DanW

Modbus is a project.  Here's some tips on the Omron end. 1. The spec sheet says that the Omron E5AC uses Modbus RTU over RS-485.  The Omron is a Modbus slave. Modbus/RS-485 is a communications option, make sure your device's model number decodes as having the Modbus option. The PLC will need an RS-485 port and whatever firmware it needs to run as a Modbus master. 2. The Omron user manual tells you where to - select the Modbus protocol (not the Omron CompoWay protocol) - configure the serial settings for RS-485 (baud rate, parity), which have to be the same on both ends. - the communications data length (data bits, presumably) defaults to 7, must be changed to 8 for Modbus RTU. - I recommend 1 stop bit because some devices do not handle two stop bits correctly. - configure the slave node ID number (Communications Unit No.) - wire the RS-485, terminals 13 B(+) and 14 A(-).  The Omron lacks a signal ground terminal which can create problems requiring an RS-485 isolator, but try it and see how is works.   Definitions of A/B or (+)/(-) vary from vendor to vendor.  It's supposed to be A to A, B to B, or (+) to (+), (-) to (-), but sometimes the definition is opposite and the A/B wiring needs to be swapped at one end. 3. There is a separate communications manual for Omron devices.  The comm manual will tell you which value is in which Modbus register. 4.  Data formats Omron calls a 16 bit Modbus register an "element".   Omron calls a one element, 16 bit integer "two byte mode" Omron calls a two element, 32 bit floating point values "four byte mode" Each value has both a 16 integer and a 32 bit floating point value, mapped to different locations, so you can pick which data format is easiest to deal with on the PLC The data is most likely in 'Holding Registers' that the Master uses Modbus Function Code (FC) 03 to read, or FC 06 or 16 to write values to. 5.  The Omron being the slave is essentially passive once you configure and wire it.  It waits for a command to provide data or change a data value when the command it receives is a Modbus write command. 6. If you're new to Modbus, it sometimes pays to get a generic Windows Master and a USB/RS-485 converter and experiment communicating with Omron with the Windows Modbus master because it is so quick to change settings (don't need to download to make a change).  Modscan, Modpoll or Simply Modbus are the Modbus Masters I frequently see people use. 7.  Get the Modbus comm manual and work on the PLC Modbus master end.

It is my impression from minor exposure 5 years ago that the development software version has to match the CPU firmware version.  The patch is not likely to load without the presence of the development software.   A document I found indicates that the current software version is R170. Honeywell ControlEdge Builder development software is licensed software, available only through authorized distributors or sales offices. Software purchase includes a software license with a multi-digit license code, that is necessary for downloading updates or for purchasing upgrades.  Be certain you get and save the license code. One can purchase the media kit-DVD version that includes the software on a DVD or media kit-ESD which provides a web link through which the software can be downloaded. The software license does not include documentation.   Documentation can be downloaded from the Documentation tab on this page: https://www.honeywellprocess.com/en-US/explore/products/control-monitoring-and-safety-systems/Scalable%20Control%20Solutions/Pages/ControlEdge-PLC.aspx I have no idea what export restrictions might apply to the availability of the software. You really need the advice and support of an authorized distributor to get the right combination of software/firmware to get a functional PLC.   

1. Schneider claims a non-re-wiring migration path to Foxboro EVO https://download.schneider-electric.com/files?p_enDocType=Brochure&p_File_Name=ID%2342_998-19865506_GMA-US_A4_WEB.pdf&p_Doc_Ref=PAS_63680_CPM16104&_ga=2.203063126.699307783.1532672213-458034261.1531877776 2. This Emerson RA Delta V blurb claims there is some means of 'saving existing wiring'. https://www.emerson.com/documents/automation/brochure-emerson-migration-solutions-for-moore-systems-pss-en-67768.pdf 3.  Honeywell  claims "a phased migration can also use existing wiring" for its PKS DCS.    My limited exposure to Honeywell is that the full blown PKS will be overkill for an APACS replacement.  The distributor supported ControlEdge UOC is probably more in line with APACS system performance, but I suspect that there are no wiring adapters. https://www.honeywellprocess.com/library/marketing/brochures/Competitive-Displacement-eBook.pdf 4.  Siemens hosts a User forum for the PCS7.  You might try an inquiry there for experiences with a migration from APACS.   Registration is required for the site is required. https://support.industry.siemens.com/tf/us/en/threads/135/?page=0&pageSize=10

Gotta admire performance for 40 years.   I, too, look forward to your reports on progress.

Noise. Almost every flowmeter has a setting called something like Low flow cutoff.   It is a signal level at which any flow below that level is reported as zero flow, primarily to cover this circumstance.  Find the low flow cutoff, figure out what units it uses, (% of span, counts, engineering units) and put in a number slightly higher than your existing low flow values. As a side note, unless the flow meter has a tight shutoff valve on both ends, there can be actual flow even though the pump is not running.  Bleed level flows happen as the sytem equilibrates after the pump turns off and gravity works on the remaining liquid in the pipes, sometimes even siphoning flow.

> i dont have any rs485 card or com port on my PC to directly connect to it. It pays to have both a USB/RS-232 and a USB/RS485 converters for a PC when you have to deal with industrial serial communications. Those with an FTDI chipset have served me well.  They are not very expensive.    I prefer flying leads (individual wire conductors) on the RS-485 converter because the connection is almost always screw terminals.

http://www.plctalk.net/qanda/showthread.php?t=127931&highlight=joystick

I'd suggest you look at the Blog at the link below, Understanding Control Signal Jargon, aimed at the control of electric actuators. https://blog.belimo.com/Blog/bid/47275/Understand-Control-Signal-Jargon I suspect that your actuator is in the group called "3-point, Tri-State, Floating Control" (to which I can add: position proportional, Three position step control, PAT, valve motor) You need to understand exactly which control mode your actuator requires.

The Moisture Meter supports only Function Code 03, Read Holding Register (this device is limited to one read or one write at a time) and Function Code 06, Write single value to a Holding register. From that one might deduce that K0 means that the register addresses use zero based addressing and that K5 and higher are read-only registers Meter  zero-based  one-based           Type K0      0000             (4)0001        R/W, FC03 or FC06 K1      0001             (4)0002        R/W, FC03 or FC06 K2      0002             (4)0003        R/W, FC03 or FC06 K3      0003             (4)0004        R/W, FC03 or FC06 K4      0004             (4)0005        R/W, FC03 or FC06 K5      0005             (4)0006        R, FC03 K6      0006             (4)0007        R, FC03 remainder are read only The data values are most likely 16 bit integers, where K5 is a signed integer with a range of -5 to +5.   The other registers could be signed integers, too, but they all appear to positive values. The K1 value seem to be truncated to the two high order decimal digits: 11 = 1100 25 = 2500 It's not my moisture meter so I only know what the sheet says,but K0 appears to be a control status word. the value 0 = stopped, the value 1 means it is in manual mode, value 2 means it is in auto mode.  This is most likely a read/write register so that one can remotely run the device in manual or auto mode or stop it by writing the appropriate value. Regarding K2 Moisture setting address K1, it appears that this device somehow changed moisture content, from the statement, "When the measured moisture vlue for three consecutive times is less than or equal to the set moisture value . ".  The 'set moisture value' appears to be a control setpoint, hence K1 register (4)0002, is the moisture setpoint value.  Again, not my box . . . K3 is the the type of grain that is being measured. K6 Actual Measured Address probably means the measured moisture value, residing at register address (4)0007   One uses zero or one based address values depending on what the master uses or requires.    

1. valve/actuator Realities a. A 3 way valve has 3 ports, either one inlet and two outlets or two inlets and one outlet. Why are you using a 3 way valve for steam?  How does that work?  Do you waste steam when the valve is in the 50% position? Normally a heat-only application uses a 2 way valve, one inlet, one outlet. b. On/off or modulating Depending on the actuator a valve can be controlled as either - open or closed, or on-off, or - modulating, where the actuator partially opens or closes the valve over the range of 0% (closed) or 100% (open). Questions: Is your valve/actuator that you are working with an on/off valve actuator or a modulating valve? What input signal does it expect? Is it driven by 4-20mA, one relay or two relays?   2. Control modes a. heat (reverse action) Heating action uses only one control output, either - a single relay or - a single 4-20mA, - the special application of driving a modulating electric actuator with two relays, where one relay drives the electric motor to a closed position, and the other relay drives the electric actuator to an open position. Honeywell calls this position proportional when there is slidewire feedback from the actuator or "Three position step control (TPSC)", an open loop control mode with no feedback for motor position. TPSC uses timing to estimate the motor position.   The controller's output for PID Heating action is 0% is closed, 100% is open.   b. Heat/cool control mode uses 2 control outputs.  One output is dedicated to the heating loop.  The other output is dedicated to the cooling loop.   When the PV (temperature) is below setpoint, the heating output is controlled and the cooling output is OFF, closed, at 0%. When the PV (Temperature) is above setpoint, the cooling output is controlled adn the heating output is OFF, closed, at 0%.  There is a setting, typically called deadband, which is a range around the setpoint where both heating and cooling are disabled (at 0%) because there is rarely an application where heating and cooling are needed to maintain setpoint.   3. All that said, what's going on? a. it isn't clear whether your valve is modulating or on-off: >"valve is 50 mm , step is 10 mm per minute"  An electric actuator takes time to close or open a valve but what is the intended design of your valve/actuator?  on/off or modulating? b.  I suspect that what you call a 3 way valve has an actuator that expects to be controlled with two relays, one to drive the motor open, one to drive the motor closed.  Is your term '3 way' related to the number of wires on the actuator or the number of ports on the valve?   c. >"when temp is going up  Delta DT320 is operating at the same time OUT1(because temp is lower then 13) and the same time OUT2 is try to close, This sounds like your are trying to drive an electric actuator with two relays, one relay to close the valve, the other relay to open the valve, which is the position proportional or 3 position step action described above. That's not the action that the relays are performing - the action that the relays are performing is heat/cool action: the heat relay is enabled (on a time proportional (a form of pulse width modulation) basis while the cooling relay is OFF. The control of two relays to drive an electric actuator is a special function.  Only one relay is enabled at a time.  The ON time must be calculated and controlled.  That motor control function is not mentioned in Delta DT3 instruction sheet, at least, I could not find it. Page 8 of the instruction sheet describes the control outputs and their allocation as Heat, Cool or Heat/Cool control outputs or as alarm outputs.  No mention of actuator control.    

I've never used Anybus, but their demo program for the config software appears to be the same model you have.  It might be worth 4 minutes of you time to watch it.   https://www.anybus.com/products/gateway-index/anybus-xgateway/configuration-manager

In 2012, Kepware published a manual for their OPC version at the time.  It was definitely OPC DA, not OPC UA.   manual is attached. Honeywell-hc900-ethernet-manual-Kepware 2012.pdf

I use the writer app in LibreOffice, a freeware competitor to Microsoft's app Word in MSOffice. LibreOffice Writer is far less fussy than MSWord when placing graphics on the page.  I struggle with Word when I was adjacent photos (on a horizontal axis), not just sequential (vertically one after another).  Have to be careful to save docs as .docx rather than their proprietary format, but that's not a big deal.    

Maybe, it's a big world out there, but I doubt it. Typical serial I/O modules use either a defined proprietary protocol or use Modbus. The Advantech Adam 4050 has 8 DO's but only part of the message written is the bit pattern for which bit is on or off.  The protocol uses ASCII characrters, with this syntacx (for that specific module) [delimiter character][address][command][data][checksum] [carriage return]. That series of I/O modules does not have RS-232, they use RS-485, so you'd have to use an RS-232/485 converter, or use the Red Lion RS-485 port.  

One key word under product description is 'single ended'.  That means the (-) side of all the signals are connected all together at one point. The terminal labeled RTN on the Field Wiring Terminals table means return, or the common, (-) side of the input(s). The wiring diagram shows the field device on the left with its positive output connecteed to In, (-) connected to RTN. The In (I2, I4) number represents the current source field device (I is current in Ohms Law). What is not spelled out is what happens when the field device is a loop power transmitter and needs a loop power supply. So the (+) side of the current signal goes to the An terminal,  which is either - the negative terminal on a loop powered transmitter (because the positive terminal of the transmitter is connected to the Power supply (+), or - the positive output from a 3 wire or 4 wire field device. and then either - the negative (return) of the loop power supply output connects to the RTN terminal - the negative outputs from either 3-wire or 4-wire field devices are run to terminal blocks, jumpered together and then connected to RTN. The wiring diagram essentially shows the same thing - Test it with a single field device. I haven't a clue what all the Bn connectors do.  Shame they can't be used as RTN or (-) connections.