DESIGNETICS
e3 Series
Communications
MANUAL
Contents
Welcome! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Connecting to the OCS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Uploading Programs from the Horner OCS Unit . . . . . . . . . . . . . . . . . . . 7
3 Installing Designetics e3 Program Updates . . . . . . . . . . . . . . . . . . . . . . . 8
Installing a Designetics Program Update . . . . . . . . . . . . . . . . . . . . . . . 8
4 Modifying the Hardware Configuration/Changing the IP address: . . . 10
e3mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
e3multi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Connecting an Allen-Bradley Controller to the Horner OCS . . . . . . . . 14
6 e3 Ethernet IP I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
e3mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
e3multi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Appendix A Acquiring and Setting up Cscape© Software . . . . . . . . . . . . . 20
Horner Configuration Before Connecting and Downloading: . . . . . . 20
This manual, along with all accompanying information, is the confidential and proprietary intellectual property
of Designetics, Inc. and may not be used in any manner without the written approval of Designetics, Inc.
Certain Images and/or information depicted in this publication are the intellectual property of Rockwell
Automation and/or Horner Automation and are herein used with the permission of the respective owners and
is intended solely for educational purposes.
2
Welcome!
We thank you for choosing the Designetics e3 Series Fluid Application System to meet your precision fluid
application needs.
This manual is intended to provide the user with information on setting up and using Ethernet-based
communication protocols to communicate with and to send/receive data to/from the Designetics e3 fluid
application system control panel. Communicating with the e3 panel utilizing the ethernet-based
communication protocol will allow the user to remotely:
• Modify setpoint data, such as pump speeds.
• Monitor setpoint values such as current pump speeds.
• Obtain notification of alarm generation at locations remote from the e3 panel.
• Start and stop the automatic operation of the e3 system.
3
Scope:
The data and procedures included in this publication explain how to update a e3mini or multi program. The
information within will also instruct the IT or maintenance professional on the steps necessary to modify the
e3 panel’s Ethernet Communication protocol.
It is necessary to utilize these procedures when:
• A new e3 unit is being integrated to your network.
• The e3 unit is being repurposed and a program modification is needed.
• The Horner PLC/HMI (OCS) has been replaced and requires configuration.
Prerequisites:
The information provided in this document is intended to be utilized by the Maintenance and/or Information
Technology Professional that possesses a thorough understanding of Ethernet Communication protocols.
Prior to using the information provided in this publication the user should be familiar with and understand the
many aspects of IP (Internet Protocol) addressing, data word bit translation, netmasks, gateways, etc. as well
as understanding the operational aspects of the e3 system.
The Designetics e3 Fluid Application systems employ a Horner Automation™ OCS, which is a combined HMI
(Human-Machine Interface) and PLC (Programmable Logic Controller) device for accomplishing machine
operation and control. This device includes a touch-screen HMI user interface for interacting with the User
Screens. The PLC logic and the User Interface screens are loaded as one program, negating the use of
separate, additional software applications for PLC logic and creating/editing User Screens.
The Horner Automation™ programming software is called “Cscape©” and is provided as a free download.
Download and set-up instructions are found in Appendix A. Cscape© can be used by Designetics’ customers
to install an updated Designetics e3 program, or to reconfigure the e3 panel’s IP Address.
To ensure the continued safe operation of Designetics equipment and to guard our intellectual property, the
e3 Fluid Application system is protected by security measures, including multi-level password-protection. By
default, the customer has only limited functionality within the Cscape© environment. This document includes
the password and instructions required in order to allow access to re-configure the IP address of the
Horner™ OCS Controller to match the individual customer requirements.
4
1 Connecting to the OCS Controller:
The following instructions will allow you to connect your computer to the Horner OCS Controller in order to
upload (transfer from the OCS to an external device, such as a computer) or download (transfer from an
external device, such as a computer, to the OCS) Designetics’ e3 programs to the OCS, or to alter the
hardware configuration of your OCS platform.
1. Connect an Ethernet cable from your Computer to the Ethernet port found either on the right side of the
e3multi Panel, under the protective cover, or directly to the LAN1 port on the bottom of the OCS Controller
inside the e3mini panel. Ensure your computer’s Ethernet adapter is set in the subnet range of
192.168.1.xxx (using Windows Open Network and Sharing Center), where xxx is any 3-digit number
(except for 101 or 102, which are reserved for the Horner OCS. If you choose 101 or 102 as the 4th octet in
your IP address an IP Conflict will occur, and the connection will not be established.
2. With Cscape© installed (see Appendix A) start the
Cscape© program. Once the application loads the
Connection Wizard dialog box will be displayed
(Image 1-1). This wizard will allow you to select the
communication protocol that you will use to
communicate with the OCS Controller. Select
Ethernet and then click Next. The IP Setting
dialog box will display as shown in Image 1-2.
Image 1-1. Connection Wizard
3. Enter the IP address, 192.168.1.101, (Image 1-2).
Ensure that the remaining field’s values match the
values shown in Image 1-2. Once the IP address is
entered and you have confirmed the other field’s
values click Finish. There may be a several
second delay while the connection is being
attempted.
Image 1-2. Connection Wizard
4. If the connection is successful, the Status bar in
the lower right corner of the Cscape© window will
display (R) for Ready as shown in Image 1-3.
Image 1-3. Connection Status
5
5. Additionally, the icons shown on Image 1-4 will be
enabled (no longer “grayed out.”) Image 1-5
displays where in the main Cscape window you
will locate the Online Status display and the
On-Line Icons.
Image 1-4. Online Icons
Image 1-5. Connection Status Indicators
6
Upload/Download
and Controller
Mode (Stop, Idle,
Run) icons
Online Status
Message area
2 Uploading Programs from the Horner OCS Unit
In order to modify the Horner OCS Controller’s Hardware Configuration, or to review, replace or modify the
system logic program or screens, it is necessary to upload the program file from the OCS Controller to your
computer. Follow the steps below to transfer the program from the OCS to your computer.
1. Follow the instructions shown in Chapter 1 to establish a connection between the OCS Controller and a
computer. Once the connection has been established click the “Upload from Controller” icon from the
Cscape© application’s tool bar or select Program>Upload from the Cscape© menu to begin the upload
process.
2. After clicking the Upload from Controller icon or
selecting Upload from the Program menu of the
Cscape© application, the default target window,
(Image 2-1) will display. Ensure that the values
displayed in the Upload Program from Target
dialog box match those shown in Image 2-1. Press
OK.
Image 2-1. Upload Program from Target
3. The security Logon dialog box will be displayed as
shown in Image 2-2. By the use of this dialog box
you will be prompted for a password. The
password is 4321. After entering the password
press OK.
Image 2-2. Security Log-on
4. The program upload process will begin. You will
see several Communication Progress dialog
boxes open and close as the different elements of
the OCS program are uploaded. Image 2-3 is an
example of a Communication Progress dialog box.
Image 2-3. Communication Progress Dialog Box
7
3 Installing Designetics e3 Program Updates
Occasionally, situations arise where it becomes necessary to install an updated program to the OCS
Controller, or to restore the original program in the event of a failure of the OCS Controller. Designetics will
provide the customer with the required program updates when:
• A safety issue or a program “bug” has been identified and needs to be addressed.
• New options or features are purchased by the customer and need to be added to an existing e3 system.
• A replacement OCS Controller is installed.
It is NOT recommended that OCS programs that are generated by parties other than Designetics be installed
to the OCS Controller without review and approval of the program by Designetics Technical Support.
Unapproved programs may potentially violate the e3 unit’s safety protocols and may also void the e3 unit’s
warranty, should the warranty period still be in effect.
Installing a Designetics Program Update:
1. Follow the instructions shown in Chapter 1 to establish a connection between the OCS Controller and
your Computer.
2. Open the Horner Cscape© software
3. Load your received program into Cscape© by either double-clicking the .csp file or selecting Open from
the File menu in the top menu bar of the Cscape© program, navigating to the file storage location, selecting
the file and clicking Open.
4. With the updated program loaded into the Cscape© application, click on the Download to Controller icon
or select Download from the program menu item.
5. The Download to Target dialog box box, Image 3-1
depicted, will appear. Do not change any of the
settings in the dialog box. Be sure to leave the
SmartLoad checkbox checked.
Note: You may receive an error message
stating that the IP Address has been changed,
which you may ignore by clicking the OK button
in the error message dialog box.
Image 3-1. Download to Target Dialog Box
8
6. The program will begin transferring to the OCS Controller. You will see a progress indicator displayed on
the Horner HMI screen as the data is transferred.
7. When the program transfer is completed, the OCS will automatically restart. Once the OCS restarts and
completes its power-on self-test routines the Designetics “splash screen” will be displayed, followed by the
e3 system’s Main Screen.
8. Confirm that all program functions and system functions (Pump Run FWD, Pump Run Rev, App Fill, Line
Fill, etc.) are operational.
9
4 Modifying the Hardware Configuration/Changing
the IP address:
If you are connecting the e3 unit to your local Ethernet network, it may be necessary to change the OCS unit’s
IP Address in order to comply with your network’s IP structure. Follow the steps below to modify the OCS
unit’s IP Address.
e3mini:
1. Select Hardware Configuration under your program file name in the Navigation pane of the Cscape©
application window as shown circled in red on Image 4-1 below. Then click on the Config button (circled in
red on Image 4-1 below) located to the right of the LAN1 field under the Network Ports section of the
Hardware Configuration window
Image 4-1. Hardware Configuration Dialog Box
10
2. The LAN1 Configuration dialog
box will display, as shown on
Image 4-2.
3. The IP setting values (IP
Address, Net Mask and
Gateway) are circled in red in
the Image 4-2. These are the
values that will need to be
modified. Set the IP Address to
whatever value your Network
Administrator requires.
Normally the Net Mask value is
set to 255.255.255.0 and the
Gateway value is set to 0.0.0.0.
These values may need to be
modified depending on your
network’s configuration. Your
network administrator can
provide the necessary values.
Unless instructed to do so, do
NOT modify any other values
on the LAN1 configuration
dialog box.
Image 4-2 LAN1 Configuration
4. Once you have modified the
necessary values click on the
OK button.
5. If you are configuring an e3mini
system, the LAN1 configuration
is complete. Click OK to exit
the Hardware configuration
dialog box, then follow the
steps to download the modified
hardware configuration to the
OCS shown on Page 8 in
Chapter 3.
11
If you are setting up an e3multi system, please follow the steps below for additional configuration steps that
must be completed.
e3multi:
The e3multi system utilizes a SmartRail I/O device. When changing the IP address of the Horner OCS in an
e3multi, you must also modify the SmartRail device’s IP Address. Follow the procedure below to change the
IP Address of the SmartRail.
1. To set the IP for the SmartRail
device click the LAN1 I/O tab.
The LAN1 Hardware
configuration dialog box will
display as shown in Image 4-3.
A
B
Image 4-3. LAN1 Configuration
2. Select the existing IP Address
shown in the left pane of the
LAN1 I/O dialog box (A) (in
image 4.3 above) and then click
the Config button (B). The
Configure SmartRail dialog box
will display as shown in Image
4-4.
C
D
3. Enter the desired IP Address in
the Base IP field (C) and the
Mac ID in the MAC ID field (D).
Image 4-4. SmartRail Configuration
12
The Mac ID for the SmartRail device can be found
on a label placed above the Ethernet switch inside
the e3multi panel as shown in the Image 4-5.
MAC ID Label
SmartRail
Image 4-5. SmartRail MAC ID Location
It is not necessary to change any other values in the SmartRail configuration.
4. Click OK to save the SmartRail Configuration and exit the SmartRail Configuration dialog box.
5. Click OK to save the Hardware Configuration and exit the Hardware Configuration dialog box.
6. Follow the procedure shown on page 8 to download the modified hardware configuration to the Horner
OCS unit.
13
5 Connecting an Allen-Bradley Controller to the
Horner OCS
To establish a connection to the Horner OCS unit from your Allen-Bradley Controller a generic ethernet
module needs to be added to the control structure of the AB PLC. Follow the steps outlined below to add a
generic ethernet module.
1. Open Studio 5000.
2. Open an existing or a new project.
3. From the View menu select Controller Organizer.
4. Right-click on the ethernet section of the Controller Organizer as shown in the Image 5-1 below, then
select New Module. The Select Module type dialog box will be displayed.
Image 5-1. Creating a New Module
14
5. In the Select Module Type dialog box, Image 5-2 below, begin typing Generic Ethernet Module (A) in the
search field circled in the Image below. After typing several characters, the system will begin to display
matching items. Select the Generic Ethernet Module (B) as shown in Image 5-2 below and then click the
Create(C) button to create the module.
A
B
C
Image 5-2. Selecting Newly-created Module
6. After clicking on the Create button the newlycreated module will appear in the Controller
Organizer and the New Module dialog box will be
displayed (shown in Image 5-3). This dialog box is
where the parameters for the newly-created
module are set.
7. Enter the IP Address, Module Name, Description
and assembly information (shown in Image 5-3)
and also found in Table 5-1.
Name: This field is by user-choice. The module
name should be relevant to the project, i.e. Horner
e3.
Image 5-3. New Module configuration
with Assembly Instances Setting
Description: This field is not necessary, but it is
good practice to provide a short description of
what the module’s purpose is.
Input Assembly
Output Assembly
Configuration
Comm Format: Select Data - INT
Instance - 100
Instance - 101
Instance - 30
Size - 10
Size - 10
Size - 0
IP Address: Enter the IP address of the e3mini
or multi Controller you are establishing a
connection to.
Table 5-1 Assembly Instances
15
7. After clicking OK the Module Properties (A) dialog box (Image 5-5) will be displayed in the program
window’s right pane as shown below. In the Request Packet Interval (RPI) field enter 10.0ms and check the
box for Use Unicast Over Ethernet/IP (B).
8. Click OK.
B
A
Image 5-5. Module Properties Dialog Box
9. Download the project to the AB Controller as shown in Image 5-6.
Image 5-6. Downloading Project
16
Once the project has downloaded to the AB Controller the online connectivity can be verified by observing
the icon for the Generic Ethernet Module that was created and configured. If connection has been established
the AB program will display the text circled in red on Image 5-7 for the new module.
Image 5-7. Confirming Connectivity
If the connection to the ethernet module has NOT been established the AB program will display an
exclamation point to the left of the newly-created module as shown in Image 5-8.
Image 5-8. Module Non-Connectivity
If the connection fails, please review the settings you have entered to confirm that they are correct. Also,
check the physical connections of the Ethernet cable to ensure that they are securely connected.
17
6 e3 Ethernet IP I/O Mapping
The e3 system has the ability to communicate via ethernet. Data is passed between the two control systems
using data words. These words are “translated” into commands, status bits, alarm reporting, etc.
When communicating with the e3’s Horner OCS Controller via the Ethernet communication protocol it is
possible to remotely change the system’s current operating mode (Manual/Auto,) initiate a program cycle (Run
Pump), set pump run speed values, monitor a pump’s running speed, or monitor the status of various alarms
via the transmission of Data Words. A data word is a 16-bit series of 1’s and 0’s (machine language) sent via
ethernet to or from the OCS Controller and translated into a bit map by the receiving system. The resultant
bits are then used to modify pump speed values, place the e3 into Auto Mode, initiate a fluid application
cycle, or obtain status information from the OCS Controller. The following pages detail the bit mapping as
used on the e3mini and Multi platforms.
e3mini/e3multi:
There are 10 read words and 10 write words established for communication with the Controller.
Note: These are 16-bit words. If your network control system or robotic Controller has a selection for
Word Type, ensure that 16-bit words or equivalent are selected.
The Assembly instances and sizes are shown in Table 6-1:
Input Assembly
Output Assembly
Configuration
Instance - 100
Instance - 101
Instance - 30
Size - 10
Size - 10
Size - 0
Table 6-1 e3mini/e3multi Input/Output Assembly Configuration
18
Words Produced
Word #
Function
Word #1
Pump 1 Speed Setpoint
Word #2
Pump 2 Speed Setpoint
Word #3
Pump 3 Speed Setpoint
Word #4
Control Bits
Bit #
Function
#1
Auto Mode
#2
Run Pump 1
#3
Run Pump 2
#4
Run Pump 3
#11
Run Stir Plate 1
#12
Run Stir Plate 2
#13
Run Stir Plate 3
#1
Estop Active
#2
Auto Mode Active
#3
General Pump Drive Failure
#4
Low Air
#5
General Low Chemical Level
#6
Spare
#7
General Stir Plate Fault
#8
Pump 1 Low Chemical
#9
Pump 2 Low Chemical
#10
Pump 3 Low Chemical
#11
Run Stir Plate 1
#12
Run Stir Plate 2
#13
Run Stir Plate 3
Words Consumed
Word #1
Pump 1 Running Speed
Word #2
Pump 2 Running Speed
Word #3
Pump 3 Running Speed
Word #4
Status Bits
Table 6-2. e3mini/e3multi Data Words
19
Appendix A Acquiring and Setting up Cscape©
Software
The Designetics e3 Series fluid application systems use a Horner Automation™ OCS, which is a combined
HMI (Human-Machine Interface) and PLC (Programmable Logic Controller) device for accomplishing machine
operation and control. This device includes a touch-screen HMI user interface for interacting with the User
Screens. The PLC logic and the User Interface screens are loaded as one program, negating the use of
additional, separate software applications for PLC logic creation and creating or editing User Screens.
The Horner Automation™ PLC/HMI software is called “Cscape©” and is provided as a free download. It can
be downloaded from the Horner Automation web site at the following URL:
https://hornerautomation.com/cscape-software/
Cscape© can be used by Designetics’ customers to re-install or update a Designetics e3 program or edit the
system hardware configuration.
Horner Configuration Before Connecting and Downloading:
When a new version of Horner Automation Cscape© is installed, a simple configuration change must be made
to prevent the generation of an Or around Functions Fatal Error message. Please follow the below steps to
locate and correctly set this application parameter.
Step 1: Locate and select, on the top menu bar of the Cscape© application, the Tools drop down menu
(Reference Image A-1). Towards the bottom of the menu drop box, select the Editor Options.
Image A-1. CScape© Configuration
Step 2: The window depicted in Image A-2 will appear. Locate and check the Allow OR around Functions
(highlighted in Image A-2) and then click OK.
Image A-2. Cscape © Configuration
20
The Cscape© application is now
configured to prevent the generation
of the Or around Functions Fatal
Error error message
21
U.S. PATENTS:
5,131,349 / 5,743,959 / 6,471,774 / 6,547,880
6,641,665 / 6,649,220 / 7,390,533 D468,633
D480,632 / D480,959 / D576,848 / D641,255
D694,853 / D705,893 / D705,894 / D708,294
D708,295 / D708,296 / D708,297 / D708,298
D708,299 / D708,698 / D708,699 / D708,700
D708,701 / D709,165 / D709,989 / D714,420
D714,902 / D714,903 / D714,904 / D714,905
D714,906 / D714,907 / D715,399 / D715,400
D715,401 / D803914 / D805115 / D806149
D803284 / D751400 / D765522 / D715897
D755865 / D755866 / D758531 / 9433968
9061313 / 9180480
INTERNATIONAL PATENTS:
Patents issued in the UK, Germany, France,
Italy, Belgium, Spain and Brazil.
SOFTWARE COPYRIGHTS:
e3mini Software: ©Designetics, Inc., (2014).
All Rights Reserved.
e3multi Software: ©Designetics, Inc., (2014).
All Rights Reserved.
U.S. & International Patents Pending
PM9D#10 Rev. H
PROPRIETARY PROPERTY:
This manual, along with all accompanying
information, is the confidential and
proprietary property of Designetics, Inc. and
may not be used in any manner without the
written approval of Designetics, Inc.
Disclosure of this information, including
prototypes to third parties, is expressly
prohibited without written permission from
Designetics, Inc. Receiving Party agrees not
to provide such samples or prototypes to a
third party without written approval from
Designetics, Inc. Receiving Party also
agrees not to reverse engineer any of
Designetics, Inc. products.
WARRANTY:
Use of applicators and accessories other
than those manufactured and sold by
Designetics, Inc. may violate patents held
by Designetics, Inc. and will void any
warranties associated. Seller herby
disclaims all responsibility for any
alterations, modifications, or changes made
to equipment by Buyer. All expressed and
implied warranties are void.
Designetics is a registered trademark of
Designetics, Inc.
©2023 Printed in the U.S.A.
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PHONE: 419.866.0700 FAX: 419.866.0767
EMAIL: sales@designetics.com
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