placing the LonMaker software into a
new directory on the hard drive called LNM. Unless the PC is not
properly equipped for VGA graphics, choose the Graphics version
(LNMG). Once the software is installed, reboot the PC.
Figure 5-1 LonMaker Setup for Windows 95
Using LonMaker with Windows 95

Because LonMaker requires a network interface driver such as
LDVSLTA.SYS in order to connect to the LON, it is necessary to add the
device= line to the CONFIG.SYS file in the root directory. It is also
possible to set up a special boot configuration so that the SLTA driver is
loaded only when necessary. Consult the Windows 95 documentation for
instructions on how to configure the PC for multiple boot configurations.
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LonMaker will operate under Windows 95 as a DOS application as long as

the SLTA driver is present, so it is not necessary to force Windows 95 to
reboot in MS-DOS mode to run the program.
The most convenient method to run LonMaker under Windows 95 is to set

up a desktop shortcut linked to the program. To do this, right-click on the
desktop, and select the option to create a new shortcut. The shortcut
should be set to run LNMG.EXE, with the startup directory being the
database directory copied from the distribution disks. For example, if
LonMaker is installed in C:\LNM, and the database directory is
C:\LONDBAS, then the shortcut would be configured as shown in the
following figures. Remember to select the Memory tab and set the
expanded memory to 2048. If your system is not configured to use
expanded memory, then set the extended memory to 2048.
Figure 5-2 Windows 95 Memory Assignments for LonMaker
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Starting LonMaker
To run LonMaker, first switch to the project database directory (for
example, C:\LONDBAS), then type:
C:\LNM\LNMG
If LonMaker is not installed in C:\LNM, then substitute its actual location

in the line above. If the PC has enough free conventional memory,
LonMaker will start. If it does not locate a parts database under the
current directory, it will abort. If this occurs, confirm that the current
directory is the correct database directory, and that there are data files in
the sub-directories of the project database directory.
Basic LonMaker Tasks

LonMaker allows for the installation and maintenance of nodes on the
LON. The following procedures show how this is done.
Node Installation
Node Installation is usually performed only during system installation.

For most CDWeb systems, the initial installation will have been done at
the factory during system testing. However, there may be times when it is
necessary to install one or more network nodes in the field. To do this,
follow this procedure(to replace a previously installed node, use the next
procedure, “Node Replacement”, instead):
1. Connect the PC to the LON by connecting the serial port on the PC to

the serial side of the SLTA, and the RJ45 side of the SLTA to the service
port inside the CDWeb Manager. Check that the SLTA has power by
turning it on and observing the service light. If it does not flash on
power-up, then there is insufficient power in the SLTA battery. Plug
in the supplied adapter before proceeding.
2. Switch to the sub-directory on the PC hard drive containing the project

database for the system. From this sub-directory, run LNMG.EXE.
This may also be set up as an icon on a Windows 95 system. As
LNMG.EXE starts up, it will check for sufficient conventional memory
and the presence of a parts database. If it encounters a problem, it will
report the problem, and may abort the loading process. Rectify the
problem, then re-start.
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3. After LNMG.EXE starts, follow the screen prompt by clicking on the

mouse button or striking a key. The LonMaker control screen will
appear. The default CDWeb database is defined with a single domain
called cdweb_system.
4. To connect to the local operating network, select Channel Setup, then

select chan_b1_s1. Click on the Attach button (or hit the F6 key) to attach
to the LON. If all of the SLTA connections have been made properly,
the attachment icon at the top-right corner of the screen will change to
show a valid connection. If an error message comes up reporting a
connection problem, check that all of the SLTA connections are secure,
and that the SLTA has power. Confirm that the correct channel has
been selected in Channel Setup.
5. Once connected to the network, select Installation. The screen will switch
to display all available locations, and the devices that are associated
with the selected location. A dot preceding a device on the device list
indicates that the device has not been installed into this particular
system. This may be because the device is not part of the system, or
has not been previously installed at the factory. To install a device, use
the mouse or the Tab and arrow keys to choose the appropriate
location, then highlight the device and hit Enter to select it. The
selection will be confirmed by the Device: text box at the top of the
screen.
6. Selecting the Install button (or hitting F3) will display a screen
prompting for the installation method to be used. Choose the Service
Pin method, then continue. LonMaker will then wait for a service pin
message. For CDWeb processors and network routers, the service pin
message is generated by pressing the Service button found on the front
panel of the device. For CDConnect assemblies, a service pin message
is generated by disconnecting, then re-connecting, the quick-connect
cable.
7. If the device has previous network configuration information already,

LonMaker will display a dialog box stating this, and asking whether or
not to proceed. Unless the service pin message was generated from the
wrong device, select Continue. If the message was in error, select
Cancel to abort.
8. LonMaker will proceed to send network and device configuration data

to the selected device. Depending on the device, this may take
anywhere from several seconds to a minute. Once LonMaker has
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finished configuring the node, it will report that the node has been
successfully installed. If LonMaker encounters any problems during
the configuration such as a failed message, it will abort the process and
display an error message. Refer to the Troubleshooting LonMaker
section later in this chapter for common problems and solutions.
9. If there are more nodes to install, repeat steps 5 to 8. Once all nodes
have been installed, end the LonMaker session by select the Exit button.
LonMaker will automatically save all of the changes to the project
database. Once LonMaker has closed, run EXPORT.BAT from the
project database subdirectory to create a new EXPORT.CSV file.
10. To finish the installation, refer to the procedure later in the section
discussing how to use the TERM utility to transfer the EXPORT.CSV
file to the CDWeb processor.
This same procedure applies to all network nodes, including network

routers and the CDWeb processor.
Node Replacement
If a CDConnect assembly or other network component fails during

operation and needs to be replaced, it is necessary to modify the project
database to remove the defective component and add a replacement unit.
LonMaker has built-in tools to aid in this.



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select chan_b1_s1. Click on the Attach button (or hit the F6 key) to attach
to the LON. If all of the SLTA connections have been made properly,
the attachment icon at the top-right corner of the screen will change to
show a valid connection. If an error message comes up reporting a
connection problem, check that all of the SLTA connections are secure,
and that the SLTA has power. Confirm that the correct channel has
been selected in Channel Setup.
5. Once connected to the network, select Repair. The screen will switch to
display all available locations and their associated devices. Using the
mouse or the Tab and arrow keys, find and select the device to be
replaced. Make sure that the device has been properly selected by
checking that the device name appears in the Device: text box at the top
of the screen. Press the Replace button (or hit F4). LonMaker will
prompt for a service pin message from the replacement device. For
CDConnect assemblies, this is generated by disconnecting, then
reconnecting, the quick-connect cable. For routers and CDWeb
processors, the service pin message is generated by pushing the
Service button found on those devices.
6. Once LonMaker detects the service pin message, it will query the
device to see if it already has network configuration data on board. If
it does, LonMaker will ask for confirmation before proceeding to
install the device as a replacement. Select the Continue button (or hit
F2). After configuration of the replacement device is finished, exit
from LonMaker.
7. From a command prompt, switch to the project database subdirectory,

and run EXPORT.BAT to generate a new EXPORT.CSV file, then use
TERM to transfer it to the CDWeb processor.
Troubleshooting LonMaker
LonMaker will report any error or problem it encounters during
operation. To resolve these problems, there are several basic steps to take.
1. Check that the network connection through the SLTA is properly

connected. Any problem with the SLTA or its connections will
manifest itself through an inability for LonMaker to attach to the
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network. Check that the SLTA has sufficient power by pushing its
Service button and observing the Service LED. If it does not flash once
after the Service button is pushed, ensure that the SLTA power switch
is in the On position, and supply it with external power from its power
supply adapter. Also check the serial cable connection between the PC
and the SLTA, and the twisted-pair cable between the SLTA and the
LON.
2. Ensure that the correct Channel has been selected in LonMaker.

Typically, LonMaker should be connected to channel chan_bl_s1 to
install or repair nodes. This can be confirmed by selecting the Channel
Setup button. The current channel will be shown in a text box on the
right side of the screen. If the wrong channel is selected, network
messages will not get through and LonMaker will report an error.
3. If messages to a specific node are failing, try turning off the power to
that node, then restoring power to it. In the case of the CDWeb
processor, turn off the rack power supply to remove power from the
processor node.
4. Confirm that the node has power and that its communications cabling
is in place. In the case of a CDConnect, listen for the audible click of
the run-away protection relay making contact when the quick-connect
cable is installed. If this click cannot be heard, open the CDConnect
using the supplied tool, and observe the LED on the circuit board as
the quick-connect cable is removed and re-installed. It should flash
once upon power-up. If it does not, make sure that the six-position
connector on the circuit board is securely installed. Replace the
CDConnect circuit board if necessary.
Export
After a node has been installed or replaced in the project database, it is
necessary to create a new EXPORT.CSV file from the database for the
CDWeb processor. Creating this file is accomplished using the LM2CSV
utility. The process has been further simplified by the provision of a batch
file, EXPORT.BAT, in the project sub-directory. This batch file contains
the following commands:
c:\lnm\util\lm2csv db_inst export.csv
This assumes that the LM2CSV utility has been properly installed on the
PC in the C:\LNM\UTIL\ sub-directory. The batch file instructs
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LM2CSV to operate on the contents of a sub-directory named DB_INST to

create a file called EXPORT.CSV. This command must be issued from the
directory immediately above the DB_INST sub-directory in order to work.
The batch file is placed by default in the parent directory of DB_INST.
As LM2CSV works, it may report that it is unable to locate the SNVT file
or the user type file. This is normal, as these files are not required for
CDWeb systems. Once LM2CSV is finished, it will place the
EXPORT.CSV file in the project directory.
TERM/Term95
TERM.EXE and TERM95.EXE are programs that allow a user to connect to
a CDWeb Manager via an Ethernet network connection to monitor
diagnostic messages and to remotely log into the CDWeb Processor for
system maintenance tasks. TERM.EXE is a MS-DOS program that
requires FTP Software’s PC/TCP communications protocol package.
TERM95.EXE is a Windows95/WindowsNT application that uses the
Microsoft TCP/IP protocol supplied with those operating systems. In
either case, the first step is to ensure that the communications protocol is
properly installed.
TERM and PC/TCP

Systems supplied with TERM.EXE will also have been supplied with a
run-time version of the basic PC/TCP programs. These can be found on
one of the system distribution disks in a directory called PCTCP. The
directory and all of the files in it should be copied onto the hard drive of
the maintenance computer.
In order for PC/TCP to work properly, the TCP/IP packet driver for the
network adapter card in the maintenance computer must be installed. The
packet drivers are usually supplied with the network adapter card on a
disk. If the packet driver for the network adapter is not found, contact the
network adapter manufacturer or supplier.
Once a packet driver is available, a MS-DOS batch file similar to the

following can be used to start the PC/TCP protocol software:
@ECHO OFF
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c:\pktdrv\xpspd.com Åstart packet driver

set pctcp=c:\pctcp\pctcp.ini Åset variable
c:\pctcp\ethdrv -m Åstart PC/TCP driver
The PCTCP.INI file should be edited to set the IP-address of the

maintenance computer. In that file, locate the following section:
[pctcp ifcust 0]
ip-address = 192.206.218.100
subnet-mask = 255.255.255.0
interface-type = PKTDRV
frame-type = DIX-Ethernet
The address in the line “ip-address = 192.206.218.100” must be

changed to one that will work on the actual control network. If the control
link to the CDWeb Manager is via a serial link, then the default address
(as shown in the above example) will work.
Term95 Installation and Setup

If the maintenance computer has Windows95 or WindowsNT installed,
then Term95 should be used instead of TERM. Term95 does not require
PC/TCP as it uses the Microsoft TCP/IP protocol supplied with
Windows95 and WindowsNT.
To use Term95, first ensure that Microsoft TCP/IP protocol has been
installed on the maintenance computer. If it is not, then locate the original
Windows95 or WindowsNT installation disks and install the TCP/IP
protocol. To check the current installation in Windows95, click on the
Start button on the taskbar, select the Settings tab, then select the Control
Panel item. When the Control Panel folder opens, double-click the
Network icon. This will bring up a dialog box similar to the following
figure. Note that the devices and services listed in the dialog box will
most definitely vary from system to system.
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Figure 5-3 Network Settings Dialog Box in Windows95
To check if the TCP/IP protocol has been installed, it will appear on the
list of installed network components (usually towards the bottom of the
list), bound to a network adapter. If it is not installed, then select the
Add… button found below the list of installed components. A window
will appear asking for the component type. Select the Protocol type, then
click OK. A list of manufacturers and protocols will appear. Choose
Microsoft as the manufacturer, then TCP/IP from the list that appears. At
this point, the computer may ask for one of the original Windows95
installation disks, unless it locates the installation files on the hard drive
(many laptop computers are often manufactured with the Windows95
installation files supplied on the hard drive).
Every time Term95 is used with a different CDWeb system, it is important

to first check that the Windows95 TCP/IP address settings match the
address requirements of the control network. To do this, again access the
Network settings dialog box as described earlier, then locate on the list of
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installed network components an entry that shows the TCP/IP protocol

“bound” to a network adapter (typically shown as “TCP/IP->Network
Adapter” where Network Adapter is the name of the actual adapter). If such
an entry is not found, but the TCP/IP protocol is definitely installed, then
locate the entry for the network adapter itself, select it, then press the
Properties… button. On the dialog box that appears, select the Bindings
tab. A list of protocols will appear along with checkboxes showing if the
protocol is bound to the adapter. Make sure the checkbox is ticked, then
click OK to return to the first dialog box. Again scroll down the list of
installed components, and select the TCP/IP protocol that is bound to the
network adapter.
Figure 5-4 TCP/IP Settings in Windows95
In the TCP/IP Settings dialog box, set the IP-address of the maintenance
computer so that the first three groups of numbers (192.206.218 in the
example shown) match the numbers for the rest of the equipment on the
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control network. This will allow Term95 to initiate communications to the

CDWeb Manager. For CDWeb Managers on serial links, the default IP-
address is 192.206.218.158, and a typical maintenance computer address to
use with it is 192.206.218.157.
Running TERM and Term95

TERM and Term95 both require that the maintenance computer be
connected to the CDWeb processor via a network connection. This
connection can be made by connecting the maintenance computer’s
network adapter to the same control network that the CDWeb Manager is
connected to, or by connecting directly to the CDWeb processor through
the use of a cross-over cable plugged into the Ethernet port on the front of
the EPC-8A. If setpoints and actuator state commands are to be sent to the
actuator controllers, it is necessary to disconnect the CDWeb Manager
from the control network and connect directly using the cross-over cable.
If this is not done, any setpoints and actuator commands will be over-
ridden by the values coming from the control system.
To run TERM, change to the directory where TERM.EXE is located, then

type:
TERM -h <CDWeb Mgr IP-address>
where CDWeb Mgr IP-address is the appropriate address for the CDWeb
Manager. For users who are familiar with networking and PC/TCP, a
hosts file can be set up and the alias used as the CDWeb Mgr IP-address
instead of the actual address.
Users of Term95 can either select Term95 from Windows95 Explorer, or

create a shortcut to Term95 and use it to start the program. If no address
is given to Term95 as a parameter, Term95 will attempt to locate any
CDWeb Managers on the same subnet (i.e. the same first three numbers of
the IP-address) as the maintenance computer. If one is found, it will
automatically connect to it. If more than one is found, it will display a list
of them and ask the user to select one.
Using TERM
When TERM is run, it attempts to connect to the CDWeb Manager at the
specified address. Once connected, it communicates to the diagnostic task
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in the CDWeb Manager. Any diagnostic messages sent by the task can be
displayed in the diagnostic window of TERM. This diagnostic window is
what first appears after TERM connects. Color-coded messages will
appear, providing diagnostics for the various software tasks running on
the CDWeb processor. These messages can vary in severity level from 1
(most severe) to 7 (information only). When TERM first starts up, the
filtering level is set to 7, meaning that all messages are displayed.
The amount of message filtering can be modified by the number keys.

Pressing a number key sets the message filtering to the corresponding
level. So, pressing the 3 key means that only diagnostic messages with a
severity level of 3 or less (ie. levels 1, 2, and 3) will be displayed.
Messages can also be logged to a file. The file logging is controlled by

pressing Alt and a number key. So pressing Alt-3 would log all diagnostic
messages with severity level 3 or less to a file. The log file is called
term.log and is located in the current working directory of the
maintenance computer. By default, no file logging occurs.
Term also attempts to detect CDWeb Manager failures by monitoring the

time between messages. By default, if no messages are received from the
CDWeb Manager for five seconds, then term assumes the CDWeb
Manager has had to restart itself. Term will then attempt to reconnect.
This behavior is controlled by the term command line parameter -t (see
below).
File transfers are initiated by pressing s to send a file and r to receive a

file. The user is guided by a series of prompts for the source and
destination file names and the file type. The file type is an important
aspect of file transfer to the CDWeb Manager computer because files
stored under QNX are not stored in the same format as files stored under
DOS or Windows. Consequently the program must know whether the file
is a text file or a binary file in order to perform the necessary conversion.
In general, program files (eg. lon, act, odx, scl, and debug) are
binary files. Scripts and other files (eg. webstart, cdweb.ini,
export.csv, and hosts) are text files.
A file transfer can be aborted at any prompt by pressing the ESC key.
A QNX terminal can be started by pressing the L key to login. This creates
a split screen with the login window at the top and the diagnostic window
at the bottom. The login display can be zoomed (or unzoomed) by
pressing the F10 key. A terminal session can be logged to a file by pressing
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the F9 key. After pressing F9, the user is prompted for a filename. The
entire session is the captured in the named file until F9 is again pressed or
the session ends.
The login display is essentially a remote user shell for the CDWeb
processor. This is the same shell that is available if a VGA monitor and a
PS/2-style keyboard are plugged into the connectors in the front of the
CDWeb processor.
At the QNX terminal, any QNX task can be started, but this is most often
used to start the CDWeb Manager console task. Please refer to the
“CDWeb Manager” section for a description of the various tasks found in
the CDWeb Manager.
The QNX terminal can be terminated by typing logout or exit at the $

prompt.
In summary, the TERM command line parameters and built-in commands

are:
Command Line:
term -h host [-t timeout] [-f level]
where:
host is the IP address or name of the CDWeb Manager
timeout timeout value before a reconnect is attempted (0 means no
timeout)
level start file logging diagnostic messages at this level
Possible actions:
s send a file to the CDWeb Manager
r receive a file from the CDWeb Manager
d run a DOS shell (exit to return to term)
l log-in to the CDWeb Manager (exit or logout to quit)
F9 when logged in, log all screen messages from remote shell to
user-specified file, log ends when pressed again.
F10 when logged in, change between split-screen
and full screen modes
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Using Term95
Term95 can connect to a specific CDWeb Manager if an IP-address is
specified as a command line parameter used to run it. Alternatively, if no
CDWeb Manager is specified on the command line (see below), Term95
attempts to locate any CDWeb Managers attached to the network. If only
one CDWeb Manager is found, Term95 connects to it. If more than one is
found, Term95 allows the user to select the CDWeb Manager from a list.
Once connected, the program behaves exactly like TERM. It

communicates to the diagnostic task in the CDWeb Manager, and any
diagnostic messages sent by the task are displayed in the diagnostic
window of Term95. This diagnostic window is what first appears after
Term95 connects. Color-coded messages will appear, providing
diagnostics for the various software tasks running on the CDWeb
processor. These messages can vary in severity level from 1 (most severe)
to 7 (information only). When Term95 first starts up, the filtering level is
set to 7, meaning that all messages are displayed.
The amount of message filtering can be modified by the number keys.

Pressing a number key sets the message filtering to the corresponding
level. So, pressing the 3 key means that only diagnostic messages with a
severity level of 3 or less (ie. levels 1, 2, and 3) will be displayed.
Messages can also be logged to a file. The file logging is controlled by

pressing Alt and a number key. So pressing Alt-3 would log all diagnostic
messages with severity level 3 or less to a file. The log file is called
term.log and is located in the current working directory of the
maintenance computer. By default, no file logging occurs.
Term also attempts to detect CDWeb Manager failures by monitoring the

time between messages. By default, if no messages are received from the
CDWeb Manager for five seconds, then term assumes the CDWeb
Manager has had to restart itself. Term will then attempt to reconnect.
This behavior is controlled by the term command line parameter -t (see
below).
File transfers are initiated by pressing s to send a file and r to receive a

file. The user is guided by a series of prompts for the source and
destination file names and the file type. The file type is an important
aspect of file transfer to the CDWeb Manager computer because files
stored under QNX are not stored in the same format as files stored under
DOS or Windows. Consequently the program must know whether the file
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is a text file or a binary file in order to perform the necessary conversion.

In general, program files (eg. lon, act, odx, scl, and debug) are
binary files. Scripts and other files (eg. webstart, cdweb.ini,
export.csv, and hosts) are text files.
A file transfer can be aborted at any prompt by pressing the ESC key.
A QNX terminal can be started by pressing the L key to login. This creates
a split screen with the login window at the top and the diagnostic window
at the bottom. The login display can be zoomed (or unzoomed) by
pressing the F10 key. A terminal session can be logged to a file by pressing
the F9 key. After pressing F9, the user is prompted for a filename. The
entire session is the captured in the named file until F9 is again pressed or
the session ends.
The login display is essentially a remote user shell for the CDWeb
processor. This is the same shell that is available if a VGA monitor and a
PS/2-style keyboard are plugged into the connectors in the front of the
CDWeb processor.
At the QNX terminal prompt ($), any QNX task can be started, but the
session is most often used to start the CDWeb Manager console task.
Please refer to the “CDWeb Manager” section for a description of the
various tasks found in the CDWeb Manager.
The QNX terminal session can be terminated by typing logout or exit

at the $ prompt.
Command Line:
term95 -h host [-t timeout]
where:
host is the IP address or name of the CDWebManager
timeout timeout value before a reconnect is attempted (0 means no
timeout)
Possible actions:
s send a file to the CDWeb Manager
r receive a file from the CDWeb Manager
d run a DOS shell (exit to return to term)
l log-in to the CDWeb Manager (exit or logout to quit)
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F9 when logged in, log all screen messages from remote shell to
user-specified file, log ends when pressed again.
F10 when logged in, change between split-screen
and full screen modes
CDWeb Explorer
CDWeb Explorer combines the functions of LonMaker and
TERM/Term95 into a single user interface. While both the SLTA and the
network adapter connections are required in order to perform all
functions, only a single program is needed.
Here is a listing showing which port (the SLTA or the network) is used for
certain tasks. If both the SLTA and the network are checked off, that
means either can be used:
Table 5-1. CDWeb Explorer tasks versus port used
Task SLTA Ethernet adapter
installing new or replacement actuator controllers 9

configuring/tuning/calibrating actuator controllers 9 9
monitoring actuator controller status messages 9 9
sending commands to actuator controllers 9 9
sending setpoints to actuator controllers 9 9
viewing control task diagnostic messages 9
file transfer to CDWeb processor 9
The majority of maintenance tasks can be performed remotely through the

network connection, with the exception of installing a new or replacement
actuator controller into the system. This is similar to how LonMaker and
TERM/Term95 interact; LonMaker is used to replace an actuator
controller, while TERM/Term95 is used for all other tasks. With CDWeb
Explorer, it is also possible to perform many of these other tasks through
the SLTA, increasing versatility for the user. This allows for basic actuator
maintenance and control even if the CDWeb processor is not active.
The built-in Help system in CDWeb Explorer provides the current

program description and basic step-by-step methods to perform simple
tasks. Please refer to it if any questions arise while using the software.
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Installing CDWeb Explorer

CDWeb Explorer is provided in a self-installing format on a disk shipped
with the system. In order to use CDWeb Explorer, a maintenance
computer must have either Windows95 or WindowsNT4.0 as its operating
system, along with the Microsoft TCP/IP protocol provided on the
original Windows installation disks. Installing the TCP/IP protocol is
covered in the Term95 section of this chapter. Please refer to that section if
TCP/IP needs to be installed in the maintenance computer. A serial port
and a network adapter are also needed in order to use CDWeb Explorer.
To install CDWeb Explorer, insert the floppy disk into the maintenance
computer’s floppy disk drive, then select the SETUP.EXE program on the
floppy and run it. Follow the on-screen prompts to select the installation
directory and begin the installation.
Using CDWeb Explorer

To use CDWeb Explorer, follow the instructions in the Help system found
on the menu bar after CDWeb Explorer is started. It is also necessary to
connect the maintenance computer to the CDWeb System using one or
both of the SLTA and network connections.
To use the SLTA, connect a serial cable between the serial port on the
maintenance computer and the serial port on the SLTA, then connect the
straight-through cable with RJ-45 network connectors between the RJ-45
socket on the SLTA and the installation tool/service port located on TS-6
in the CDWeb Manager cabinet.
To use a network connection to the EPC-8A, connect the network adapter

of the maintenance computer to the control network that the CDWeb
Manager is linked to. Note that if the CDWeb Manager is online and
communicating with a host control system, any setpoint or actuator state
commands sent from CDWeb Explorer will be over-ridden by the host
values and may cause control problems. If it is necessary to send setpoints
or other actuator commands to perform maintenance tasks, it is best to
disconnect the CDWeb processor from the control network by unplugging
the RJ-45 connector and cable from the Ethernet port on the front of the
EPC-8A, then connect the maintenance computer’s network adapter
directly to the EPC-8A using a cross-over cable with RJ-45 connectors. A
straight-through cable and a cross-over cable are both supplied with the
CDWeb system.
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Chapter 6. How to …
Introduction
This chapter contains descriptions of how to perform common tasks for
CDWeb systems. Procedures are given for users using LonMaker and
TERM/Term95, and for users using CDWeb Explorer. Before attempting
these procedures, first ensure that the software tools have been properly
installed on a suitable maintenance computer. See the utilities chapter for
information on installing the software tools and how to use them.
Throughout this chapter, we will be referring to CDConnects, controllers,

and actuators. In CDWeb ProFlow systems, a CDConnect box contains
four controller assemblies. Each controller handles the motor output,
feedback, and diagnostics for four ProFlow actuators. The actuators
assigned a controller are defined by a zone map file stored in the CDWeb
processor.
ProFlow Installation Box

With each ProFlow system there is an installation box shipped. This box is
used to generate service pin messages from the controllers without having
to open the CDConnect box. As well the box can be used to move an
actuator via use of a toggle switch (used to set the actuator to the crack
open point). To use this installation box, install the five- and six-pin cables
supplied with the box to the appropriate connectors on both the
installation box, as well as on the CDConnect box containing the controller
that you wish to work with. The connectors on the CDConnect box are
capped to prevent damage when not in use; retain these caps and re-
install after the maintenance task is over.
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Chapter 6. How to … CDWeb Control System Manual
If you are using the installation box to generate a service pin message,
only the five and six-pin cables are needed. However, if you are using the
installation box to manually drive an actuator motor, it will also be
necessary to disconnect the actuator’s motor cable (the one attached to the
connector on the actuator’s motor cap) from the CDConnect box, and
connect it to the four-pin connector on the installation box.
To generate a service pin message for a controller, press the button on the
installation box corresponding to the number of the controller within the
CDConnect box. This number can be determined by looking at the
connector labels on the outside of the CDConnect box; each controller has
four sets of connectors associated with it, lettered A to D.
To drive an actuator motor manually, use the toggle switch on the

installation box.
Configure, Tune, and Calibrate Actuators

Each CDConnect needs certain information in order to operate correctly.
Such information includes how often it should communicate with the
CDWeb Manager, and how much the position sensor signal varies with a
given change in position.
This information is sent to the actuator through three LonWorks network

variables: nci_ActConfig, nci_ActTuning, and nvi_ActCommand. In the
case of a ProFlow, each controller actually receives four sets of these
variables, one set for each actuator controlled.
Configuring a CDConnect lets it know what type of actuator it is and

certain values required for LON communications. Tuning provides
operational limits and alarm thresholds. Calibration consists of the values
required to transform the sensor input into useful output.
A CDConnect is configured by sending it a network variable message for

nci_ActConfig with meaningful values. Similarly tuning an actuators
consists of sending it a new nci_ActTuning network variable.
An actuator is calibrated in a slightly different manner: a sequence of

nvi_ActCommand network variables must be sent to the actuator. The
reason calibration is not performed the same way as is configuration and
tuning is because the calibration information is usually not available. The
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CDWeb Control System Manual Chapter 6. How to …
commands that are sent to the actuator cause the actuator to measure its
power supply and feedback sensor as the actuator is moved a known
amount. The actuator measures the changes in the signals in order to
effect the calibration.
Configuring actuators
TERM/Term95 method
1. Make sure that the supervisory control system is not currently
communicating with the CDWeb Manager. If necessary, remove the
CDWeb Manager from the network on which the control system is
electrically located. Connect the maintenance computer directly to the
CDWeb processor by using a cross-over cable between the
maintenance computer’s network adapter and the Ethernet port on the
front of the CDWeb processor.
2. Log on to the CDWeb Manager with Term/Term95.

Type term -h <IP-address of CDWeb Mgr>
or
Run Term95 from Windows95 or WindowsNT(refer to the Utilities
section for computer setup information)
3. Start the QNX shell.

Type L
4. Log on to the CDWeb processor.

Enter username (usually spidey)
5. Start the console task and connect it to the actuator task (the
actuator task name will be dependent on the actuator type).
Type console proflow11
(If the actuator task name is not known, type sin name to receive a
listing of all active tasks and their names).
6. Scroll to the desired actuator by pressing the left or right arrow key
until the desired actuator number appears.
7. Switch to the configuration menu.

Type c
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8. Poll the current configuration from the actuator. Watch the diagnostic
window to make sure that the request completes successfully.
Type p
9. View the current configuration and make sure that the correct actuator
has been selected (an unconfigured actuator should have zeros for at
least the first two values in the network variable).
Type v
10. Edit the configuration. Remember that values shown in parentheses

are the current values and will be retained if no new value is entered.
Editing can be aborted by pressing the ESC key. For descriptions of the
fields and typical values see the CDConnect Assembly chapter.
Type e
11. If all actuators require an identical configuration, flush the current

configuration to all actuators.
Type f
CDWeb Explorer method

2. Start CDWeb Explorer and load the .web file for the system.
3. Select the actuator that requires configuration from the tree structure
and highlight it by clicking on it.
4. Select the configuration message from the right pane showing the
variables for that actuator. After double-clicking on it, a network
variable viewing window will appear with the variable contents.
5. After the window has appeared, enable edit mode by pressing the edit
mode button on the tool bar.
6. Edit the values that require changing. After all changes have been
made, pressing the edit mode button again will send the values to the
actuator.
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7. If the values need to be flushed through to other actuators, select the

Copy to All button or the Copy to button.
Tuning an actuator
TERM/Term95 method
2. Log on to the CDWeb Manager with Term.

4. Scroll to the desired actuator by pressing the arrow keys until the
desired actuator number appears.
5. Switch to the tuning menu.

Type t
6. Poll the current tuning from the actuator. Watch the diagnostic
window to make sure that the request completes successfully.
Type p
7. View the current tuning and make sure that the correct actuator has
been selected (an untuned actuator should have all 0’s in the network
variable).
Type v
8. Edit the tuning. Remember that values shown in parentheses are the
current values and will be retained if no new value is entered. Editing
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can be aborted by pressing the ESC key.

Type e
9. If all actuators require identical tuning values, flush the current tuning
to all actuators.
Type f

3. Select the actuator that requires tuning from the tree structure and
highlight it by clicking on it.
4. Select the tuning message from the right pane showing the variables
for that actuator. After double-clicking on it, a network variable
viewing window will appear with the variable contents.
5. After the window has appeared, enable edit mode by pressing the edit
mode button on the tool bar.
6. Edit the values that require changing. After all changes have been
made, pressing the edit mode button again will send the values to the
actuator.
7. If the values need to be flushed through to other actuators, select the

Copy to All button or the Copy to button.
Calibrating actuators with default values

TERM/Term95 method
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5. Switch to the scaling menu.

Type a
6. Poll the current calibration values from the actuator. Watch the
diagnostic window to make sure that the request completes
successfully. (Systems with version 1.00 actuators skip to step 7).
Type p
7. View the current calibration values and make sure that the correct
actuator has been selected (an uncalibrated actuator should have all 0’s
in the network variable, newer versions may have default calibration).
Type v
8. Switch to the commands menu.

Type ESC then o
9. Send default calibration values to the actuator. In the case of an

ProFlow, this is equivalent to sending the following network variable
commands: function 102 with 4, 4883, and 0 (calibrate to millivolts),
function 102 with 5, 2028, and -132 (calibrate to flow), and function 101
with 0, 0, and a user supplied position (calibrate to position).
Type Shift-c (appears as a capital C in menu)
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10. If all actuators require default calibration, send default values to all
actuators.
Type Alt-c

3. Select the actuator that requires calibration from the tree structure and
4. Select the command message from the right pane showing the
5. Use the default calibration macro button to send the default calibration
to the actuator. Holding down the Alt key before pressing the macro
button will send the default calibration to all actuators.
The default values a acceptable in order to get actuator movements but an

automated two point calibration is recommended for all ProFlow
actuators.
Calibrating an actuator manually/Two-point calibration

This step should only performed after configuration, tuning, and a default
calibration have been sent to the actuator.

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5. Switch to the tuning menu.

Type t
6. Poll the current tuning from the actuator.

Type p
7. View the tuning for the actuator making sure that the scaling values
are correct.
Type v

Type ESC then o
9. Start a two-point calibration, this should prompt the actuator to move

the actuator to its low stop then high stop collecting the data at each of
these points.
Type Shift-t (appears as a capital T in menu)
10. Reset the actuator.

Type Shift-r (appears as a capital R in menu)
11. At this point you are ready to move the actuator to its crack open point
by using setpoint moves or the installation box.
Type Shift-s (to enter new setpoints)
12. Once the actuator is at the crack open point initiate a define position
command to collect the crack open data.
Type Shift-p (to collect the crack open data)
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Type Shift-r (appears as a capital R in menu)
14. If the actuator was originally in auto, then return it to that state.
Type Shift-a

5. Use the two-point calibration macro button to start a two-point

calibration for the actuator. Follow the screen prompts that follow.
Defining the current position of actuators

This step should only performed after configuration, tuning, and
calibration values have been sent to the actuator.

electrically located.

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(If the actuator task name is not known, type sin name at a command
prompt to receive a listing of all active tasks and their names).
5. Switch to the status menu.

Type s
6. Poll the actuator to update the status message in the CDWeb

processor’s database.
Type p
7. View the current status to verify that this is the correct actuator. Note
its current mode (0 is manual, 1 is auto).
Type v

Press ESC then type o
9. Move the actuator to the crack open point using setpoint moves, or by
using the installation box.
Type Shift-s
10. Place the actuator in manual.

Type Shift-m
11. Define the current position of the actuator.

Type Shift-p then enter the new value for the current
position.

Type Shift-r
13. If the actuator was originally in auto, then return it to that state.
Type Shift-a

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5. Use the define current position macro button to redefine the current
position of the actuator. Holding down the Alt key before pressing the
macro button will define the current position for all actuators.
Replace a Failed CDConnect controller

If a CDConnect controller assembly or other network component fails
during operation and needs to be replaced, perform the following
procedure.
LonMaker method
1. From the control system, place all actuators in Manual mode. Failing
to do this can disrupt the controlled process.


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select chan_b1_s1. Click on the Attach button (or hit the F6 key) to
attach to the LON. If all of the SLTA connections have been made
properly, the attachment icon at the top-right corner of the screen will
change to show a valid connection. If an error message comes up
reporting a connection problem, check that all of the SLTA connections
are secure, and that the SLTA has power. Confirm that the correct
channel has been selected in Channel Setup.
6. Once connected to the network, select Repair. The screen will switch
to display all available locations and their associated devices. Using
the mouse or the Tab and arrow keys, find and select the device to be
checking that the device name appears in the Device: text box at the
top of the screen. Press the Replace button (or hit F4). LonMaker will
prompt for a service pin message from the replacement device. This
can be done by using the installation box and pressing the appropriate
service pin button, or opening the controller box and shorting the
service pin input. For routers and CDWeb processors, the service pin
message is generated by pushing the Service button found on those
devices.
from LonMaker. Do NOT make a new EXPORT.CSV file. It is not
needed, as the current one is still valid.

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3. Select the controller that requires replacement from the tree structure
and highlight it by clicking on it.
4. Select the install function from the right-mouse button menu for that
actuator. Follow the on-screen prompts. Service pin messages on a
controller can be done by using the installation box and pressing the
appropriate service pin button, or opening the controller box and
shorting the service pin input. For routers and CDWeb processors, the
service pin message is generated by pushing the Service button found
on those devices.
Replace a Failed LonWorks Router
LonMaker method
1. Follow steps 1-5 of the “Replace a Failed CDConnect” procedure to
connect to the local operating network with LonMaker.
2. Once connected to the network, select Repair. The screen will switch
to display all available locations and their associated devices. Using
the mouse or the Tab and arrow keys, find and select the router to be
checking that the device name appears in the Device: text box at the
top of the screen. Press the Replace button (or hit F4). LonMaker will
prompt for a service pin message from the replacement device. For
CDConnect assemblies, this is generated by disconnecting, then
reconnecting, the quick-connect cable. For routers and CDWeb
processors, the service pin message is generated by pushing the
Service button found on those devices.
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from LonMaker.

A failed router is handled in exactly the same way as a failed CDConnect.
Select the router’s right-mouse-button menu and use the install function
found there. Follow the on-screen prompts. A service pin message is
generated by the router whenever the service button in the recessed hole
on the front panel is pressed.
Replace a Failed CDWeb Processor

If a CDWeb Processor fails during operation and needs to be replaced, one
must first determine if the EXM-LonTalk Network Interface card can be
re-used. If so, then the EXM-LTNI can simply be installed in the new
CDWeb Processor and no other changes are needed. However, if the
EXM-LTNI cannot be reused, then it is necessary to do the following.
LonMaker and TERM/Term95 method

1. Follow the “Replace a Failed CDConnect” procedure to replace the
EXM-LTNI. The service pin message is generated by pressing the
service button on the EXM-LTNI. Exit LonMaker.
2. Connect to the CDWeb Processor via the 10Base-T port on the front of
the unit.
3. Connect to the CDWeb Processor using the TERM/Term95 utility.
4. Once connected, logon to the CDWeb Processor using the QNX shell
command L.
5. Check the contents of the /cdwebman/webstart file by using the

cat webstart command. Refer to the “CDWeb Manager” chapter
for details. Exit the QNX shell by typing exit at the command
prompt.
6. If a backup copy of the system webstart file is available, compare it

to the one on the CDWeb Processor. If different, and the backup copy
is known to be the exact file used on the original CDWeb Processor,
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then transfer it to the CDWeb Processor by using the file send

command.
Type s
If no backup copy of the webstart file is available, transfer the file

from the CDWeb Processor to the PC by using the r command in
TERM. Edit it using any text editor program, then transfer it back to
the CDWeb Processor with the s command in TERM/Term95.
7. Upon starting the send command, TERM/Term95 will ask for the
name of the local file to be transferred.
Type webstart
8. TERM/Term95 will then ask for the name to give the remote file,
providing the same name as the local file as a default. Accept this
default by hitting the Enter key.
9. Select the file type by choosing either (T)ext or (B)inary.

Type T
10. Confirm the action by hitting Enter. TERM will then proceed to
transfer webstart from the PC to the CDWeb processor.
11. If the EXPORT.CSV file on the replacement CDWeb Processor is not

the most current one (typically, the EXPORT.CSV file will never
change, so if a spare CDWeb Processor is supplied pre-configured for
the system in as-shipped condition, it is not necessary to change the
EXPORT.CSV file), then repeat the send command for the
EXPORT.CSV file (it too is a text file).
12. Once the transfer is complete, exit from TERM by hitting the ESC key.
Reboot the CDWeb processor by toggling the rack power supply
switch.

A failed CDWeb processor is handled in exactly the same way as a failed
CDConnect. Select the CDWeb processor’s right-mouse-button menu and
use the install function found there. Follow the on-screen prompts. A
service pin message is generated by pressing the service button on the
front of the EXM-LTNI. The replacement CDWeb processor should
already be pre-configured from the factory for the system. If necessary,
highlight the CDWeb processor and view the list of files that will appear
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in the right-hand pane. These files can be transferred to and from the
maintenance computer. Read the Help file for details on how to do this.
Install and Bind New CDConnects

Node Installation is usually performed only during system installation.
For most CDWeb systems, the initial installation will have been done at
the factory during system testing. However, there may be times when it is
necessary to install one or more network nodes in the field. Before even
considering this, contact the factory to discuss why this is necessary. To
replace a previously installed node, use one of the node replacement
procedures instead.
LonMaker method
turning it on or by pressing its service button. If the service light does
not flash when the unit is turned on or when the button is pressed,
then there is insufficient power in the SLTA battery. Plug in the
supplied adapter before proceeding.



select chan_b1_s1. Click on the Attach button (or hit the F6 key) to
attach to the LON. If all of the SLTA connections have been made
properly, the attachment icon at the top-right corner of the screen will
change to show a valid connection. If an error message comes up
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reporting a connection problem, check that all of the SLTA connections

are secure, and that the SLTA has power. Confirm that the correct
channel has been selected in Channel Setup.
5. Once connected to the network, select Installation. The screen will

switch to display all available locations, and the devices that are
associated with the selected location. A dot preceding a device on the
device list indicates that the device has not been installed into this
particular system. This may be because the device is not part of the
system, or has not been previously installed at the factory. To install a
device, use the mouse or the Tab and arrow keys to choose the
appropriate location, then highlight the device and hit Enter to select it.
The selection will be confirmed by the Device: text box at the top of the
screen, as well as a diamond (♦) next to the device.
6. Selecting the Install button (or hitting F3) will display a screen
prompting for the installation method to be used. Choose the Service
Pin method, then continue. LonMaker will then wait for a service pin
message. For CDWeb processors and network routers, the service pin
message is generated by pressing the Service button found on the front
panel of the device. Service pin messages on a controller can be done
by using the installation box and pressing the appropriate service pin
button, or opening the controller box and shorting the service pin
input.
7. If the device has previous network configuration information already,

LonMaker will display a dialog box stating this, and asking whether or
not to proceed. Unless the service pin message was generated from the
wrong device, select Continue. If the message was in error, select
Cancel to abort.
8. LonMaker will proceed to send network and device configuration data

to the selected device. Depending on the device, this may take
anywhere from several seconds to a minute. Once LonMaker has
finished configuring the node, it will report that the node has been
successfully installed. If LonMaker encounters any problems during
the configuration such as a failed message, it will abort the process and
display an error message. Refer to the Troubleshooting LonMaker
section later in this chapter for common problems and solutions.
If there are more nodes to install, repeat steps 5 to 8. Once all nodes have
been installed, any necessary network connections, or bindings, must be
created. These have been pre-defined in the database, but must be
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installed through LonMaker for each specific system. Bindings must be

made between the CDWeb processor and all CDConnect devices.
9. Select the first device, then press the Connect button (or hit F8).
LonMaker will prompt for the second device that the first device is to
be connected to. Using the mouse or the Tab and arrow keys, select
the second device (the adjacent actuator, for example).
10. If pre-defined bindings exist for these two devices in the project
database, a new button, Auto (F3), will appear. Press this button to
automatically choose the necessary bindings. A plus-sign (+) will
appear next to the second device to indicate that there are bindings
pending. Bindings will only be invoked after all selections have been
made and the Continue button (F10) is selected.
11. If more bindings to the selected first device are required, select a new
second device and repeat step 10. Once all required bindings for the
selected first device have been chosen, press the Continue button (F10).
12. Repeat steps 9 to 11 for any other installed nodes. Once all bindings
have been performed, end the LonMaker session by select the Exit
button. LonMaker will automatically save all of the changes to the
project database. If the CDWeb processor has already been installed,
then run EXPORT.BAT from the project database sub-directory to
create a new EXPORT.CSV file (refer to the “Creating and Transferring
an EXPORT.CSV File” section for detailed instructions). Otherwise,
install the CDWeb processor first by following the next procedure.
13. To finish the installation, refer to the procedure later in the section
discussing how to use the TERM utility to transfer the EXPORT.CSV
file to the CDWeb processor.
NOTE: A new EXPORT.CSV file is only needed when an additional actuator is

added to a CDWeb system. Replacing a failed actuator (see the
Replacement procedure) does not require a new EXPORT.CSV in the
CDWeb processor.

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turning it on or by pressing its service button. If the service light does
not flash when the unit is turned on or when the button is pressed,
then there is insufficient power in the SLTA battery. Plug in the
supplied adapter before proceeding.
2. Edit the .web file for the system to add the additional actuator into the
system definition. Ideally, a new .web file for the system should be
obtained from the factory to ensure that the additions are made
correctly.
3. Start CDWeb Explorer, then load the .web file for the system.
4. Locate the new, un-installed actuator on the tree structure under either
the Beam branch or a Router branch, depending on the view.
5. Select Install from the right-mouse-button menu.
6. When prompted, generate the service pin message for the new
actuator. Service pin messages on a controller can be done by using the
installation box and pressing the appropriate service pin button, or
opening the controller box and shorting the service pin input. For
routers and CDWeb processors, the service pin message is generated
by pushing the Service button found on those devices.
7. All bindings are automatically performed by CDWeb Explorer as the

installation progresses, so no bindings need to be manually made.
8. After confirming that all messages have transferred properly, and no

errors occurred during the installation, generate a new EXPORT.CSV.
Install and Bind a New LonWorks Router

Installing an additional LonWorks Router is similar to installing a
CDConnect.
1. Follow steps 1 to 8 of the procedure for installing and binding

CDConnects to install the LonWorks Router into the database. The
service button to generate the service pin message is located in
recessed hole on the front panel of the Router.
2. No bindings are required for LonWorks Routers.
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Install and Bind the CDWeb Processor

Installing the CDWeb processor is similar to installing CDConnects. The
difference is in the number of bindings involved.
1. Follow steps 1 to 8 of the procedure for installing and binding

CDConnects to install the CDWeb Processor into the database. If using
CDWeb Explorer, no other steps are necessary. If using LonMaker,
continue to step 2.
2. To bind all of the CDConnects to the CDWeb processor, select the

CDWeb processor using the mouse or the Tab and arrow keys. The
selection is confirmed by the Device: text-box at the top of the screen,
as well as the appearance of a diamond (♦) next to the device, then
select Connect (or hit F8).
3. Select a CDConnect device, and press the Auto (F3) button that should
appear. A plus-sign (+) will appear next to the CDConnect device to
indicate that bindings are pending. If no plus-sign appears, the
bindings may have already been installed previously.
4. Repeat step 3 for up to a total of eight CDConnect devices, then select

Continue (F10). Although it is possible to select all of the CDConnect
devices at once, it is generally safer to do only up to eight at a time to
prevent LonMaker from encountering an error and corrupting the
database. It is not possible to recover a corrupted database. It is often
a good idea, in the case of larger systems, to make backup copies of the
project database periodically during an installation or binding session
to protect against database corruption.
5. Once all bindings have been installed between the CDWeb processor
and the CDConnect devices, exit from LonMaker. If the CDWeb
Processor and router(s) have already been installed, then create a new
EXPORT.CSV file for the CDWeb processor by referring to the “Create
and Transfer an EXPORT.CSV file” procedure.
Create and Transfer an EXPORT.CSV File

A new EXPORT.CSV is only required when a new actuator has been
added to the system (that is, in addition to the number of actuators that
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were in the original system, ie. from an original 68 actuators, for example,
the system is being expanded to 76 actuators). If this is the case, then
generate a new EXPORT.CSV file as follows:
LonMaker and TERM/Term95 method

1. Change to the project database sub-directory (example C:\LONDBAS).
Type cd c:\londbas
2. Check that an EXPORT.BAT batch file exists in the sub-directory. If it

is missing, refer to the Utilities chapter for further information. If it is
present, run it by typing EXPORT then hitting the Enter key.
Type export
3. After the batch file has finished, a new EXPORT.CSV file will exist in
the project database sub-directory. This needs to be transferred to the
CDWeb processor using TERM.
4. Make sure the CDWeb Manager is not connected to the control system
network, and connect the PC to the CDWeb processor through the
10Base-T network port on the front panel of the CDWeb processor.
This assumes that the PC is equipped with a network adapter card and
the appropriate cabling and connectors. If connecting directly to the
CDWeb processor through its 10Base-T port, be sure to use a cross-
over patch cable; if such a cable is not available, then connect through a
10Base-T network hub. If the CDWeb Manager is equipped with a
converter to adapt the 10Base-T port to another network cabling type,
then it is acceptable to access the CDWeb processor through the
converter.
5. Switch to the project database sub-directory where EXPORT.CSV is

located. (example C:\LONDBAS)
Type cd c:\londbas
6. Run TERM on the PC to connect to the CDWeb processor.

or
Run Term95 from Windows95.
7. Once a connection has been made, choose the send command.

Type s
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8. Enter the name of the local file to be transferred.

Type export.csv
9. TERM will then ask for the name to give the remote file, providing the
same name as the local file as a default. Accept this default by hitting
the Enter key.
10. Select the file type by choosing either (T)ext or (B)inary. EXPORT.CSV
is a text file.
Type T
11. Confirm the action by hitting Enter. TERM will then proceed to
transfer EXPORT.CSV from the PC to the CDWeb processor.
12. Once the transfer is complete, exit from TERM by hitting the ESC key.
Reboot the CDWeb processor by toggling the rack power supply
switch. The CDWeb processor will process the new EXPORT.CSV file.

3. Select the CDWeb processor from the tree structure, then select the
Export Database option from the right-mouse-button menu.
4. Select the option of sending the file to the processor, and follow the on-
screen prompts.
CDConnect Maintenance using LonMaker

The following section describes how to use LonMaker to calibrate
CDConnect devices. The same functions are provided through the TERM
utility. It is highly recommended that the TERM utility be used where
P/N 6510020139 - Rev. 02 98/11/09 139 - 151

possible, as it is faster and more convenient. However, if TERM is either

not available or cannot be used, then the following procedures will allow
for the same functions through the LonMaker interface. Remember that
the TERM utility connects to the CDWeb processor through its Ethernet
port, while LonMaker communicates directly to each node on the LON
through a SLTA connected directly to the LON. CDWeb Explorer can use
either connection method.
Actuator Calibration
For any of the following sections describing calibration methods, the user
must initiate an actuator command message to the controller.
The general format for an actuator command message is:

function_number
param_1
param_2
param_3
param_4
where:
function number = one of the functions described later in this section
param_1 = action, depending on function:
0 - Store initial data, for a two point calibration.
1 - Calibrate for mV (second point in a two point calibration) this will

A/D counts. (only in versions 1.02 and greater)
2 - Calibrate for mm (second point in a two point calibration) this will

A/D counts. (only in versions 1.02 and greater)
3 - Calibrate for both mV and mm this will calculate a slope and an

intercept based on the differential of the A/D counts. (only in
versions 1.02 and greater)
4 - Send a slope and intercept directly for mV.
140 - 151 98/11/09 P/N 6510020139 - Rev. 02

5 - Send a slope and intercept directly for flow.
param_2 = data
In action 0,1,3 this parameter is the value in mV.
In action 4,5 this parameter is the slope
param_3 = data
In action 0,2,3 this parameter is the value in mm.
In action 4,5 this parameter is the intercept value.
param_4 =not used
To send an actuator command using LonMaker, the following general

procedure can be followed:
• Select the Control option.
• Confirm that the correct Location and Device are selected.
• Select Data action button[F9].
• LonMaker will display the defined output and input network
variables for that node. Select the actuator command input network
variable (e.g. nvi_ActCmd).
• Select the Modify action button [F2].
• Enter the command data. For example:
function_number = 102
param_1 = 4 (manual calibration)
param_2 = 4883 (default slope for Voltage)
param_3 = 0 (default voltage intercept)
• After entering the data, select the Done action button [F10]. This will
cause LonMaker to send this command to the node.
P/N 6510020139 - Rev. 02 98/11/09 141 - 151

A/D Calibration (Voltage):

Two-point: (only in versions 1.02 and greater)
This calibration should be done at test time when access to the circuit
board is available and is not recommended to be done in the field unless
access to the circuit board and voltage measurement is available.
• Set the actuator to a given position and measure the voltage with a
DVM.
• Initiate a function 102 with the following parameters.
param_1 = 0 (store initial data)
param_2 = 3500 (the measured voltage at the current position in mV)
• Move the actuator to a new position ( the larger the voltage change
the better ) and measure the voltage with a DVM.
• Initiate a function 102 with the following parameters
param_1 = 1 (calibrate to mV)
param_2 = 4500 (the measured voltage at the current position in mV)
Manual Calibration:
This calibration should be used when initial data has been lost from a
module or the module has been replaced and access to the circuit board is
not possible.
param_2 = 4883 (default slope for Voltage)
param_3 = 0 (default intercept for voltage)
A/D Calibration (Position):

Two-point Automated:
This is the preferred method of calibration for a ProFlow as it will
automatically move the actuator to its low and high stop, then calculate a
slope and intercept based on these points.
142 - 151 98/11/09 P/N 6510020139 - Rev. 02


param_1 = 6 (Auto two point calibration)
param_2 = 0
param_3 = 0
This will cause the actuator to initiate and compete the two point
calibration. Note that a define position or crack open command must be
issued after an actuator has been calibrated.

This method of calibration is preferred for field use when a dial gauge and
hand wheel are present on the actuator.
• Set the actuator to a given position and read the dial gauge.
param_2 = 0
param_3 = 0 (position in flow)
• Move the actuator to a new position ( the larger the change the
better) and record the new dial gauge position in mm.
param_1 = 2 (calibrate to flow)
param_2 = 0
Manual Calibration:
This calibration should be used when initial data has been lost from a
module or the module has been replaced.
param_2 = 2028 (default slope to flow)
param_3 = -132 (default intercept to flow)
P/N 6510020139 - Rev. 02 98/11/09 143 - 151

A/D Calibration (Voltage and Position):

This method of calibration is intended for use at test time when access to
the circuit board and voltage measurement are available.
• Set the actuator to a given position and read the dial gauge position
and measure the voltage in mV.
param_2 = 3500 (the measured voltage at the current position in
mV)
• Move the actuator to a new position ( the larger the change the
better) record the new dial gauge position in mm, and measure the
voltage in mV.
param_1 = 3 (calibrate to mm)
param_2 = 3600 (the measured voltage at the current position in
mV)
Redefining Current Position for a Single Actuator (Crack

Open)
This calibration is to be done after the actuator has been set to its crack
open position. It will adjust the intercept of the actuator position
calibration curve to make the calculated actuator position equal to the
specified position.
This calibration assumes that the A/D has been previously calibrated for
position (i.e. a valid slope is present in memory).
• Set valve to the crack open position using either setpoint moves or
the installation box to move the actuator.
• Initiate a function 101 and enter the parameters. For example, if the
actuator is at a position of 0 microns, enter:
144 - 151 98/11/09 P/N 6510020139 - Rev. 02


param_3 = 0
Changing the IP address of a CDWeb Manager

CDWeb Managers are shipped from the factory with a default IP address
if no installation-specific IP address is provided with the technical design
information at the beginning of a project for a LAN-based system. As
well, all serial link systems use this IP address for use with TERM,
Term95, or CDWeb Explorer. The default addresses used are:
Default Alias (node description) Default IP address

CDWebMan (CDWeb processor) 192.206.218.158
host (Application Manager) 192.206.218.160
These addresses are to be found in the /etc/hosts file on the CDWeb

processor (refer to Chapter 2. CDWeb Manager for further information).
Note that the default host address is only present that the file if the system
was factory-configured for use with a LAN-based control system.
To change the address or addresses in the /etc/hosts file, do the

following:
TERM/Term95 method
1. Remove the CDWeb Manager from the network on which the control
system is electrically located. Connect the maintenance computer
directly to the CDWeb processor by using a cross-over cable between
the maintenance computer’s network adapter and the Ethernet port on
the front of the CDWeb processor.
2. Log on to the CDWeb Manager with Term/Term95.

or
Run Term95 from Windows95 or WindowsNT(refer to the Utilities
section for computer setup information)
P/N 6510020139 - Rev. 02 98/11/09 145 - 151

3. Once TERM or Term95 connects, choose the receive file function.

Type r
4. When prompted, enter the full path and filename of the hosts file in the
CDWeb processor.
Type /etc/hosts
5. At the next prompt, enter the path and name for the local copy of the
file that will be edited.
Type hosts (stores it in working directory)
6. Choose to receive the file as a text file.

Type t
7. Confirm that you wish to receive the file, and proceed.
8. Once the file has been downloaded, either go into a DOS shell and start
a text editor such as MS-DOS EDIT (if using TERM), or open NotePad
to edit the file (if using Term95). Change the IP address(es) to the
desired addresses, then save the file and exit the editor. If using
TERM, return to the program by typing exit at the DOS prompt. Do
not change the aliases, or else the CDWeb applications will not
function!
9. Send the edited file back to the CDWeb processor using the send file
function.
Type s
10. At the prompt, enter the appropriate path and name for the edited file
on the maintenance computer.
Type hosts (retrieves it from the working directory)
11. At the next prompt, enter the location on the CDWeb processor (this
location must be /etc/hosts for the CDWeb processor to function!)
Type /etc/hosts
12. Send the file as a text file, and confirm.

Type t
13. Once the file is sent, log into the CDWeb processor using the login
function, as username spidey.
Type l (a lower-case L)
Type spidey
146 - 151 98/11/09 P/N 6510020139 - Rev. 02

14. Change to the /etc directory, and view the hosts file contents to
confirm that the file has been successfully updated.
Type cd /etc
Type cat hosts (displays text contents on screen)
15. If the file has not been successfully updated, review this procedure and
determine what you did wrong, then repeat.
16. If the file has been successfully updated, you may restart the CDWeb
processor by turning off, then on, the rack power supply. After the
CDWeb processor restarts, it will be using the new IP address from the
updated hosts file.

1. Remove the CDWeb Manager from the network on which the control
system is electrically located. Connect the maintenance computer
directly to the CDWeb processor by using a cross-over cable between
the maintenance computer’s network adapter and the Ethernet port on
the front of the CDWeb processor.
3. Select the CDWeb processor, and right-click to get the options menu
for it. From that menu, select the Receive function.
4. For the local file name, specify an appropriate name and location on
5. For the remote file name, the file name and path is /etc/hosts.
Type /etc/hosts
6. The file type is text, so check the appropriate option, and press the OK
button.
7. Open the received file using a text editor such as NotePad, and change
the IP address(es). Save the file when done. Do not change the aliases,
or else the CDWeb applications will not function!
8. Select the CDWeb processor, and right-click to get the options menu
for it. From that menu, select the Send function.
P/N 6510020139 - Rev. 02 98/11/09 147 - 151

9. For the local file name, specify an appropriate name and location on
10. For the remote file name, the file name and path is /etc/hosts.
Type /etc/hosts
11. The file type is text, so check the appropriate option, and press the OK
button.
12. To confirm that the file has been updated properly, right-click on the
CDWeb processor, select the View… QNX Console function, and login
as username spidey.
13. Change to the /etc directory, and view the contents of the hosts file.
Type cd /etc
Type cat hosts
14. If the file has not been successfully updated, review this procedure and
determine what you did wrong, then repeat.
15. If the file has been successfully updated, you may restart the CDWeb
processor by turning off, then on, the rack power supply. After the
CDWeb processor restarts, it will be using the new IP address from the
updated hosts file.
RJ-45 Connector Pin Numbers

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Straight-through Cable Cross-over Cable

(SLTA/2 to Installation Port) (PC to CDWeb Processor)
Figure 6-1. RJ-45 cable connections
148 - 151 98/11/09 P/N 6510020139 - Rev. 02

Appendix A. Installation Requirements
CDWeb Environmental Specification

All Honeywell CDWeb Managers have the following environmental
specification:
Cabinet Rating: NEMA 4, IP 56

Operating Temp.: 0°C to 50°C
Storage Temp.: 20°C to 75°C
Operating Humidity: 30-90% Relative Humidity(non-
condensing)
Storage Humidity: 20-90% Relative Humidity(non-
condensing)
Higher operating temperatures than 50°C can only be achieved through

the use of cooling. The supply of a cooling system with a Honeywell
CDWeb Manager is non-standard and is considered an engineering
special.
Mill Power Requirements

This specification defines the requirements for AC source power for the
operation of the ProFlow CDWeb Manager. For more details on power
requirements, see the Installation Requirements for conformance to
Standards manual, Honeywell part number 65 1002 0134, shipped with
the CDWeb Manager.
P/N 6510020139 - Rev. 02 98/11/09 149 - 151

Appendix A. Installation Requirements CDWeb Control System Manual
Voltage, Current and Frequency Ratings

The required source voltage for the ProFlow CDWeb Manager is 100/120
VAC or 200/240 VAC. The ProFlow CDWeb Manager requires a source
power rating of 2.5 kVA. Specific systems may require more power
depending on the number of ProFlow actuators, so the system electrical
drawings should be consulted to determine the actual power
requirements for a particular system.
The source frequency should be 60 Hz ± 2 Hz, or 50 Hz ± 2 Hz. Short or

long term variations outside these limits will degrade system reliability.
The voltage supply must not deviate from these specifications. The
supply should be conditioned to correct for any drift that may occur from
facility load changes, or starting and running current requirements.
Voltages in excess of 10% above nominal, including noise up to 100kHz,

should not be applied to the CDWeb Manager.
Installation of distribution Circuits

Selection of wire sizes, cable type, colour, conduit, switch panel, breakers,
transformers, and miscellaneous hardware, must conform to local
electrical codes and to standard practice. Circuit breakers must be sized
according to Honeywell equipment power requirements and should be
installed in close proximity to the equipment they power. Refer to the
cable/conduit schedule included with the system drawings for specific
details.
CDWeb Manager Installation Details
Enclosure Installation
The CDWeb Manager enclosure is shipped from the factory unchanged
from the original manufacturer’s NEMA 4 condition. Any modifications
done to the enclosure during installation can compromise the seal
integrity of the enclosure and reduce the enclosure performance to below
NEMA 4. Consult Honeywell if a non-standard installation method is to
be used.
150 - 151 98/11/09 P/N 6510020139 - Rev. 02

CDWeb Control System Manual Appendix A. Installation Requirements
The CDWeb Manager enclosure is a wall mounted cabinet with the

following dimensions:
Single door cabinet

Height: 1000 mm
Width: 800 mm
Depth: 300 mm
All CDWeb Managers are equipped with grounding terminals to be

connected to mill ground during installation as per standard practice or
regional regulations. Failure to provide a primary ground connection to
the grounding terminals (consult system electrical drawings for exact
locations) can lead to personal injury and may be in violation of local
electrical code.
Cable Installation
Where possible, cable entry into the CDWeb Manager enclosure should be
from the bottom to prevent condensation or moisture in the cable conduit
from dripping into the enclosure. All cables and conduits shall use water-
tight cable glands or fittings to preserve the NEMA 4 rating of the
enclosure.
Cables and wires shall be terminated according to the control cabinet

electrical wiring diagrams supplied with the system. Refer to the wire
and cable schedule provided with the system for minimum recommended
cable sizes and types.
P/N 6510020139 - Rev. 02 98/11/09 151 - 151

Appendix A. Installation Requirements CDWeb Control System Manual
Storage Instructions
In order to maintain integrity of actuator components, storage of all
actuator equipment must be within these parameters:
Acceptable
Acceptable
Duration of Storage Temperature
Humidity Range
Range
Short Term Storage

-25C to 45C 20-90% non-condensing
(less than one week)
Long Term Storage -10C to 40C 20-90% non-condensing
152 - 151 Revisedb03/11/04 P/N 6510020139 - Rev. 02

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CDWeb Control

Revised November 2003

Chapter 1. CDWeb System Overview ................................................................................................ 1

P/N 6510020139 - Rev. 02 98/11/09 i

Chapter 2. CDWeb Manager.................................................................................................................7

Chapter 3. Host Communications......................................................................................................31

ii 98/11/09 P/N 6510020139 - Rev. 02

Write System Status ....................................................................................................... 33

P/N 6510020139 - Rev. 02 98/11/09 iii

Supported Functions and Setup for SCL Link........................................................................52

iv 98/11/09 P/N 6510020139 - Rev. 02

Host Setpoint Registers ....................................................................................................... 68

Chapter 4. CDConnect Assembly...................................................................................................... 71

P/N 6510020139 - Rev. 02 98/11/09 v

Crack Open to Low Flow.....................................................................................................83

vi 98/11/09 P/N 6510020139 - Rev. 02

Using CDWeb Explorer........................................................................................................... 115

Chapter 6. How to ….......................................................................................................................... 117

P/N 6510020139 - Rev. 02 98/11/09 vii

Appendix A. Installation Requirements ........................................................................................149

viii 98/11/09 P/N 6510020139 - Rev. 02

Figure 5-3 Network Settings Dialog Box in Windows95................................................................ 107

P/N 6510020139 - Rev. 02 98/11/09 ix

About This Manual

Within this document exists a detailed description of the workings of the

Both hardware and software aspects of the system are discussed.

This manual contains 6 chapters and an appendix.

Chapter 1, CDWeb System Overview, contains a brief discussion about

Chapter 2, CDWeb Manager, describes the equipment and software

Chapter 3, Host Communications, provides details about the

Chapter 4, CDConnect Assembly, talks about the actuator controllers,

P/N 6510020139 - Rev. 02 98/11/09 x

Chapter 6, How To…, gives step-by-step procedures for working with a

Appendix A, Installation Requirements, provides necessary information

Honeywell P/N Document Title / Description

65 1002 0134 Installation Requirements for Conformance to

Boldface Boldface characters in this special type indicate your input.

Italics In a command line or error message, words and numbers shown in

P/N 6510020139 - Rev. 02 98/11/09 xi

lowercase In an error message, words in lowercase are filenames or words that

Type Type means to type the text on a keypad or keyboard.

Press Press means to press a key or a button.

Double-click Double-click means to position the mouse pointer on an item, then

xii 98/11/09 P/N 6510020139 - Rev. 02

Honeywell Part Numbers

P/N 6510020139 - Rev. 02 98/11/09 xiii

• Reduced floor space required for interface cabinets;

• Improved installation costs by using a bus topology that reduces the

• Better performance by replacing a centralized PLC-based controller

P/N 6510020139 - Rev. 02 98/11/09 1 - 151

Profile Link Host

Power and Communications Bus

Figure 1-1. CDWeb System Schematic (AutoSlice)

The main components of the CDWeb System are:

• CDWeb Manager: The CDWeb Manager contains an industrial

• CDConnect assemblies: the function of these devices depends upon

• Power and Communications Bus: the bus supplies power and

2 - 151 98/11/09 P/N 6510020139 - Rev. 02

NOTE: ProTrim sensor support requires additional hardware - a PLC CPU, at