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HC900 Process & Safety Controller

1. Number Possible Cause Scanner Action User Action of Strobes 2 The scanner has no configuration Modules are not scanned and the outputs are 1 Verify that the address data because it is unable to either at failsafe or in the power down state If switches on the scanner are communicate to the controller communication was lost while the modules set correctly ae went aas sate Wcommmaneaten 2 75 oniy Very that he CPU Possible causes include 3 i A cable is connected to the A was never established to the Scanner then port and the CPU B cable is Scanner address switches are the module outputs are in the power off state not correctly set connected to the B port on the Scanner 2 2 C7 ly The C75 i ee oo hee cae i 3 If a switch is used check that ll cables are properly 21 a Scanner i port connected to the switch 3 Ifa switch is used there may proper crossover cables are be a problem with it used that the switch is 4 Cables are defective or are not powered and it supports 100 properly shielded Base T 5 Controller CPU is not powered 4 Check cable shielding for proper grounding and noise Controller CPU and Scanner immunity firmware versions are incompatible 5 Make sure the cables have the correct pinout 7 Defective Controller CPU Scanner power supply or rack 6 Cycle power to the Scanner Cycle power to the switch 8 Cycle power to the controller CPU 9 Replace the expansion rac
2. 0 cccccceceeeeceeceeeeeeaeeeeneeseeeeecaaeeseaaeeeeeesaeeesaaeseeaeeseeeeeseaesesaeeseneeesaees 82 VO Terminal Block Wiring Diagrami cccccscccecssceeeessneeeeeceeeececaeeeceseaeeeeessaeeeeesaaeeeeesaeeesseneeeessseeeeess 89 Communications Installation ac ctesccst rsccited dcenenetlancises inecoaaboceiiged aacicetenaieset sbde cad ocaoeatete 125 CVENVIOW EET E AS E E E A A TE 125 EAn e sand CADIIAG A TAE T AE AA A E T A T ET 125 Connecting the Operator Interface to the Controller c cccecccceeeeceeeeeeeeeeeceaeeeeeaeeeeneeseeeeesaeeesaeeseneessaees 129 Connecting the HC900 Controller to a PC with the Designer Software cccccceccceceeeeeeeteeeeteeeeeeesaees 130 Connecting the HC900 Controller to Modbus device s ecececeeeeeeeeeeeeeeeceeeeeeaaeeeeneeseeeesaeeeeeaeeteeeeseaes 150 Operating Characteristics cic bees ieet dn atat tated lect tehsil t eh cal teat eect teeta htt 153 rodicio nsn EE eae cha bates Recht th atat cna bated ere ACG 153 DINETAN IN 25 fac cL EE ales ccs iu ce DSc wadatetas E ocey dates dtcuahstnydacensuewsbduraditi vues ahi E EEE 153 Power Down Power UDeinsse erinnern naan E EREE gcetede a e E teh rienaiv eben NEES 153 Controller Mode Sirini ia eiai neea iene nis aaa ee A eee 156 File Download Upload FUNCTIONS samisi ortini n aara i ot REA E ATARE E E AA R A 161 Redundant Operating Characteristics cc s2ccccc teciecantevigaestectecesdevbieysdceiniendeciyeusbeviceseiaet 163 OTA E A A ade
3. Configuration Download Configuration files include the items indicated in Table 25 Downloading of some items is mode dependent That is downloading of some file types is not permitted in the Run mode or in the Offline mode Table 25 Configuration file downloading Downloading of Permitted When Controller is in Configuration items PROGRAM Mode RUN Mode OFFLINE Mode Controller Configuration Files Yes No Note 1 No Setpoint Profiles Setpoint Yes Yes Schedule Recipe Files Yes Yes Data Storage Configuration Yes Yes Yes Files Data Storage Non volatile Yes Yes Yes parameters Note 1 Controller files can be downloaded with the controller in Run Mode with the Mode switch set to Run Program but not with the switch set to Run Lock The download from the host processor is directed to an area of controller memory separate from that used for running the controller and hence has no effect on the active process The host signals the controller when the download is complete and requests a configuration validation test and report from the controller The controller then checks the new database and compares it to the current running database Using the test report as a basis the host then presents the operator user with a dialog box containing a set of choices begin using the new database with no cold start use it with a re start or abort the download Configuration Upload Controller configur
4. Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 241 for RTP internal schematic Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 239 June 2015 8 Point Analog Output Connect field wiring LOADS ARE 0 to 750 ohm RTP A for Inputs 1 to 8 EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN to 9 External 24VDC supply 24VRTN to 11 240 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 RTP A Cable wire positions and colors for cable assembly drawing applies to 8 AO Twisted Pair Number of HC900 Module TB Position RTP A J1 Plug Connector Color Cable A 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 36 17 Black 35 16 Blue 5 36 15 Black 35 14 Yellow 6 10 12 Black 11 11 Brown 7 12 1 Black 13 2 Orange 8 15 4 Red 16 5 White 9 3 8 Red 8 18 Green 10 9 13 Red 14 3 Blue RTP A J2 J3 J4 J5 HC900 ov o Terminal y y y i Block C1 c1 c1 SW SPST TB1 1 2 m 2 4 5 O 7 10 8 36
5. Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 21 I O Expansion Rack T O expansion remote racks shown in Figure 8 are available to accommodate additional input output modules and or to enable location of I O modules close to the process and remote from the controller For C75 C75S all I O is in a rack or racks separate from the controller rack Scanner type must match controller type i e example S5OS may only be used with C50S or C70S S50S cannot be used with a C50 or C70 An I O expansion rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3 Scanner 1 Module S50 S50S shown or Scanner 2 Module S75 S75S 4 Grounding bars for I O wiring optional required for safety applications 5 Input Output modules 6 I O Terminal Blocks 7 Power Status Module PSM req d if using Reserve Power Supply 8 Reserve Power Supply optional Available in 8 or 12 slot racks Figure 8 I O Expansion Rack Components 22 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Rack Options Racks are available in 4 slot 8 slot and 12 Slot versions Racks are interchangeable between the Controller rack and an I O expansion rack and all three versions shown in the following figure are available for either purpose 8 and 12 slot I O racks can be modified with additional slots for optional
6. Digital Output Relays 8 channe e0oHo1 z002 o Digital Output 24V00 16 channe e00fo2 z010 no Digital Output 24V00 32 channel e00fs2 2001 no Digital Output 120 240 VAC 6 channel e00H03 2010 no 300K01 010 NA No No NA No No No No No No NA Reference only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library support Public Downloads HC900 SafetyControllerModulesRevisions zip 2 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction vocomonens T S WOComponents o C C SOSC SSSSSCSC S Kisa accessories O o NA 51452041 501 Reference only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library support Public Downloads HC900 SafetyControllerModulesRevisions zip Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 3 June 2015 Introduction Oraccessoresa Ks O O S 10 Screen Protective Films 10 900 Control Station User Manual paper 15 Screen Protective Films 10 24VDC Power Supply for 15 GSM GPRS Cellular Modem Kit New Non SIL System C E Conrolercs0cPu f 00050 03600 no o o S Conwolercz0cPU e0000 2036000 o OS Conwolercz5cPu eooo7s lt o86000 n O TO Scanner 2 Por 1 per VO ra 800575 0
7. J 2 Wy ATS JOPIOCOK 10 5 to 32 Vdc QDE AN amp OOOOO OOOGOOOOOOOO00 d fi Figure 64 32 point DC Output Module Wiring AC Output Module Wiring The AC Output Module provides eight output circuits Each output is isolated from the other outputs An example of AC output wiring is shown in Figure 65 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 113 June 2015 Output Loading Voltage 85 to 240 Vac Maximum per output 2 0A resistive load Maximum per module 8 0A NOTE When exceeding 1 0 A per output it is recommended but not required to connect the high current loads to every other output for example outputs 1 3 5 7 or 2 4 6 8 This distributes heat more evenly across the heat sink Jumper Comb A ten position jumper comb is available for inter connecting all L1 Hot terminals 1 3 5 7 9 11 13 15 17 19 See Figure 66 Replaceable Fuses Each output circuit on the AC Output Module includes a plug in replaceable fuse Replacement fuse is from Wickmann part 3741315041 This is a 3 15 Amp time lag
8. Controller Module Replacement cece eeeesceesceeeceecesecesecsaecsaecaeecseesaeesaeseaeeeeeeesenssenseeaeesaeenaes 195 Table 36 Scanner Module Replacement 00 eee eee eeeeeseeeceeceesecesecsecesecsaecnaecaeecaaeeaeseaessaeeeeessseseesesaeenaeenaes 196 Table 37 RIUP Potential Hazards and Recommended Actions ceesceceseceeneeceseceeneeceaeeeseeecaeeeeaeeceaeeeeneeees 197 Table 38 1 O Module Replacement 3 is 5c sscssseesces sessabtpsssesesesscesscossesstescavbastetsvecosnapsqesgebavesdetesvbssedusesveesscessees 198 Table 39 Installing Backup Battery CPU not initialized oe eee cee cesecse esse cee cneecaeeeaeseeeeseeeseeeenseenseenas 200 Table 40 Replacing a Backup Battery CPU Powered 0 0 0 eee ceescesceseceecssecnsecseecaeecseeeaeseeeeseeeeseneenseenseenaes 201 Table 41 HC900 PV Input Types and Ranges cece ceeeesceeeceescesecesecsecsaecssecseecaeecseseaeseeeeseeeeesseenseeseenaes 208 Table 42 System Size and Availability Summary 000 0 ccc eee eecesecesecesecaecnaecseecaeecseseneseaeeeeeeenseenseeseenaes 211 Table 43 Fiber Optics Equipment Recommendations 0 eee eeeeseceseceeecseecaeecsecneecaeecaeseneseneeseeeeeeeenseenseenaes 212 x HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Figure 1 Small HC900 Controller Configuration 0 0 ccc eecesscesecsecsseceecseecaecsaecsaecaeeeseseaeseeeeseeeeenseeeseseseenaes 9 Figure 2 Expan
9. rack mounting an bos in Rack Options ianea a eee RAM a a E S 256 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Redundancy Switch Module RSM cesesseeeee 11 21 27 Redundant 2 systems W PC supervision cecceseeteeseeseeeseeseeeseees 146 C7OR controller MOGUIC ce eeseeeeeeeeeeeeeeneeeeeeaeeeeeees 26 COMPOMENtS isa is eho a ela ete Obs aaa 18 controller TACK riirii aasia aaa a aait 21 Controller Rack components cssccsseeeseeesteesseeesneees 21 defa ltgateWwaya nein AE E EE a 40 Ethernet CONNECTIONS snina a 143 example of single process cesccsssessteeeseesseesseeeseeess 11 failOVER ige s r E ESA S features hardWare esssessssrrrrresesrirrreserrreresserrrrrresee FONEtWOTK oniiir aeaea eaaa aaiae aeaaea apia 1 0 wiring NetWOKK ossee network connections Sa MIANO A e E EEE E N E E Operating characteristics cccceesesseeeseees 1 153 163 Peer tO peer iia i vaghvrlanc aetna 36 Power Status Module ee eeeeceesceeeeeseeeeeeeeeeeeneeeaeeeeees 25 power supplies Wiring Of cscccsscesseestessseesseesresees 57 power supply installation cccsccsssesssssesessteesneeeees 73 rack dimensions sser keai 48 Start UDr eai a aaee a r eae A Ei 163 steady state Operations ccccceesssceeeseeeeesteeeeeneeees 164 Relay Output Module Wiring ccscceeeeseeereees 117 119 Removal and Insertion Und
10. 8 point Universal Analog Input module Galvanically isolated input to chassis and input to input With the exception of RTD types which has four groups of isolation 1 2 3 4 5 6 7 8 4 channel Pulse Frequency Quadrature I O module Galvanically isolated channel to chassis 28 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Each I O module includes a status indicator for the module Digital Input and Digital Output modules also include a status indicator for each channel Terminal blocks available include the Euro style Figure 16 left and the Barrier style Figure 16 right For more information on I O modules and associated terminal blocks refer to the section in this manual on Input Output Installation and Wiring Personal Computer A Personal Computer is required to create the control and data acquisition strategy configuration file that runs in the controller using the Designer configuration software The PC can also be used to download upload configuration files to from the controller and can be used to download program updates to firmware in the Controller Module and or Scanner Modules e A PC can be connected to the controller via the RS 232 port for legacy system e For the new system a PC can be connected to the controller via the RS 485 to USB cable connected to RS485 Port which can be connected to external Honeywell qualified RS485 to USB converter and can also be networ
11. C70 C75 E1 192 168 1 254 E2 192 168 2 254 Must be on different subnets Set IP addresses and subnet masks Links to controller communication ports Refer to Table 17 and the figure in Step 2 above Port availability depends on Controller model Coniroller Port Connector Type Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector RS 485 3 Plug connector RS 485 3 Plug connector RS 485 3 Plug connector Table 17 Links to Controller Communication Ports Link Type Controller to Desktop or Laptop PC Modbus master controller is single slave Modbus master controller is one of multiple slaves Modbus slave network controller is master Operator interface Modbus master controller is slave Modbus slave network controller is master Cable Type RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 to RS 485 converter RS 232 to RS 485 converter RS 232 to RS 485 converter Belden 9271 or equivalent Belden 9271 or equivalent Belden 9271 or equivalent To Device Port Serial port of PC w Null Modem cable or Modem Refer to RS 232 Remote Connection to PC Configuration Tool on p
12. I Analog Input 16 pts 75 mA 50 mA I Analog Output 4 pts 40 mA 200 mA I Analog Output 8 pts 225 mA 350 mA 1 Analog Output 16 pts 350 mA 700 mA I AC Digital Input 16 pts 130 mA 0 mA I 0 DC Digital Input 16 pts 130 mA 0 mA I 0 AC DC Digital Input 16 pts 130 mA 0 mA I 0 Contact Input 16 pts 130 mA 40 mA I DC Digital Input 32 pts 215 mA 0 mA I 0 AC Digital Output 8 pts 220 mA 0 mA 1 0 DC Digital Output 16 pts 340 mA 0 mA 1 0 DC Digital Output 32 pts 235 mA 0 mA 1 0 Relay Output 8 pts 110 MA 100 mA 1 Pulse Frequency Quadrature 110 mA 250 mA 1 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 45 June 2015 Limit 10 4 channel Analog Output modules per I O rack Total mA 5V Total mA 24V Limit 4 PFQ modules per I O rack I Complete columns A D and E above 1 Is column D total mA 5V less than 2000mA Yes No 2 Is column E total mA 24V less than 900mA Yes No 3 If the answers to 1 and 2 are YES go to 4 If the answer to 1 or 2 is NO use power supply 900P01 0001 4 Multiple column D total by 5 1 5 Multiple column E total by 24 5 6 Sum results of 4 and 5 7 Divide results of 6 by 1000 8 Is the result of 7 less than 28 Yes No If the answer to 8 is Y
13. Table 7 Site and Equipment Preparation Step Procedure Reference 1 Verify that sufficient numbers of the following items are on hand Racks 4 8 and 12 slot Power Supplies 1 per rack or 2 per rack if redundant powered rack C30 C50 C70 Controller Module or Scanner 1 port 1 per rack Redundancy Each Controller Rack 2 Power Supplies 2 C75 CPUs 1 Redundancy Switch Module Each I O Rack 1 Scanner dual port module 1 Power Supply 1 reserve Power Supply optional 1 Power Status Module optional I O Modules correct type for each configured slot Terminal Blocks Barrier or Euro style 1 for each I O Module Jumpers 2 position or 10 position for designated Terminal Blocks Tie Wraps 1 or 2 for each Terminal Block I O Label one per terminal block by module type Filler Block Cover 1 for each slot not occupied by an I O Module Blank label 1 for each Filler Block Cover Grounding Bars for I O wiring shields 1 or 2 for each 4 slots in each rack Wiring terminal lugs for connecting I O shields to grounding bars Sheet metal screws steel 10 or M4 for mounting racks in enclosures 4 screws for 4 slot racks 8 screws for 8 or 12 slot racks e Section on Pre Installation Planning e Sections on installation Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 65 Step Pro
14. 37 OUT 14 18 ie 20 K Mm _ Com 2 Out 1 8 Com 2 Out 9 16 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 V1 V2 OUT 9 OUT 10 OUT 11 OUT 12 OUT 13 OUT 14 OUT 15 OUT 16 D DOOS OGS HHOoDOdoIdS Figure 62 DC Output Module Wiring Diagram lt D U me Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 111 DC Output Jumper 9 11 for one V Supply to both s groups of outputs Jumper 10 12 for one Common apanan Ground for all outputs Figure 63 DC Output Jumpers 112 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 32 point DC Output Wiring The DC digital Output module provides 32 externally powered outputs in 2 groups of 16 Figure 64 The outputs are high side switching current sourcing type Over current protection is provided for each channel in 4 groups of 8 channels In case of short circuit for any output channel that whole group of 8 is switched off Power cycling is not required to reset the module SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details A green LED on the module provides indication of an ON state for each output Requires Low Voltage Euro style 36 terminal terminal block
15. Controllers C30 C30S C50 C50S C70 C70S and C75 C75S Serial Interface Ports For legacy systems two serial ports S1 and S2 each configurable as RS 232 or RS 485 provides interfaces to a PC external modem Modbus devices or Operator Interfaces For new systems two galvanically isolated RS 485 serial ports S1 and S2 provide interfaces to PC using RS 485 to usb cable External modem or Modbus devices may be interfaced using RS 485 to RS 232 converter RS 485 interfaces to PC Control Stations or Modbus devices host Ethernet LED status indicators for communications functions Connection to I O port of Scanner Module C50 C50S C70 C708S C75 C75S only Second Ethernet E2 Host Connection to PC applications or peer HC900 controllers C70 C70S C75 C75S only First Ethernet E1 Host Connection to PC applications or peer HC900 controllers LED status diagnostic indicator for serial port S2 left LED status diagnostic indicator for serial port S1 right 10 LED status diagnostic indicator for controller module 11 Mode switch Pgm Run Pgm Run Not present on C75 C75S see RSM Figure 12 Controller Module Redundant controller rack contains two C75s or C75Ss Left CPU is designated CPU A right CPU is CPU B either CPU can be Lead 26 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Redundancy Switch Module
16. Manuals CD 900ME 1 0040 40 8 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction Functional Description All Controllers The Honeywell HC900 Process Controller is an integrated loop and logic controller that is designed specifically for small and medium scale unit operations It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range of process control applications The HC900 Process Controller can consist of a single rack as indicated in Figure 1 or can be can be networked with other controllers via Ethernet links to expand the dimensions of control over a wider range of unit processes as indicated in Figure 2 Although the HC900 E1 E2 ports provide protection against Cyber security DOS type attacks additional protection is required for safety applications using a firewall device configured to prevent uncontrolled messages into the controller Please refer to Ethernet Devices Considerations Section in this manual for further information The figures in this manual assume the firewall is installed properly above the controller s Ethernet connection s E1 and E2 Figure 1 Small HC900 Controller Configuration Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 9 June 2015 Introduction til Qualified Ethernet Switch i J 3 Figure 2 Expanded HC900 Controller Conf
17. OFFLINE RUN Function Block execution starts immediately Any calibration process that was in progress is immediately aborted and the results are discarded 160 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 File Download Upload Functions The following is a general description of file transfers between the controller and computer devices external to the controller A CAUTION Performing download procedures incorrectly could cause loss of control in an operating process or loss of data and program files in a controller Refer to the appropriate User s Manuals for download upload procedures Failure to comply with these instructions may result in product damage Two types of software files can be downloaded to the controller e Configuration files e Firmware files Configuration files can also be uploaded from the controller for archiving Firmware can only be downloaded to the controller Pathways for file transactions between the controller and computer devices external to the controller are shown in Figure 88 PC Configuration Tool Ol 900 Control Station Operator interface Host device w PC Configuration Tool Legend Firmware Download only Configuration Download Upload Figure 88 Pathways for Upload Download Transactions Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 161
18. Process amp Safety Controller Safety Manual for additional details Before installing be sure to determine power requirements See page 45 and 85 Requires Low Voltage Euro style 36 terminal terminal block Isolation The outputs are grouped with 4 outputs per group outputs 1 4 5 8 9 12 13 16 Groups are isolated from each other outputs are non isolated within each group 98 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring form power sources before servicing Failure to comply with these instructions could result in death or serious injury ee ZNI A COCHA OOOOODOOOOOOOOOOO YC QOOI Figure 53 8 channel Analog Output Wiring Diagram Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 99 June 2015 O gt Oo eas 1 i i ao I i i 1 1 1 1 Li Li O O E aioe OO Q AOOO a N COMO OOO OOOOOOODOOOOODO VY IO 1m 24VDC Figure 54 16 channel Analog Output Wiring Diagram DC Input Module Wiring The DC Input Module has sixteen inputs in two groups of eight inputs per group The groups are isolated from each other inputs are non isolated withi
19. Setting Position Function 1 OFF UP Normal DTR operations 2 OFF UP Verbal word results 3 ON DOWN Enable result codes 4 OFF UP Displays keyboard commands 5 ON DOWN Disables auto answer 6 OFF UP Modem sends CD signal when it connects with another modem 7 OFF UP Loads YO Y4 configuration from user defined nonvolatile memory NVRAM 8 ON DOWN Enables recognition smart mode 2 Connect the modem to a PC If your computer s RS 232 port has a 25 pin connector use a DB 25 male to DB 25 female RS 232 cable If your computer s RS 232 port has a 9 pin connector use a DB 25 male to DB 9 female modem cable Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected oOo ao Ff O Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key The modem should respond with OK 138 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Action 10 11 12 13 14 15 16 17 18 Key in the following command string AT YO Then press the ENTER key The modem should respond
20. blinking LED follow the actions described in the I O Module Diagnostic Indication page 184 An Al module s CJ temperature reading is indicating a thermal problem The scanner determines this problem not the Al module therefore the module s status LED will not indicate this diagnostic Possible reasons for this diagnostic are One of the two Cus on the module is indicating a temperature reading greater than 70 degrees C 2 Both cold junction sensors are failing to convert 3 The Cus are converting properly but their differential is greater than 10 degrees C No action is taken 1 Improve ventilation to rack 2 Replace Al module Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 181 Number Possible Cause Scanner Action User Action of Strobes 6 The scanner determined that a No action is taken Refer to the Bad I O Channel module has a bad channel In this Diagnostics on page 185 to condition the module s status LED determine the nature of the will not indicate the failure problem and possible user because the Scanner determines actions the condition not the module itself 7 One of the power supplies failed No action is taken Replace the power supply 182 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 I O Module Indicators Figure 93 I O
21. o 35 16 15 2s 16 9 10 i 11 ra 14 2 13 26 12 2 36 3 35 CON40 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 241 June 2015 16 Point Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect terminal block end of desired cable assembly to 16 point Analog Output module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long 9OORTC 3250 Remote Terminal Cable assembly 5 0 meters long Install 16 point Analog Output label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible 2 Mount RTPs to DIN rail Latch to rail See page 251 Connect cables to RTPs Cables are marke
22. use the Utilities Worksheet in the HC Designer software to select the modem as the current port A button will appear to allow you to dial a selected controller Current PC to Controller Connection Settings Port e c EMS ele us Loop Back Statistics Dial Xircom CardBus Ethernet 100 Modem 56 Modem Interface Protocol Honeywell Inc ELN Speed bps N A PC Port Setup 7 Network COM1 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 135 June 2015 Modem requirements Most commercially available modems can be used with the HC900 Controller The modem must have the following capabilities RS 232 interface Auto answer Can operate at 1200 2400 4800 9600 19200 38400 57600 baud recommended 9600 or 19200 or 38400 baud 8 data bits 1 stop bit and no parity Hardware handshaking can be disabled Software handshaking can be disabled Data Terminal Ready DTR input can be disabled Result codes can be suppressed Echo can be disabled Must be equipped with non volatile memory NVRAM so that settings that are configured using command strings can be retained during a power outage Must be able to load the NVRAM settings automatically on power up Cable requirements You will need an interface cable to connect the modem to the 25 pin connector be sure to use a DB 25 to DB 9 modem cable H TIP The Null Modem cable used to directly connect a PC running Designer Software to the control
23. 0 July 2014 SafetyWrite updates 4 0 June 2015 Support and Contact Information For Europe Asia Pacific North and South America contact details refer to the back page of this manual or the appropriate Honeywell Solution Support web site Honeywell Organization WWW Address URL Corporate Honeywell Process Solutions HPS Technical tips http www honeywell com www honeywellprocess com https vww honeywellprocess com en US explore products control monitoring and safety systems scalable control solutions hc900 control system Pages hc900 controller aspx Telephone and Email Contacts Area Organization Phone Number United States and Canada Honeywell Inc 1 800 343 0228 Customer Service 1 800 423 9883 Global Technical Support Global Email Support Honeywell Process Solutions Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com iv HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Symbol Definitions The following table lists those symbols that may be used in this document and on the product to denote certain conditions Symbol Definition This DANGER symbol indicates an imminently hazardous situation which DANGER if not avoided will result in death or serious injury This WARNING symbol indicates a potentially hazardous situation which if AX WARNING pot avoid
24. 4 twisted pairs of wires and a drain wire Each pair consists of a solid color wire and a color wire with a white stripe 2 For straight through cable arrange wires as shown in the following table Wires go straight through 3 Crimp an RJ45 connector to each cable end To ensure reliability do not untwist the pairs any more than necessary to complete the crimp connection Use care to ensure that the cable drain wire is securely connected to the shield of the RJ45 connector when the cable is crimped Reference the manufacturer s instructions 54 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Electrical Considerations All racks should be mounted in an appropriate metal enclosure A diagram that shows recommended wiring practice for the cabinet enclosure is given in Figure 31 Cabinet Wiring Single Chassis and Figure 32 Cabinet Wiring Multiple Chassis When Redundant power supplies are used in Redundant controller racks or I O racks separate line power sources are recommended to provide the highest level of redundancy and system operation Deviations from the installation conditions specified in this manual may invalidate this product s conformity with Low Voltage and EMC A WARNING Ay Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources Failure to comply with these instructions could result in death or serio
25. Boards associated with blocks from sources of power before I O Modules removing the terminal block from Hazardous Voltages the I O module Each signal at each of the Either A CAUTION terminals for an I O module has a Loss of control or view of Specific function Any or all of the Using trained personnel and signals may be vital for safely appropriate control mechanisms a running process controlling a process transfer to manual control for each signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON HAZARDOUS Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 81 June 2015 I O Module Installation Procedures Table 14 Connect Input Output Wiring Step Procedure Comments Reference 1 Using Rack Slot Channel data from a Mefa ORANGE WHITE TEXT Designer Software report Select Label fill in the tag names on the eoi os Fa GREEN WHITE TEXT Label for each configured i p I O Module Module slot ragnames Moreen were Text position should take heat de rating into account oO RED WHITE TEXT See Heat Rise De rating an page 51 GREEN W
26. Control Stations and PC SCADA software applications 9 RS 232 For legacy system Null modem cable up to 50 Third party suppliers or 15 24m PC modem cable if used with Modems Honeywell For new systems RS 485 to USB converter connects galvanically isolated RS 485 port to USB port Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 19 June 2015 Hardware Components This section contains general descriptions of each of the major components of the HC900 system For environmental specifications refer to the section on Pre Installation Planning HC900 Controller Rack An HC900 Controller local rack is shown in the following figure As indicated in this figure the Controller Rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3 Controller Module 4 Grounding bars for I O wiring optional 5 Input Output modules 6 I O Terminal Blocks Figure 6 Controller Rack Components 20 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 HC900 Redundant Controller Rack A HC900 Redundant Controller is shown in the following figure 1 Rack 2 Redundancy Switch Module RSM Interface between Lead Reserve controllers 3 Lead Reserve controllers Two C75 CPUs designated CPU A left CPU B right 4 Two 900P01 xxxx or 900P02 xxxx Power Supplies Figure 7 Redundant Controller Rack Components
27. Default IP address is 192 168 2 254 Default IP address is 192 168 1 254 Default IP address is 192 168 2 254 Software configuration software 1 O Single I O rack Shielded Ethernet C50 C70 Controller s I O No foreign messaging 100Base T CAT5 cable with RJ port to Scanner 1 s I O permitted 45 connectors port 1 O Single I O rack Shielded Ethernet C75 CPU A s I O portto No foreign messaging 100Base T CAT5 cable with RJ Scanner 2 s I O A port permitted 45 connectors C75 CPU B s I O port to Scanner 2 s I O B port Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 127 June 2015 O 100Base T 2 or more I O racks Shielded Ethernet CAT5 cable with RJ 45 connectors C75 CPU A s I O port to approved unmanaged switch From this unmanaged switch to each Scanner 2 s I O A port One 1 additional unmanaged switch may be used for a total of 2 unmanaged switches between CPU A and the I O racks C75 CPU B s I O port to approved unmanaged switch From this unmanaged switch to each Scanner 2 s I O B port One 1 additional unmanaged switch may be used for a total of 2 unmanaged switches between CPU B and the I O racks No foreign messaging permitted 128 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Connecting the Operator Interface to the Controller Using parts in Table 18 connect the Opera
28. Low Voltage Directive and 2004 108 EC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed EN61326 Electrical Equipment For Measurement Control and Laboratory use EMC requirements ATEX The apparatus fulfills the requirements for Group II Category 3 equipment in accordance with Directive 94 9 EC ABS Type Approval Certificate of Design Assessment No 06 HS186538 4 PDA June 2014 No 06 BA766694 X York Location No BY1100081X Pune Location HC900 control system is NOT to be used for direct propulsion steering navigation or safety systems The controller must be installed in a grounded metal enclosure and must not be used in non weather protected spaces Each application is to be approved on a case by case basis General Purpose Safety Compliant with EN61010 1 UL UL 61010 1 2 edition CSA C22 2 No 1010 1 Hazardous Classified Location Safety FM Class I Div 2 Groups A B C D CSA Class l Div 2 Groups A B C D Class 1 Zone 2 IIC Ex 113 G Ex nA IIC T Gc AMBIENT TEMPERATURE 0 C to 60 C Module Temperature Module Type T Module Type T Classifications Rating Rating Redundant CPU Rack T6 Scanner 2 T4 Redundant PS Ext Rack T5 Analog Input 8 channels T6 8 Slot Redundant PS Ext Rack T6 Analog Input 16 chan T6 12 Slot Redundant PS Ext Rack T6 Analog
29. Master Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed One RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up to the maximum 1024 parameters per controller Up to 32 Up to 1024 max per controller Selectable per device 1 second fastest load dependent Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 205 Communications C30 C50 C70 C75 Modbus Master Advanced Application Speed Recommended for use with gateway devices As fast as 500ms ATTENTION Safety Applications are required to use a properly configured firewall device Ethernet Modbus TCP Initiator Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed One Models C30 and C50 Two Models C70 and C75 RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up to the maximum 1024 parameters per co
30. Module LED indicators Table 30 LED Indications on I O Module Blinking Green Figure 93 item LED LED State Color Description 1 Module Status Off No power Solid Red Hardware failure Blinking Red Diagnostic Code refer to Table 31 I O Module LED Diagnostics Blinking Yellow At least one output is Forced Solid green Cold start with passing diagnostics Normal scanning 2 Channel LEDs one per input or Green On Off For Inputs indicates On or Off status output of the field input even if Forced to the opposite state For Outputs indicates On or Off status of the output including if Forced Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 183 June 2015 I O Module Diagnostic Indication To indicate the type of diagnostic failure the module s status LED is flashed red with a number of quick strobes followed by a long off time Table 31 outlines the potential module diagnostics A WARNING Ay Hazardous voltages exist at terminal blocks AO8 and AO16 modules require at least one channel to be configured prior to a cold start for the module to work properly Subsequent channels then may be added with a hot start Failure to comply with these instructions could result in death or serious injury Table 31 I O Module LED Diagnostics Numberof Failure Descripion Al AO DI DO PFQ User Action Contact AC DC Relay ac DC 1 FAIL SAFE The
31. O Wiring Type Terminal Block Styles Gauge wires Shield terminals Removable terminal blocks 20 screw Barrier or Euro style tin plated or gold plated for DC connections 36 screw Euro style gold plated Required with certain higher capacity modules 20 screw Barrier style 14 to 26 AWG solid or stranded Euro style 14 to 26 AWG solid or stranded 36 screw Euro style 12 to 26 AWG solid or stranded Optional brackets mounted top bottom of rack Power P01 Voltage Universal power 90 to 264VAC 47 to 63 Hz In Rush Current 7 Amps peak to peak for 150 ms at 240VAC Input rating 130 VA Output rating 60W Fuse Internal non replaceable fuse User installed external fuse Power P02 Voltage Universal power 90 to 264VAC 47 to 63 Hz In Rush Current 7 Amps peak to peak for 120 ms at 240VAC Input rating 90 VA Output rating 28W Fuse Internal non replaceable fuse User may install external fuse Power P24 Voltage 21 to 29VDC In Rush Current 30A for 3ms 29VDC Input rating 72 5W Output rating 60W Fuse Internal non replaceable fuse User may install external fuse Normal Scan Time 500ms Each analog input card has its own A D converter providing parallel processing Fast Scan Time 25ms for up to 250 fast 10ms for up to 250 fast 10ms for up to 330 fast 25ms for up to 500 fast logic blocks logic blocks logic blocks logi
32. Output is rated at 8A per module and 1A per output Limited to 4A per group of 8 ATTENTION The RTP combines the two groups of 8 outputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect desired cable to 16 point DC DO module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DO label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 233 16 Point DC Digital Output Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP 3 Set verify jumper positions as shown J6 C C C J3 J5 J7 J9 swm C C CO Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page
33. Power Supply Scanner Honeywell Rack Module and I O modules C50 C70 CPU only 3 Control Station 900 Control Station operator interface communicates Honeywell via Ethernet or galvanically isolated RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Serial Controller Module to a serial port on the PC software is from connection l Honeywell RS 485 to option e For new system The PC Configuration tool USB converter is a third connects from the galvanically isolated RS 485 port party device available of the Controller Module using an external from Honeywell Honeywell qualified RS 485 to USB converter 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMIs other HC900 Controllers and supplier HMI software is Interface other networks including Internet available from Honeywell Typically includes HMI operating software Experion HS or SpecView32 or from May also include Designer Software configuration tool third party supplier and utility software i 6 Qualified un Enables connection of the private Ethernet 100Base T Qualified third party managed port on a Controller Module to the Scanner modules devices available from Ethernet on 2 3 or 4 I O Expansion racks C50 C70 CPU Honeywell 100Base T only If a single I O expansion rack
34. RTP B connect the following terminals 1 22 2 23 5 24 6 25 13 26 14 27 17 28 18 29 Figure 107 Current connections with 2 wire transmitter Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 245 June 2015 32 Point DC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 32 point DC Digital Output is limited to 6A per RTP and 0 5A per output Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect terminal block end of desired cable assembly to 32 point Digital Output module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 32 point DC DO label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Mount RTPs to DIN rail e Latch to rail See page 251 e Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to outputs 1 16 RTP B to outputs 17 32 You can write on the RTPs labels to distinguish them Jumper open Jumper closed Module Removal Insertion Under Power RIUP is suppor
35. Reserve Power Supply and Power Status Module Note You can install redundant power on any 8 or 12 slot I O rack 41 0 Slots 900R04 EA eaa 81 0 Le Ley eT i TULE r 900R12 Se aes een auton ant L Scanner Module Slot 75 shown E Se Power Supply Slot beweneenne Power Status Module l req d if using Reserve Power Supply heii Optional Reserve Power Supply Power C75 RSM C75 Power Supply CPU CPU Supply Figure 9 Rack Options Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 23 June 2015 Power Supply The P0O1 Power Supply shown in Figure 10 provides 5 Vdc and 24 Vdc to the backplane connectors in the local and remote racks Power Supply is used in each Controller Rack I O expansion racks and for all rack versions 4 slot 8 slot and 12 Slot The lower capacity P02 power supply is available for reduced I O applications and for Redundant Controller rack power P24 power supply provides 5VDC and 24VDC to satisfy the power requirements of a single controller with I O a Remote I O rack or a Redundant C75 CPU The 60 watt capacity requires minimal de rating of the available HC900 T O modules A tool secured door covers the voltage connections An internal non replaceable fuse limits supply current under certain fault conditions Each power supply includes an internal 5 0 amp fuse that is not field replaceable An external fuse may be added
36. Single process with redundancies RedundantlO Communications ee S O Redundant CPUs Redundancy is provided by two C75 CPUs operating in a controller rack this rack has no I O A Redundancy switch module RSM sits between the CPUs Redundant CPU Power Two power supplies P0O1 and P02 one for each C75 CPU Model numbers are 900P01 0101 900P01 0201 900P02 0101 900P02 0201 Redundant CPU I O connection Each CPU has its own 100 base T Ethernet physical communication link with one or more racks of I O Multiple I O racks require Ethernet switches 1 0 racks 5 racks shown top to bottom 4 slot w 1 power supply 8 slot w 1 power supply 12 slot w 1 power supply 8 slot w redundant power supplies 12 slot w redundant power supplies A Power Status Module PSM is required with redundant power supplies High and low capacity power supplies are available Dual Networks for Host communications Dual Networks for Host communications are provided on the C75 CPU Both network ports are continuously active on the Lead controller The network ports on the Reserve CPU are not available for external communications Experion HS and the 900 Control Station 15 inch model support Dual Ethernet communications and automatically transfer communications to the opposite E1 E2 port during a network failure Connections to these ports are to be considered part of the control network layer and as such care must
37. Supplementary bonding of the controller enclosure to a local ground using a No 12 4 mm copper conductor is recommended This may help minimize electrical noise and transients that may adversely affect the system e Separate external wiring group connecting wires into bundles see Table 5 and route the individual bundles through separate conduits or metal trays e Use shielded twisted pair cables for all Analog I O Process Variable RTD Thermocouple de millivolt low level signal 4 20 mA Digital I O and computer interface circuits Ground shields as described in the section I O Module Installation and Wiring page 75 e Use suppression devices for additional noise protection You may want to add suppression devices at the external source Appropriate suppression devices are commercially available e Refer to document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments for additional installation guidance Grouping Wires for Routing Wires that carry relatively high electrical energy can produce unwanted noise in wires that transmit signals of relatively low energy particularly when they are placed parallel in long wiring runs Collect and bundle wires of similar type and route the bundle separate from bundles of other types Table 6 provides suggested guidelines for grouping wires Table 5 Guidelines for Grouping Wires Wire Group Wire Functions High voltage e AC Line power wir
38. The signal at the terminals is more than 10 over the range of the sensor Check the signal level being applied to the terminals Replace module Failing to convert When attempting to take a reading the ADC fails This could result if the incoming signal is either too large or small It also could result if the ADC circuit is failing If the problem is the ADC circuit most likely other channels will have the same failure Check the signal level being applied to the terminals Replace module AO Bad Channel The board indicates that the channel is failing to output the correct value Check terminal connections Replace module DO Bad Channel The number of configured channels in the DO function block exceeds the number of hardware channels on the DO card Reconfigure the DO function block Replace DO card with correct number of channels Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 185 Ethernet Switch indicators Table 33 LED Indications on Ethernet Switch LED LED State Color Description 10 100 Base T port Legacy XMT upper LED LINK lower LED Green On Off Green On Off On while a message is being sent from the Main CPU otherwise Off On while the Main CPU is receiving a message Remains On as long as host is present Off when the host is removed from the link New System
39. a a la t ie PERCE BERBUEBEOBEGBEBECEEGEGIL HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 W JAIOQOHOIOC IA OQA OOQ OOO 125 voc f Legend 5 External r s Disconnect s eee r wi i r OOOOQOQOCOOQOQQOQOQOQOQOQOQQQ QOQ Fuse D0 User Supplied Safety Deviceg i Figure 60 AC DC Isolated Input Module Wiring Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 107 Contact Input Module Wiring The Contact Input Module has sixteen inputs in one group An example of Contact Input wiring is shown in Figure 61 SIL applications require an external blocking diode used to insure inputs are protected from ground faults See HC900 Process amp Safety Controller Safety Manual for additional details Specifications for the Contact Input Module and other modules are given in the Specifications manual Internally Powered Input Channels The Contact Input Module provides voltage to the field contacts CAUTION Do not apply any external power to the field device or to the input terminals Doing so could damage the module Common terminals Four common terminals are provided for the 16 inputs Terminals 9 10 11 and 12 are connected in the Contact Input module A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices discon
40. and 32 point DO modules e Terminal blocks must be keyed by the installer to prevent high voltage terminal blocks from being installed on low voltage modules See Table 14 e Any of the color coded labels will fit into the door of any terminal block Use care to ensure that all hardware components match each other and also match the control strategy in the configuration file Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 77 June 2015 Remote Termination Panel RTP The optional Remote Termination Panel RTP provides an easy way to connect the HC900 controller to the field wiring The RTP integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I O modules See Appendix Installation of Remote Termination Panels RTPs page 215 for details Terminal Block to Field Signal Wiring Although both of the two available terminal block styles can be used on all I O module types wiring methods vary with the module type and with the type of field devices connected to the terminal block The descriptions that follow provide details Wiring can be routed through the terminal block at the top at the bottom or both Wiring should be fixed in place using wire ties at the slotted tabs that are molded in at top and bottom of each termina
41. and must be installed in a grounded metal enclosure Tools Required The primary tools required during installation are listed in Table 6 Table 6 Installation Tools Item Description Comments 10 11 Common tools Wire strippers Crimper Screwdrivers Small flat tip Small medium flat tip or Phillips Large long blade Other Electric drill with drill bits for 10 or M4 screws and with drill bit extender Vacuum cleaner brush Pen ball point or felt tip for entering data on labels for I O modules Multi Meter Volt Ohms Amps Soldering pencil or gun for attaching filter capacitors to I O wiring shields Special tools Precision meters For Power Supply and for I O Wiring For Terminal Lugs on Power Supply wiring and on I O wiring shields For Euro style Terminal Blocks For Barrier style Terminal blocks also for captured screws in Terminal Blocks For use as I O Module extractor For rack mounting For use during and after drilling operations For entering data on labels for I O modules For safety checks and for equipment test For attaching filter capacitors on I O wiring shields If required for testing Analog calibration refer to Analog Calibration in this manual 64 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Equipment Preparation A checklist for site preparation is given in Table 7
42. and or replace any I O module particularly in a system that is actively controlling a process In legacy systems all of the I O Module types in the HC900 Controller System include the Removal and Insertion Under Power RIUP feature That is while the rack is powered any of the I O Modules can be removed or inserted e With no physical damage to the module to the rack or to other modules in the rack e Without disturbing the functions of other I O modules in the rack or in the system Under carefully controlled circumstances this feature enables the user to remove and insert an I O module without completely shutting down a running system However it must be recognized that removing or inserting an I O module under power is potentially hazardous to property and to personnel In new systems the CPU and Scanner modules support RIUP Circumstances that dictate prudent actions depend on conditions and specific process applications at each user facility It is the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 13 provides some general guidelines for establishing appropriate procedures at a given installation Table 13 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s Potentially lethal voltages on Disconnect all signals at terminal A WARNING Ay Terminal
43. and user selectable I O module types Rack Mounting and Surface mounting with 4 screws in back of rack Installation Installation Category II Pollution Degree 2 IEC 664 UL840 Installation coordination Controller I O 4 8 or 12 I O slots per Rack None requires support remote I O racks Remote I O racks None 1 w o switch using Ethernet direct cable Up 1 wo switch using to 4 with recommended Honeywell switches Ethemet direct cable Up part no 50008930 001 50089785 001 to 5 with recommended 50089785 002 Honeywell switches part no 50008930 001 Remote I O interface None Separate Ethernet 100Base T port on CPU RJ 45 connection type dedicated communications link Remote I O Distance None 100 m 328 ft Ethernet cable controller to remote rack or controller to switch Up to two switches per connection 300m 984 ft and maximum distance 750m 2460 ft Fiber optic cable controller to remote rack or controller to switch Up to two switches per connection 1500m 4920 ft maximum distance Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 100BaseT X to 100BaseFX multi mode fiber port with SC connectors require 24VDC power Fiber Cable Multi mode Duple
44. as I O Expansion Network page 33 with the following exceptions notes e In Figure 21 any of the racks shown in each controller configuration can be 4 8 or 12 slot versions Redundant I O power not available with 4 slot e Double the amount of Switches and Ethernet cables are required to configure the redundant I O Link e Maximum of 2 switches between each CPU CPU A and CPU B and the I O racks Ethernet Open Connectivity Network The configuration of the Ethernet Open Connectivity Network varies with specific applications in purpose and in complexity In some applications configuration is straightforward and within the capabilities of experienced installation technicians In other applications for example those that include inter connection to other networks such as Intranet and Internet a working knowledge of networking is required The Ethernet Open Connectivity Network for a given HC900 Controller enables e Redundant Networks e Peer to peer communication e Connection to other PC hosts e Inter connection to other networks such as for sending Alarm Event messages via e mail e These ports are to be considered part of the control network layer and as such care must be taken to reduce exposure to uncontrolled network influences A properly configured firewall such as the MOXA EDR 810 is recommended to help mitigate CAUTION Communications lockout is possible in high network traffic conditions Extraneous traffic is p
45. be taken to reduce exposure to uncontrolled unknown network communications A properly configured firewall such as the MOXA EDR 810 is recommended to help mitigate the exposure Scanner 2 module has 2 ports one for each CPU connection to I O This IO network between the controllers and scanners is considered proprietary with no other Ethernet traffic Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 11 June 2015 Introduction Feature Summary Hardware e Modular rack structure components are ordered individually as needed e CPU with Ethernet and isolated RS485 communications e Easy to assemble modify and expand e C30 and C30S controllers provide local I O connections while C50 C70 and C50S C70S Controllers provide for remote input output rack connections over a private Ethernet linked network e Parallel processing a microprocessor in each I O module performs signal processing to preserve update rates e Power supplies provide power to CPU rack and Scanner I O racks Redundancy e Redundant C75 CPU e Redundancy Switch Module RSM required between redundant CPUs e Redundant Power Supply provides redundant power to any CPU rack or Scanner2 I O rack e Power Status Module PSM required when using a second power supply in Scanner2 I O rack Communications All CPUs except where noted e Serial Ports Legacy Two serial ports configurable for RS 232 or galvanical
46. blocks set their IO statuses to either Channel No Comm if the module cannot be communicated to or a message indicating the bad channel condition 3 Associated rack monitor block s module fail pin is turned on 4 Associated rack monitor block s RACK OK pin is tumed off 5 ASYS and FSYS blocks HW OK pins are turned off Locate the Scanner 2 that has a status LED indicating a diagnostic and follow the scanner 2 diagnostic section to solve the problem See the associated rack s Rack Diagnostics Overview display for details regarding the diagnostic See Rack Diagnostics dialog box Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 175 Number of Red Strobes Possible Causes Lead and or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication High temperature condition in a Scanner 2 rack has been detected 1 Associated Al blocks that are configured as T Cs set their fail pin on their wam pin off and their output pin to the failsafe value 2 Associated Al blocks that are configured as T Cs set their IO status to either CJ High Temperature if one of the two CJs on an Al card is indicating a temperature greater than 70 degrees C CJ Failure if both CJ sensors are failing to convert 3 Associated rack monitor block s module fail
47. by the user See page 22 Items shown with key numbers WARNING 1 Voltage test points PO1model only LOCK HAZARD MAY BE REQUIRED TO A DE ENERGIZE UNIT 2 AC DC Input terminal block y SV GND 3 Wiring label 4 Grounding lug Reference lug is not part of Power Supply it is staked to bottom of Rack Figure 10 Power Supply 24 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Power Status Module PSM The Power Status Module PSM Figure 11 sits between redundant power supplies on the T O rack see page23 It is a status module for both power supplies and indicates which are in use PS 1 left or PS 2 right or both typical When the status indicator for either or both of the power supplies is lit it is reporting that the status of the associated power supply is good and that the outputs are within specified limits When the status is off either the power supply is off or the voltages are out of tolerance Figure 11 Power Status Module PSM Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 25 Controller Module C30 and C30S C50 and C50S C70 and C70S C75 and C75S Controllers share the same features with exceptions noted CPU model number C30 and C30S C50 and CS50S C70 and C70S C75 and C75S Lithium battery battery tray which is readily accessible for field replacement Battery tray on
48. failover Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 165 June 2015 Lead Controller Reserve Controller Get Inputs Get Inputs SYNC SYNC Control SYNC Control SYNC Execute Control Strategy Execute Control Strategy Write Outputs Diagnostic Check Diagnostic Check Communications Figure 90 Lead Controller synchronization Failover Automatic Failover e Triggered on any of the following conditions of the Lead Controller Loss of communications with I O Rack s Processor exception conditions e Error conditions that occur in the following areas will not cause a failover Loss of communications to a Host on a network Loss of communications to Modbus Slave devices Loss of communications to Operator Interface Loss of communications with a Peer controller e During the transition from the Lead to the Reserve analog and digital output status is maintained at the T O racks 166 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Manual Failover e Via Key Switch on the Redundancy Switch Module in the Redundant Controller Rack When doing manual failover with keyed switch turn key to Failover and hold it there until both Reserve lights are on then release the key e Via Software Command from HC Designer amp HC Utilities PC Software e Via Software Command from Modbus TCP amp Serial Modbus RTU Hosts e Via Software Command f
49. fuse with UL CSA approval for 250 VAC A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 114 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Legend External Disconnect m User Supplied Safety Device Out 1 H Out 1 NO F Out 2 H r aa Ya Out 2 NO Q Out 3 H 8 Out 3 NO Out 4 H e Out 4 NO Out 5 H 10 Out 5 NO 11 Out H N Out 6 NO A a Out 7 H 13 Out 7 NO 14 Out 8 H gt z Out 8 NO CEDO Figure 65 AC Output Module Wiring Diagram Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 115 AC Output Figure 66 AC Output Module Jumper 116 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Relay Output Module Wiring The Relay Output Module provides eight individually isolated electromechanical relay outputs Four of the outputs are Form C and the other four are Form A A schematic showing the relationship of individual Form A relays and Form C relays to external user connections is given in Figure 67 SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safe
50. has 5 or 10 sockets software and memory resources each of which can service data requests from any networked PC on a client host server controller basis The sockets are available on a first come first served basis Typically when the data service for any PC Host request is completed or times out it allows the socket to become available to any other PC Host in the hierarchy of networks Note PDE communications discussed previously do not use the PC host connection sockets PDE communications are separate from and are transmitted concurrent with PC host to controller communications Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 37 June 2015 The PC host can include software that closely relates to and supports controller functioning and can also include other software that is related remotely or not at all Closely related software can include Either Designer Software for generating and managing configuration files Or HMI Supervisory Data Acquisition Software or Operator Panel with Modbus TCP driver Or Both configuration and HMI software and or panel All communications between a controller and a PC host use Open Modbus TCP protocol whose widespread use is making it an industry standard Modbus TCP is basically an adaptation of the Modbus messaging structure that uses TCP IP for a message carrier In general Modbus messaging is available in two versions ASCII in whi
51. is the Safety mode for Safety controllers and the proper normal operational mode for all controllers RUN PROGRAM Mode Unlocked In the Run Program mode steady state tasks are executed and on line configuration edits are permitted Configuration changes made in this mode are retained in both RAM and Flash memory in the controller The Run Program mode should be used only when changes are anticipated The Run Locked mode is the preferred operational mode to prevent any unintentional changes PROGRAM Mode Locked In the program mode all outputs are turned OFF function blocks do not execute and configuration changes are permitted Exiting the Program Mode performs a cold start which clears all timers counters totalizers and other function blocks with residual data Function blocks are initialized to their initial state with no reference to previous history Exiting the Program mode updates the RAM and Flash memory of the controller with the most recent configuration data Steady State Operations e Lead Controller issues polls to I O Racks for inputs e Both Lead and Reserve read I O responses from I O Racks e Lead and Reserve both execute function blocks in the control strategy e Only the Lead Controller writes physical outputs to the I O Racks e Lead Controller responds to communication messages from host devices on the Supervisory Network and RS 4835 interfaces e Lead Controller handles communications with HC900 peers e Lead Cont
52. modueis inthe failsafe state V V v Viv v v Jv v 1 If expansion I O rack go to step 2 because itis not receiving message If no expansion I O rack go to requests from the CPU or Scanner step 3 at a rate that satisfies the configured 2 Check the Scanner status LED failsafe tmeout see p 179 If it s flashing 6 times proceed with step 3 If it s flashing some other red status code refer to Table 29 to solve that problem first If it s flashing green the module probably is not required in the configuration If it s not on or steady cycle power to the scanner 3 Make sure the module is the correct one for the configuration 4 Remove the module and check for a bent pin then reinsert the module 5 Replace the module 6 Remove other modules and replace one at a time until the problem reoccurs Most likely the last module inserted needs to be replaced 7 Replace the rack 2 EAROM EA ROM Failed its checksum V v 1 Remove reinsert module 2 Replace module ROM Vly VW IV Vv iV 1 Remove reinsert module 2 Replace module 5 24V V v IN V 1 Remove the module and check for a bent pin then reinsert the module 2 Measure power supply voltage If not correct replace power supply 3 Replace module 4 Replace rack 6 FACTORY CAL CRC failure of primary and backup V v Replace module factory calibration 7 FIELD CAL CRC failure of field calibration Vv v 1 Remove reinsert module values 2 Replac
53. peer data exchange does not consume a host connection Up to 10 shared between two ports peer data exchange does not consume a host connection RS 232 Port Ports per controller Baud rates Modem RS 485 with Modbus RTU or Honeywell protocol 3 Plug connectors supplied 1200 2400 4800 9600 19 2K 38 4K 57 6 K 115 2K configured by Designer software or Ol For remote connection to Designer software requires external modem at controller 1200 baud to 57 6KB Galvanically Isolated RS 485 Ports Ports per controller Cable type 1042 559 Distance from controller 1042 559 Power to Ol Unit addresses Two connector supplied Honeywell or Modbus RTU protocol Only one port for 1042 559 operator interface support 2 wire plus shield Belden 9271 or equivalent 2000 ft 600 m 24VDC user provided at Ol 1 to 247 Galvanically Isolated RS 485 Ports Parity user selectable Stop bits user selectable Speed user selectable Double Register Format for Modbus RTU Slave and Master data User selectable Odd even none 1or2 1200 2400 4800 9600 19200 38400 57600 115200 Selectable byte order RS 485 Modbus Slave Operation Number of ports per controller Masters per port Principal Function Block Address Range Up to two One User selectable starting address range for registers assigned to each principal block type RS 485 Modbus
54. pin is turned on 4 Associated rack monitor block s RACK OK pin is tumed off 5 Associated rack monitor block s HITEMP pin is turned on 6 ASYS and FSYS blocks HITEMP pins are tumed on 7 ASYS and FSYS blocks HW OK pins are turned off Scanner 2 has a CPU or Memory diagnostic 1 Associated rack monitor block s RACK OK pin is tumed off 2 ASYS and FSYS blocks HW OK pins are tumed off See CPU or MEMORY in the associated rack s Rack Diagnostics Overview display See CPU or Memory in Rack Diagnostics dialog box A Scanner 2 rack has a bad power supply 1 Associated rack monitor block s RACK OK pin is tumed off 2 ASYSandFSYS blocks HW OK pins are turned off Locate the Scanner 2 that indicates a bad power supply diagnostic and replace the defective supply See POWER SUPPLY DIAGNOSTICS in the associated rack s Rack Diagnostics Overview display See Power Supply Diagnostics in Rack Diagnostics dialog box 176 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 8o0r9 If8 flashes the S1 1 ASYSandFSYS blocks HW 1 Check baud rate serial port is reporting a OK pins are turne
55. processing system monitoring functions etc and cannot be changed by the user Starting with function block number 101 the user may select the type of function to be executed e The sequence of function block execution is initially determined by the sequence in which the function blocks are placed on the graphic diagram in HC Designer Final desired sequence must be set by the user to achieve proper and optimum performance A CAUTION Incorrect execution sequences can contribute to delays in processing outputs and or improper or unexpected operation e The HC900 controller samples all inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The sequence order of the function block determines when in time the actual value will be updated It is important that algorithms that need updated input values for their calculations have the inputs execute first in the sequence e Except for Time Proportioning Output TPO Three Position Step Control TPSC and Position Proportional Output PPO function block types that update their physical output values while the function blocks are being executed all physical outputs are updated at the end of a scan Controller Modes The HC900 Controller includes three operating modes The purpose of each mode is described immediately below and salient characteristics of each are described in Table 22 The functions
56. stored Sequences is user configurable Recipes Variables Number of stored Recipes Variables is user configurable Recipe Parameters Up to 50 analog or digital Variables may include profile numbers Signal Tags Read only Up to 65 535 Tag Identification 16 character tagname 16 character descriptor 6 character units of measure analog only 6 character on off state digital only Variables Read Write Up to 2048 Variable Identification 16 character tagname 16 character descriptor 6 character units of measure analog only 6 character on off state digital only 204 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual Communications C30 C50 C70 C75 Network Communications Ports Number of Ethernet 1 1 2 2 10 100Base T connections Ethernet 10 100Base T RJ 45 connection ATTENTION Safety Applications require a properly configured firewall device Max number of concurrent Ethernet host connections Supports Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Initiator Peer to Peer and Designer Software configuration software Supports redundant Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Initiator non redundant Peer to Peer and Designer Software configuration software Up to 5
57. string AT EO Q1 swo The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller 142 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Connecting C75 Redundant Ethernet to a PC with Designer Software or other applications Only use Shielded CAT 5 cable for network connections See Figure 80 and Table 20 Gimmes Fea 168 HOUT Figure 80 Redundant Networks see Table 20 ATTENTION Always observe the wiring cabling guidelines on page 53 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 143 June 2015 Table 20 Redundant Network connections in Figure 80 Key No Connection Description la Connect CPU A E1 port to Ethernet switch 3a 1b Connect CPU B E1 port to Ethernet switch 3a 1c Connect Ethernet switch 8a to PC Ethernet port 2a Connect CPU A E2 port to Ethernet switch 3b 2b Connect CPU B E2 port to Ethernet switch 3b 2c Connect Ethernet switch 8b to Ethernet port 3a Ethernet s
58. terminal block from the module Using the extractor loop on the cover on the module pull the module from the slot as shown in the illustration at right As shown in the illustration a long flat tip screwdriver is used as an extraction lever Insert the screwdriver tip into the extraction tab on the front of the module cover and rotate the screwdriver handle toward the back using the top edge of the rack as a fulcrum Verify that the replacement module is of the proper type Then carefully insert it into the slot in the rack so as to make proper contact with the connector in the backplane Replace the terminal block on the module If the rack was powered down for the procedure restore power to the rack Re connect signals to field devices 198 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Battery Installation Replacement Advisory Regarding Battery Installation Memory for the CPU in the Controller Module includes e Volatile memory and e Non volatile memory Flash Only volatile RAM requires battery backup When power is applied to the Controller Module the CPU is initialized automatically If the batteries are is installed after initialization and if site power is maintained the current draw from the battery is very low approximately 4 microamps If site power is disconnected with the batteries in place and with the CPU in the initial
59. used for an RTD input at channel two terminals 4 and 5 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 89 June 2015 Figure 44 and Figure 48 show examples of RTD input wiring 2 wire and 3 wire RTDs Four wire RTD inputs are not available RTD 3 Wire Input RTD 3 Wire Input Figure 44 RTD Inputs OHMs Inputs Ohms inputs are wired similar to 2 wire RTD inputs That is they require a current source and thus must use one of the Iprp current sources Also two terminals are jumpered together as they are for two wire RTD inputs Analog channels wired for Ohms inputs differ from RTD inputs in these aspects e Ohms inputs connect to variable resistance devices other than RTDs and e Ohms inputs are configured in Designer Software as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in Figure 48 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 90 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 RTD 3 Wire Input IN 1 Thermocouple leo 1 amp 2 Input IN2 zs T IN
60. wanted messages and denying passage of all others The feature that gives the Router its name is it enables translation of IP addresses which enables networks with dissimilar network IP addresses to communicate as though they were members of the same network This feature is particularly useful when an HC900 Controller LAN is installed under local addressing rules That is IP addressing can be assigned without approval of or conflict with world Internet governing bodies A default IP address is provided in each HC900 Controller 192 168 1 254 Later when connecting to networks with more stringent addressing requirements it is necessary only to configure the Router with address mapping and connect it between the existing LAN and the other existing network Connections to other networks vary in purposes and methods some of these are described below E Mail Communications The HC900 Controller includes e mail software that enables communication of Alarms and Events to up to three Internet addresses Implementing this feature consists of e Using the Designer Software to configure Alarm Groups and Event Groups Assignment of specific alarms to priority and e mail enabling E Mail address lists SMTP mail server IP address Default gateway must be configured in order to send e mail With redundant controllers two default gateways need to be configured one for each of the redundant networks assuming both are being used
61. with OK Key in the following command string AT amp B1 Then press the ENTER key The modem should respond with OK Key in the following command string AT EO Q1 amp WO The Modem will not respond Power down the modem and disconnect it from the PC Set the modem switches to the following Switch Setting Position Function 1 ON DOWN Modem ignores DTR Override 2 OFF UP Verbal word results 3 OFF UP Suppresses result codes 4 ON DOWN Suppresses echo 5 OFF UP Modem answers on first ring 6 ON DOWN CD always ON Override 7 OFF UP Loads YO Y4 configuration from user defined nonvolatile memory NVRAM 8 OFF UP Disables command recognition dumb mode Connect the modem to the Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Designer Software Set up Designer Software to dial the HC900 Controller Verify that communications is established with the remote HC900 Controller Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 139 Zoom 56K Dualmode External Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 25 pin connector use a DB 25 male to DB 25 female RS 232 cable If your PC s RS 232 port has a 9 pin connector use a DB 25 male to DB 9 female modem cable 2 Connect power to the modem 3 Power up t
62. 0 92 MV 0 100 mV 0100 95 MV 10 10 mV 10 10 89 MV 50 50 mV 50 50 93 MV 100 100 mV 100 100 96 MV 500 500 mV 500500 98 V 0 1 V 01 101 V 0 2 V 02 103 V 0 5 V 05 105 V 0 10 V 010 108 V 1 5 V 15 107 V 1 1 V 1 1 102 V 2 2 V 2 2 104 V 5 5 V 5 5 106 V 10 10 V 10 10 109 Carbon 0 1250 mV n a Oxygen 30 510 mV n a 210 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 System Sizing and Availability Summary Table 42 System Size and Availability Summary Specification C30 C50 C70 C75 Combined Analog and Digital I O 384 points 1920 points 1920 points 1920 points Analog Inputs 142 points 960 points 960 points 960 points Analog Outputs 40 points 200 points 200 points 200 points Block inputs Quantity based on available memory Block parameters Quantity based on available memory Block values 375 000 375 000 375 000 124 998 FDB worksheets 20 20 40 40 Function blocks 400 2000 5000 5000 Local I O Yes Yes Yes No Loop blocks Quantity based on available memory Modbus registers used by slave blocks 1024 1024 1024 1024 Modbus slave blocks 32 32 32 32 Numeric constants Quantity based on available memory Page connectors 200 1000 2500 2500 Peer blocks 32 32 32 32 Peer data exchange items 2240 2240 2240 2240 Position proportional
63. 0 LED LED State Color Description item Scanner Status Off No power Solid Red Failed Blinking Red Diagnostic Code refer to Table 29 Scanner LED Diagnostics Solid Green Startup Mode Blinking Green Scan Mode 3 LINK lower LED 10 100 Base T port 2 XMT upper LED Green On Off Green On Off On while a message is being sent from the Main CPU otherwise Off On while the Main CPU is receiving a message Remains On as long as host is present Off when the host is removed from the link software NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by Scanner Diagnostic LED Indication The scanner uses its LED to communicate diagnostic information These diagnostics are a subset of the main CPU s and are listed below Table 29 Scanner LED Diagnostics Number of Strobes Possible Cause Scanner Action User Action 1 RAM or ROM failed diagnostics on power up Executes an infinite loop that toggles the LED Communications and module scanning are disabled Module outputs are in the power off state DO outputs are off and AO outputs are at zero milliamps 1 Cycle power 2 Replace scanner 3 Replace rack 4 Check grounding 5 Ensure system is properly isolated from noise Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 179
64. 0 to 20mA 4 channel 900B01 0301 Yes Analog Output 0 to 20mA 8 channel 900B08 0202 Yes Analog Output 0 to 20mA 16 channel 900B16 0202 Yes Digital Input Contact type 16 channel 900G01 0202 Yes Digital Input 24VDC 900G02 0202 Yes 16 channel Digital Input 120 240 VAC 16 channel 900G03 0202 Yes Digital In 120 240 VAC 125VDC 900G04 0101 Yes 16 channel lsolated Digital Input 24VDC 900G32 0101 Yes 32 channel Digital Output Relays 900H01 0202 Yes 8 channel Digital Output 24VDC 900H02 0202 Yes 16 channel Digital Output 120 240 VAC 8 channel 900H03 0202 Yes Digital Output 24VDC 32 channel 900H32 0102 Yes Pulse Freq Quad 4chan 1Quad 900K01 0201 May be used in Safety systems on the Process Worksheet ONLY Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual Introduction Reference only For the latest Hardware and firmware revision numbers can be found at www honeywellprocess com library support Public Downloads HC900 SafetyControllerModulesRevisions zip https Low VoltageTerminal Block Euro style 9O00TEK 0101 Yes Low VoltageTerminal Block Barrier style 900TBK 0101 Yes High VoltageTerminal Block Euro style 900TER 0101 Yes High VoltageTerminal Block Barrier style 900TBR 0101 Yes High Density Terminal Block Euro style 900TCK 0101 Yes Filler Block Terminal Co
65. 01 M SC Copper HC900R Copper IMC 101 M SC Distance 750M WO Rack Figure 97 Extended Distance Example 2 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 213 June 2015 Appendix Installation of Remote Termination Panels RTPs Overview The Remote Termination Panel RTP provides an easy way to connect the HC900 controller to the field wiring The RTP integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I O modules There are three RTP types See page e 8 Analog Input e Relay Output 216 223 e 16 point Analog Input Digital Input Digital Output Analog Output 227 HC900 Controller Cable various r lengths available Shield drain wire RTP mounted on Terminals for field A DIN rail wiring 111mm 4 38 Figure 98 Example installation not shown 2 RTP amp cable for high capacity Al DI DO 215 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Analog Input 8 Point Analog Input step 1 ATTENTION RTP is not for use with thermocouples ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from te
66. 238 for RTP internal schematic 234 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 Point DC Digital Output Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 Install jumper wire DC Supply Note DC Outputs provide electronic overload protection in the module but adding a fuse see picture protects the wiring Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 235 June 2015 8 Point AC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 8 point AC Output is limited to maximum of 2A per output for any VAC 6A per RTP for 240VAC 8A per RTP for 120VAC ATTENTION The RTP combines the 8 isolated outputs into one group of 8 Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect desired cable to 8 point AC DO module at controller Choose from 9OORTC H010 Remote Terminal High Voltage Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 8 point AC DO label into the module connector cover Connect shield drain wire to the grounding ba
67. 3 N a leo 3 amp 4 e Ohms IN 4 E Input N4 n E leo 5 amp 6 IN 6 Ee N mV V Pis E Input N7 Esa leo 7 amp 8 Nae N8 4 20 mA Input Figure 45 Universal Analog Input Wiring Diagram Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 91 June 2015 RTD 3 Wire Input cabelas RTD 3 Wire aaae Input prmeceeeee IN 2 _ j opmmens IN 2 z H IN 3 cunwecenwes N2 RTD 3 Wire en Input nazil i Le fennnnnnn N7 menget 788 H i d RTD 2 Wire i Input i Jumper Figure 46 Examples of RTD Input Wiring IN 1 INi La 1 amp 2 IN2 IN2 IN 3 IN3 Lap 3 amp 4 IN 4 IN4 IN 5 IN5 lm 5 amp 6 IN 6 IN6 IN7 IN7 haw 7 amp 8 IN 8 N8 A A J aolo lona aanl NaN oao 92 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Thermocouple Inputs OOG Shield Ground F typical Figure 47 Analog Input Wiring Eight TCs Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 93 June 2015 Resistance Thermistor Inputs QO Shield Ground typical GOOCDOOOOS Figure 48 Analog Input Wiring Eight Resistance Inputs 94 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Resistance Temperature Device Inputs IN 1 lt
68. 3 compatibilityi secesceiienin ahaa 8 1 0 implementation ccccccsseeseesessscesesesesessessessteeeseess 35 MO eM issocsdisie cecsasssontemtvedeveeteyontemias cetetaaccenste 136 137 138 I O Installation Procedures ccccccccsscecssscsssesessseseessseeees 82 Module Placement cccccccccssssssccsecessssssseseessssseeuseeeeeees 76 1 0 Module Diagnostics cccccseseessesseesesessssesseseeenes 184 Module Wiring s aa aeae aa e e i a aa 89 1 O Module Installation 1 58 66 76 mounting rackse eiaa heehee Ree 67 1 O numbering assignMent ccccsccescesesessesssseseseeseeees 35 I O rack address c ceeesceeeeeees N 1 0 Slot ich escasieccases 1 0 Wiring Null Modem Cable ccccccccsssessssscsssessscesssssessssssasescees 132 1 0 wiring shields Input Output Modules cceeeseesecsssessesseeseeeesesseeseeens 28 o Installation Tools e a na aa 64 Ty Co EEE E EE TE 39 OFFLINE Mode oeccccccccccccccccccccccccceccecccccccccccecccscccsecsecsecesees IPeAGOROSS ianeirensis ai RAEE EEEE NEAN EELE 36 OHMS INpuls errioan a n aR E1127 OP CZeta HO E AE AA E2127 OPC server client software a A pete E P E N T 90 Open Modbus TCP protocol isolati n CA PACITOM asenna on n ast A 79 Operating Characteristics a er IT networking professional ccccccscecssessseeeseessseeesseeees 30 Operating Modes c cccccccccsssssesseesesseesssessstsseseteseeees operator interface J CONNEC tO controller ieie JUMPE aisses
69. 48 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 i L Figure 28 Vertical Spacing of Racks all models Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 49 Remote Termination Panels If your controller will be mounted in a separate panel with intermediate terminations between field wiring and controller wiring consider using RTPs to replace the intermediate terminations Pre wired cable assemblies for the RTPs eliminate the need for separate wiring terminations between the controller and the intermediate terminal boards For details see page 215 Environment The HC900 Controller must be mounted in suitable equipment enclosures That is all components such as the Controller rack I O Racks and the 900CS Control Station manufactured by Honeywell must be mounted in approved furniture designed for industrial applications Consideration should be given to the installation so that the potential for the build up of static electricity is minimized or eliminated See Environmental Conditions and Approvals on page 207 50 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Heat Rise De rating The HC900 is rated to operate at 60 C However for maximum reliability the following guidelines should be observed for applications above 52 C 1 Locate lower power modules Analog Input
70. 6 pt DC Out 1 7 1 2 2 9 32 pt DC Out 1 2 1 8 3 0 AC In 120V 0 7 1 9 2 6 AC In 240V 0 7 7 7 8 3 AC DC In 0 7 7 7 8 3 AC Out 1 1 12 0 13 1 PFQ 6 7 0 1 6 8 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 51 June 2015 DAO VAC saacanna 264 VAC nsnnsnnnens 0 5 10 15 20 25 30 35 40 45 50 5 60 Temperature C gt Figure 29 AC Input Module de Rating 12 Number of 40 per Rack gt o 5 10 15 20 25 30 35 40 45 50 55 60 Temperature C Figure 30 Power Supply de Rating HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Cable Wiring Distance Planning For all installations observe the following guidelines Maximum length of RS 232 cabling Controller to PC is 50 feet 15 2 meters Maximum length of RS 485 cabling is 2000 feet 609 6 meters For Ethernet connections cable length must be less than 100m For greater than 100m a switch is required The use of Ethernet cables in excess of 100 meters and or devices other than recommended Switches will cause transmission delays on the I O link which could have adverse affects on Controller performance You can also use fiber optic cable for connections between the controller and a remote rack Distances up to 750m 2460 ft can be accomplished with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a rep
71. 600C 30 S 0 3100 F S 322912F 31 T 184 371 C T 200 400C 40 T 300 700 F T 328 752F 41 T 129 260 C T 50 150 C 34 T 200 500 F T 58 302 F 35 W_W26 20 2320 C W_W26 20 2320 C 52 W_W26 4 4200 F W_W26 44208F 53 W5W26 18 2316 C W5W26 20 2320 C 54 W5W26 0 4200 F W5W26 44208 F 55 W5W26 18 1227 C n a W5W26 0 2240 F n a Platinel 0 1380 C PLTNL 01380C 118 Platinel 32 2516 F PLTNL 322516F 119 Platinel 0 750 C PLTNL 70 750 C 116 Platinel 32 1382 F PLTNL 94 1382 F 117 Pt100 184 816 C Pt100 200 800 C 68 Pt100 300 1500 F Pt100 328 1472 F 69 Pt100 184 649 C n a Pt100 300 1200 F n a Pt100 184 316 C Pt100 50 150C 60 Pt100 300 600 F Pt100 58 302 F 61 Pt500 184 649 C n a Pt500 300 1200 F n a Pt1000 40 260 C Pt1000 50 400 C 120 Pt1000 40 500 F Pt1000 50 752 F 121 JIS100 200 500 C JIS 200 500C 78 JIS100 328 932 F JIS 328 932 F 79 JIS100 200 260 C JIS 0O 100C 72 JIS100 328 500 F JIS 32 212F 73 Cu10 20 250 C Cu10 20 250 C 84 Cu10 4 482 F Cu10 4 482F 85 YSI405 10 37 8 n a YS1405 50 100 n a Ohms 0 200 Ohms 0 200 86 Ohms 0 500 n a Ohms 0 1000 n a Ohms 0 2000 Ohms 02000 87 Ohms 0 4000 n a MA 4 20 mA 4 20 100 MA 0 20 mA 0 20 99 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 209 June 2015 Type Range Range High EU Reference Corresponding Low UMC800 Input type and range MV 0 10 mV 0 10 88 MV 0 50 mV 0 5
72. 86000 No SSS TO Scanner 1 Por T per UO rack 800550 086000 no SSS PowerSupis OO O O O OSS SSS CA E NCS CA E NCS C T Reference only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library support Public Downloads HC900 SafetyControllerModulesRevisions zip 4 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction SIL System Description Model Number SIL Compatible Racks 4 I O Slot Rack 900R04 0200 Yes 8 I O Slot Rack 900R08 0200 Yes 12 I O Slot Rack 900R12 0200 Yes 8 Slot Rack Red Power 900RO8R 0200 Yes 12 Slot Rack Red Power 900R12R 0200 Yes Redundant CPU Rack 900RRO 0101 Yes Controllers Controller C30 CPU SIL 900C30S 0360 00 Yes Controller C50 CPU SIL 900C50S 0360 00 Yes Controller C70 CPU SIL 900C70S 0360 00 Yes Controller C75 CPU SIL 900C75S 0360 00 Yes I O Scanner 1 Port 1 per I O rack SIL 900S50S 0360 00 Yes I O Scanner 2 Port 1 per I O rack SIL 900S75S 0360 00 Yes Documentation Full Document set on CD SIL 900ME1S 0060 00 Yes Full document set SIL hard copy 900ME2S 0060 00 Yes English VO Modules Analog Input 900A01 0202 Yes 8 channel Analog Input Hi level 16channel 900A16 0101 Yes Analog Output
73. A ST 163 S Ue a a a a A a EE nee rc eee ere 163 Modes of operation Figure 87 ccccceessececeeseeeeeeeeeeeeeeeaeeeeeesaeeeeeesaeaeeeeaeeeeeeseseseeseeaeeeeneeseseeneeaeeeeneaes 163 Steady State Operations acc leed ane ta gets dee caee aaa a aae a aaa aa aa ae a aaa eaaa 164 FallOVer i oii a E N die ule eta el en au AE VOEE ETE AEA TAA le 166 File Download Upload Functions sesiones anar a a E A AAE T EE 167 Diagnostics and Troubleshooting ssssesssseeneeeeseeetrrrrnrnessetrnrnnnrnnneertnnnnnnnnnneeeennnn 169 OVEIVIOW hioin a a a a aa a a a a dns See ee ee 169 External Indications of Diagnostic Information eee cceceeeeeeeeeeeeeeeeeeeeeeeeeeeee eee eeeeeeseaeeeeeeeeaeeeseeeaeeeeneeaees 169 Controller CPU indiCators cccccccecceeeeeeceeeeeceeeeeeeaeeeeeaeeaeeeceaeeeeaaesaaaeesaeeecaaeseeaaesdeaeesseeeecaeseeaesseaaeesenees 170 Scanner indicators aiina iaaea ety en Hebei dae aa ra in Gree behets aa aaea aga ATASA 178 VO Mod le Indicators s torerninr in n ees e ia oe ee ee VS 183 OINA E E EE E A N E A T 188 viii HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Removal and Replacement Procedures ccccccccceeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeenaaees 192 CVEIVICW aE AATE E falas basescus beets S A A A har paces Cesta Mase 192 Safety Considerations PLAN AHEAD c cceecececececeeeeeceeeeeeeeeeeeaaeeeeeeeseeeeecaaeeesaaeseeeeeseaeeesaeeeeaee
74. A and B pulses can be applied to only Channels and 2 respectively When configured for quadrature Channels 3 and 4 will still be available for use The Pulse Output functionality uses the digital output available on the module for outputting pulses Before installing be sure to set the module DIP switches for differential or single ended See page 86 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 119 June 2015 INDEX INDEX SENSE SENSE OUTPUT OUTPUT2 OUTPUT3 OUTPUT4 Figure 70 Pulse Counting Wiring IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUT3 OUTPUTS Figure 71 Pulse Output Wiring 120 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUT3 OUTPUTS COM ENCODE ENCODE ENCODE ENCODE Altention Encoder For Input Input 2 and Index reverse polarity to 200mV to a IN 1 60V a IN 1 Differential g IN 2 B i IN 2 IN 3 IN 3 IN 4 200mV to i ri H 60V 2 imi Differential Z 4 ii zai SENSE Internal jumper SENSE OUTPUTI lac OUTPUT2 OUTPUT2 OUTPUT3 R OUTPUT4 Encoder power com S ENCODE S ENCODE m gt 5Vdc to 24Vdc Figure 73 Quadrature Differential External Power Wiring Revision 4 0 HC900 Process amp Safety Controller User and Insta
75. C75 C75S only The Redundancy Switch Module RSM is shown in Figure 13 It sits between C75 C75S controllers in the redundant controller rack Left Controller is designated CPU A right Controller is CPU B Features include 1 Lead Reserve controller status indicators 2 Keyed switch for manual changes to controller modes or to facilitate a Manual Fail Over Figure 13 Redundancy Switch Module Scanner 1 Module S50 S50S only 900S50 Scanner module is shown in Figure 14 It sits in the I O rack and provides the link between the controller and remote I O Features at the front of the module include ce 1 LED status diagnostics indicator for scanner functions 2 One private Ethernet 10 100 Base T Port connects to the I O expansion port on Controller Module or to a port on a Switch that connects to the Controller Module 3 LED status diagnostic indicators for communications functions Figure 14 Scanner 1 Module Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 27 June 2015 Scanner 2 Module S75 S75S only 900S75 Scanner 2 Module is shown in Figure 15 The dual ports provide redundancy through the 2 CPUs Features at the front of the module include 1 LED status diagnostic indicator for scanner functions 2 I O port A Private Ethernet 10 100 Base T Port Connects directly to I O port on CPU A or indirectly through a switch 2 3 T O po
76. Choose from 900RTC H010 Remote Terminal High Voltage Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 9OORTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 16 point AC DI module label into module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 2 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP Set verify jumper positions as shown J2 J4 J6 J8 C Com J3 J5 J7 J9 sw C C Ca Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 238 for RTP internal schematic 232 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 Point AC Digital Input Connect field wiring Note S L1 in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 Install jumper wires 16 Point DC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 16 point DC Digital
77. Contact Input etc beside the Controller Scanner Module and keep higher power modules AC Output AC Input etc away from it For power consumption of each module see Table 4 2 For 240 Vac applications and temperatures above 56 C or 264Vac 52 C de rate the number of ON inputs per AC input module See AC Input de rating data see Figure 29 3 Limit the number of Analog Output modules to a maximum of 10 per rack see Figure 30 Table 4 Power Applied by Module Type Module HC900 Hardware Field Power Total Power Power Watts Watts Watts Controller C30 and C30S 6 0 0 0 6 0 Controller C50 and C50S 6 0 0 0 6 0 Controller C70 and C70S 7 1 0 0 7 1 Controller C75 and C75S 7 8 0 0 7 8 Redundancy switch module RSM 0 1 0 0 0 1 Power Status Module PSM 0 1 0 0 0 1 Scanner 1 Port S50 S50S 3 9 0 0 3 9 Scanner 2 Port S75 S75S 5 0 0 0 5 0 Analog Input Universal 0 8 0 0 0 8 Analog Input High level 1 6 0 0 1 6 Analog Output 4 points 5 1 0 0 5 1 Analog Output 8 pts internal 24V 9 4 0 0 9 4 Analog Output 8 pts external 24V 1 1 8 3 9 4 Analog Output 16 pts internal 24V 18 3 0 0 18 3 Analog Output 16 pts external 24V 1 7 16 6 18 3 Contact Input 1 6 0 0 1 6 Relay Output 3 0 0 0 3 0 16 pt DC In 24V 0 7 2 6 3 3 16 pt DC In 32V 0 7 5 1 5 7 32 pt DC In 24V 1 1 3 1 4 2 32 pt DC In 32V 1 1 5 1 6 2 1
78. Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 141 June 2015 SixNet VT MODEM Industrial External Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 25 pin connector use a DB 9 male to DB 25 female modem cable If your RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232cable 2 Connect power to the modem You will need to supply an external power supply with a DC voltage between 10 and 30 VDC 3 Power up the modem 4 Run a serial communication port program such as Hyperterminal 5 Within the communication program select the port to which the modem is connected 6 Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp F0 Then press the ENTER key 8 In the program s terminal window key in the following command string AT E1 QO Then press the ENTER key The modem should give an OK response 9 Key in the following command string AT amp YO amp CO amp DO amp R1 amp SO amp KO S0 1 The Modem should respond with OK 10 Key in the following command
79. D lw 1 amp 2 IN 2 TE s tim Na ay 4 L384 Oot i IN 4 D N4 Ls ese G nes l0 5 5 amp 6 e 16 Sa IN 6 Z 6 we 16 IN7 T N7 DER ko78 amp 8 PS IN 8 IN 8 N H i Shield Ground typical Figure 49 Analog Input Wiring Eight RTDs Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 95 June 2015 Slidewires Figure 50 Analog Input Wiring Slidewire Position Proportion Block 96 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 point High Level Analog Input Wiring Figure 51 Be sure to set the module DIP switches for voltage or current mode See page 85 This requires Low Voltage Euro style 36 terminal terminal block V Source Y r A OCOOQOOOCOOQQOQOQOOQQOQOQ V Input IN 4 6 IN 3 O IN 4 IN 5 Sa QO IN 8 o 4 20 mA Ne K9 Input nia K IN 9 IN 10 mg 20 oac JO K Figure 51 16 point High Level Analog Input Wiring 4 channel Analog Output Module Wiring An example of Analog Output Module wiring is shown in Figure 52 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Isolation The four outputs a
80. D input connections 2 000 eee eee eseceseceseceseceeecaeecaeeesecaeecaeecseseaeseaeeeeseeeseenseeseenaes 220 Figure 104 Two wire RTD or ohm input Connections eee eeeeeecesecesecesecesecseecaeecseeeaeseeeeeeeeereeeenseeseenaes 220 Figure 105 Slidewire feedback connections for actuators 0 0 0 eee cee cece cseeceeeeeecaeeeseeeeeeeeeeeeeeeeeseeseeaecsaeenaes 221 Figure 106 Voltage input connections iiiter essen seca soes sess sbbedhsesdescecveecsebescosbevoecb solssesdbrosssessseboasustevensboes 245 Figure 107 Current connections with 2 wire transmitter ee ee eeceeecesecesecnseceeecneecaeeeseseeeeseeeeseneenseeaeenaes 245 xii HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction Purpose Purpose Introduction This publication describes the installation operation and maintenance of the Honeywell HC900 Process Controller This publication includes the following sections Chapter Title Page Content Introduction 1 Model numbers how to verify component compatibility function description of components feature summary Components and 15 Functional features and physical characteristics of the system and of each major Architecture component of the HC900 Process Controller Networking components and methods of interconnection Pre Installation 44 Pre planning considerations and procedural guidelines for planning an ins
81. Function Blocks are not processed and outputs are Frozen in this mode inputs that is process values can vary from the values that existed when the OFFLINE Mode was entered In Controllers with firmware earlier than V 6 0 the controller will resume program execution with current available data when controller returns to RUN mode In Controllers with firmware version 6 0 or greater the controller s memory will get re initialized outputs will be de energized and the controller will restart when changing from Offline to Run mode Before entering the OFFLINE Mode e KNOW all potential consequences of suspending control action e PLAN for all operator actions required to preclude adverse consequences while processing is suspended and when resuming control processing e EXECUTE prudent control actions such as placing all control loop in the Manual Mode Failure to comply with these instructions may result in product damage Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 157 June 2015 Table 22 Controller Operating Modes Mode Name Functions in selected mode RUN I O scanning Controller and Expander Racks Function block execution outputs are set according to function block algorithms Monitoring of Diagnostics controller rack and I O expander racks Detection of I O Modules Other functions permitted e Downloading of configurations e Indications of Forces at St
82. HC900 Terminal Block 19 20 21 22 23 24 25 26 36 35 A RESLERIBNRG cons JLatch U nlatch RTP to rail Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 251 June 2015 Mounting screws must be installed at each end of the mounting rail with additional screws approx every 8 203mm to prevent twisting of the rail Insert one side of DIN rail at A DIN rail To remove using slot screwdriver to lift C up gently plastic is fragile to disengage at B Lift up and over rail then disengage at A 252 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Declaration of Conformity CE Honeywell 51452401 Issue N EC DECLARATION OF CONFORMITY We Honeywell International Inc Honeywell Field Solutions 512 Virginia Drive Fort Washington PA 19034 USA declare under our sole responsibility that the following products HC900 Hybrid Controller Models 900A01 900A16 900B01 900B08 900B16 900G01 900G02 900G03 900G04 900G32 900H01 900H02 900H03 900H32 900K01 900RSM 900PSM 900C30 900C30S 900C31 900032 900050 900C50S 900051 900052 900053 900C70 900C70S 900071 900072 900075 900C75S 900C71R 900C72R 900C73R 900S50 900S50S 900875 900S75S 900P01 900P02 900P24 900RTA 900RTR 900RTC 9OORTS NPE 1533 NPE 1534 NPE 2232 900R04 900R08 900R12 900RRO 900RO8R 900R12R 900RPE
83. HC900 Process amp Safety Controller User and Installation Manual 33 June 2015 Figure 20 HC900 Controller Configurations In any of the racks shown in each controller configuration can be 4 8 or 12 slot versions The Ethernet cables for the I O expansion links are standard shielded Cat 5 cables with standard RJ45 connectors Each cable segment can be up to 100 meters 328 feet long You can also use fiber optic cable for connections between the controller and a remote rack Distances up to 750m 2460 ft are possible with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint See page 212 and page 213 Configuration 1 is the C30 C30S C50 C50S C70 C70S CPU with I O but no I O expansion racks Configuration 2 shows the C50 C50S C70 C70S CPU with 1 I O expansion rack The Ethernet cable connects directly between the 10 100 Base T connectors on the C50 C70 CPU Controller Module and the Scanner Module ATTENTION For 2 or more I O expansion racks a switch is required Use only Honeywell recommended switches part no 50008930 001 50089785 001 The total number of switches is limited to 2 in series between a CPU and its scanners Configuration 3 shows the C50 C50S C70 C70S CPU with 3 I O expansion racks Since there are at least 2 T O expansion racks a switch is required When an Ethernet switch is used to connect to expansion I O a cable goes between t
84. HITE TEXT Be sure to use the DARK BLUE WHITE TEXT appropriate label for each module type RELAY RED WHITE TEXT ANALOG WHITE DARK GREY TEXT YELLOW DARK GREY TEXT 2 Place the appropriate label supplied with the module tagname side out into the hinged door for each I O Module Slotted tabs molded into the door at top and N F DE ENERGIZzE bottom hold the label in MODULE inp place POWER BEFORE SERVICING Term No Ni 1 N1 2 IRTOI 2 3 N2 4 N2 5 N3 6 82 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Procedure Comments Reference 3 Optional Install jumper ae wots combs into designated AC Output bli Barrier style Terminal i RO DUPUE Palay Output Blocks to reduce the wiring required to supply Pr VE power 2 2 Two position jumper for 6 the DC Input Module 6 6 and or on the DC Output j Q 0 Module O IS T Ten position jumper for lan O EE the AC Output Module S Ne Is OT Five position jumper 10 18 E Q position jumper cut in half iS D a for a Relay Output ie Module 20 20 Refer to terminal block wiring diagrams for specific information 4 For each configured and 120 240 VAC labeled I O Module break 125 VDC IN z off the key tabs in the pattern that identifies each ime module type i For a diagram of each ee key tab pattern us
85. Honeywell HC900 Process amp Safety Controller User and Installation Manual Doc No 51 52 25 154 Revision 4 0 Date June 2015 Notices and Trademarks Copyright 2015 by Honeywell Revision 4 0 July 2015 Warranty Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Honeywell Process Solutions 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners ii HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 About This Document Abstract This document provides descrip
86. IUP is supported by turning off all eight switches to allow removal of the module from the rack without causing an arc Please see page 81 for more details See page 225 for RTP internal schematic Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 223 June 2015 Relay Output Step 4 Connect field wiring DAPD OOOD OAD YN YOOYUOODOYVO ATTENTION e Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F e As shown in the schematic each switch is SPST and opens and closes one lead of the relay wiring If your application requires opening and closing both sides of the load wiring then an external DPST switch is required 224 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Relay Output RTP Internal schematic HC900 Terminal Block e o ON O oa A WO PN 10 KN tyd 4 4 e N a a O o N O Oo A U N J1 TB1 e o oo N DO oa A WO ND oO a ed N i wo AK a oe O uo ek 6 a oOo N 4 o ye oO Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 225 RTP Cable wire positions and colors applies to 8 point Al and Relay Output Twisted Pair Number HC900 Mod
87. Mark the locations for the bottom screws See CAUTION at right e Drill and tap for 10 or M4 screws e Remove the rack from the enclosure For dimensions of the pattern for drilling holes refer to the diagram below CAUTION When drilling holes prevent metal flakes from falling into the rack or onto any surface within the electrical cabinet Note Always mount racks as shown above That is never mount vertically or with backplane horizontal Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 67 Step Procedure Comments References Reference Center for Drilled Holes at Top of Rack Aluminum grounding bars for I O module wiring are optional They can be mounted at top at bottom or at top and bottom of the rack as indicated at right If grounding bars are included attach them with two M3 screws supplied with grounding bars in plastic bag Note The plastic bag also includes four M4 screws for attaching the grounding wire lugs which are attached later Attach the M4 screws loosely to the grounding bars for safe keeping Hang the rack in the enclosure on the top screws Start all screws in the bottom of the rack then tighten all screws Note You may find it easier to postpone this step until after all components have been installed in the rack Repeat for eac
88. ON To indicate sensor failure the Analog Input software will output a warning if thermocouple resistance gt 80 ohms Use appropriate gauge wiring to prevent inaccurate failure warnings Table 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F AWG No Diameter TypeK TypeJ Type T Type E Type S Type R Type W5 Type W inches PYPT110 PYPT113 W26 W26 10 0 102 0 058 0 034 0 029 0 069 0 018 0 018 0 023 0 020 12 0 081 0 091 0 054 0 046 0 109 0 028 0 029 0 037 0 031 14 0 064 0 146 0 087 0 074 0 175 0 045 0 047 0 058 0 049 16 0 051 0 230 0 137 0 117 0 276 0 071 0 073 0 092 0 078 18 0 040 0 374 0 222 0 190 0 448 0 116 0 119 0 148 0 126 20 0 032 0 586 0 357 0 298 0 707 0 185 0 190 0 235 0 200 24 0 0201 1 490 10 878 0 7526 1 78 0 464 0 478 0 594 0 560 26 0 0159 2 381 1 405 1 204 2 836 0 740 0 760 0 945 0 803 30 0 0100 5 984 8 551 3 043 7 169 1 85 1 91 2 38 2 03 Table values are shown as a reference only actual values may vary Consult manufacturer specifications Isolation This module has eight inputs which are isolated except for RTD current sources RTD Inputs RTD inputs share current sources two RTD inputs per source as shown in Figure 44 Figure 45 and Figure 46 For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 Irrp 1 amp 2 This same current source Irtp amp 2 is also
89. Output 4 chan T4 4 O Slot Rack T6 Analog Output 8 chan T4 Analog Output 16 channel T3C 8 VO Slot Rack T6 Digital Inout Contact type 16 chan T5 12 VO Slot Rack T6 Digital Inout 24 Vdc 16 chan T4 Power Supply P01 T4 Digital Inout 120 240 Vac 16 chan T3C Ta 60 deg C T4 Ta 40 deg C Digital Input 120 240VAC 125VDC T3 Ta 60 deg C 16 Channel T4 Ta 40 deg C Power Supply P02 T4 Digital Input Vdc 32 chan T3 Ta 60 deg C T4 Ta 40 deg C Power Supply P24 T4 Digital Output Relay type 8 chan T5 Power Status Module PSM T6 Digital Output 24 Vdc 16 chan T4 C30 C50 C70 C75 CPU T4 Digital Output 120 240 Vac 8 chan T4 Redundancy Switch Module RSM T6 Digital Output Vdc 32 chan T6 Scanner 1 T4 Pulse Frequency Quadrature 4 chan T5 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 207 June 2015 Environmental Conditions Ambient Reference Rated Extreme Transportation amp Storage Temperature F 77 4 5 32 to 140 32 to 140 40 to 158 C 25 3 0 to 60 0 to 60 40 to 70 Ambient Relative 45 to 55 RH 10 to 90 RH 5 to 90 RH 5 to 95 RH Humidity non condensing non condensing non condensing non condensing Mechanical Acceleration 0g 1g 1g Not rated Duration 0 ms 30 ms 30 ms Vibration 0 Hz 0 Hz to 14 Hz 0 Hz to 14 Hz 0
90. Output Internal 24v Supply Relay Output AO 4 900801 900H01 AO 8 900B08 AO 16 900816 Al 8 Validation channel in 900A01 series with Load or Al 16 900A16 Relay Output 900H01 External 24v Supply AO 8 900B08 AO 16 900816 Al 8 900A01 or Al 16 900A16 Use of External supply allows for a common relay for Analog Output External 4 24VDC aiy Supply Relay Output 900H01 AO 8 900B08 AO 16 900B16 Al 8 900A01 or Al 16 900A16 Figure 38 Series Relay for Analog Outputs System Monitor Function Blocks The HC900 Controller includes function blocks that enable the user to monitor the status of system functions When constructing a control configuration consider adding the following monitoring function blocks to the control strategy e ASYS System Monitor e FSYS Fast System Monitor e RK Rack Monitor e FMON Fault Monitor These function blocks are described in the HC900 Function Block Reference Guide 51 52 25 109 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 63 Overview Rack Installation This section contains procedures for installing one or more HC900 Controllers It is recommended that the information in this section be reviewed before beginning the installation Familiarity with the overall procedure will help to prevent errors and will promote efficiency in general ABS installations require additional protection from the environment
91. RUN Locked mode 1 Change mode back to RUN Diagnostics Locked while there are oe OR shows status as forces present on F Invalid Change of safety worksheet 2 Clear all safety forces using HCD Mode through Monitor gt Forced Blocks OR 3 Force acold start 2 Controller mode is e Controller will not go to RUN To clear the diagnostic In HCD System changed to RUN Locked mode 1 Change mode back to RUN Diagnostics Locked when safety mode aes shows status as configuration is Safety changed at run time 2 Force a cold start Configuration mis match 3 One of the following Atthe time of the exception the To clear the diagnostic force acold Ifthe lead s status Ifthe lead s status microprocessor microprocessor resets If it s the start LED is indicating LED is indicating exceptions occurred Lead controller and there is an Ifthe problem reoccurs try the the failure see the failure see e Watchdog timer available reserve a failover occurs Pied ht ot CPU in the Lead CPU Diagnostics timeout When the microprocessor 1 Ensure the system is properly CPU Diagnostics in the Lead completes its reset condition it will display Diagnostics e Address error l 2 grounded Overview dial become an available reserve if a i If the reserve s og e Prefetch error lead is present or become alead if 2 Ensure the system is properly status LED is box e Data aborterror no leadis present isolated from extemal noise sources
92. Sense is inverted when Load is placed on High side relay sinks power DI Sense is NOT inverted when Load is located on Low side relay sources power Note DI Sense is inverted Note DI Sense is inverted Figure 36 Individual Series DO connections 24VDC ora oe 110 220 oO Sas y 9 5 V gt VALID HIGH lt 32 0 V 0 0 V gt VALID LOW lt 3 5 V i yi Seuran l Relay Output 900H32 900H01 DO 8 900H03 2 lt DI a DI 16 3 aaa DPI eoocos l 900G32 900G04 75 VAC gt VALID HIGH lt 250 VAC 0 0 V gt VALID LOW lt 20 VAC a Relay Output DI 16 900H01 Q al 900G02 iS or DI 32 900G32 Relay Output Sinking DO 16 900H01 E 3 al 20008 a DI 900G04 Note DI Sense is inverted Note DI Sense is inverted when Load is placed on High side relay sinks power DI Sense is NOT inverted when Load is located on Low side relay sources power Figure 37 Common Series DO connections 62 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 intemal 24v Supply AO 4 900B01 AO 8 900B08 AO 16 900816 Relay Output 900H01 Al 8 900A01 Validation channel in or Al 16 parallel with Load 900A16 Use of Intemal supply requires one relay per Analog
93. This will typically be the LAN side IP address of the routers used to connect the controller to the external network e Installing and configuring hardware Note This data is included for reference The following items should be implemented by qualified IT MIS personnel Install and configure a Router to provide isolation and security Figure 24 This should be part of standard network installation Install and configure internet access to Simple Mail Transport Protocol SMTP server This may include the location of an existing server on an existing network Note Consult your service provider for availability of access to network local cable or DSL in your area 40 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 HC900 Controller LAN Legend Ethernet PC Host Fiber Controller sapa Sees ee ae R Controller reson y Figure 23 Typical installation using a Cable Modem Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 41 Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems Overview SHIELD TX RX TX RX Figure 24 Controller Serial Ports For Legacy systems the S1 default setting is RS 232 S2 default setting is RS 485 Each port can be set to RS 232 or RS 485 see page 43 For RS 232 cable connec
94. XD 2 TXD 3 Connects to RXD 3 DTR 4 None GND 5 Connects to GND 1 DSR 6 None RTS 7 None CTS 8 None RI 9 None 132 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Rs 232 Remote Connection to PC Configuration Tool Legacy Controllers The Controller can also be connected remotely by a set of modems which are available from third party suppliers A Null Modem Cable is used between the Controller and the modem shown in Figure 78 and shown in Table 19 A second Null Modem cable is used between the PC and the internal or external modem at the other end as shown in Figure 78 This cable is Remote controller access via dial up modem is available via the communication setup in the PC configuration tool All functions of the Designer Software configuration tool can be performed over this link Remote access functions include on line monitoring configuration upload and download and firmware upgrade PC Configuration Tool Controller RS 232 Port Null Cable J Null Cable Telephone Modem Cable Za o Telephone Cable Figure 78 RS 232 Remote Access via Modems Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 133 June 2015 B Modem Connection Modem RS 232 Configuration port 96 384 KB T 7 i Intemal Modem assigned to a COM port PC Figure 79 Modem Connection 134 HC900 Process amp Safety Control
95. a copy of the configuration or ensure that a previously SAVEd copy of the current configuration is available Apply site AC power to the Power Supply that is associated with the controller Module Press the latch on the battery cover to release the battery holder and use the molded in extension on the battery holder to extract the holder Note the orientation of the battery holder assembly for re insertion afterwards The battery is retained in the holder by spring tension of the plastic holder itself Extract the battery single battery for older models two batteries for new models from the holder by using your thumb to apply pressure to the front end of the battery and rotating it to the left Insert the negative end of the new battery into the back end of the holder and press on the battery so that it snaps into the holder To ensure that the battery is seated properly rotate it in the holder using finger or thumb pressure toward the positive front end of the battery While maintaining proper orientation battery toward the left slide the battery holder into the slot in the Controller Module until it snaps into place Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 201 Specifications General Specifications C30 C50 C70 C75 Controller Design Modular design with metal rack enclosure power supply controller CPU
96. aaeeneeeas 17 Table 2 Descriptions of Major Redundancy Components 00 cece eeeeseeeeeeeeeeeeeeeeeeeeeecesecesecaecsaecsaecsaeeaeseneeens 19 Table 3 Serial port DIP switch settings 0 0 cece ecceeseeescesecesecesecssecsaecaeecaeseseseaeeeeeesecesscsecsaeesaecsaesaaecaaeeneeeas 43 Table 4 Power Applied by Module Type ee eeceesceescesscesecssecssecsaecseecseseaeseaeeseeeeeesecseesaecnaecsuessaecaeseaeeeas 51 Table 5 Guidelines for Grouping Wires eessseessseessseeesssterresrsresresteersserrsrertentestentesrerrnertentesresteseertnsenersserenesee 58 Table 6 Installation Tools w c scc cctescccisceaseetevseccontavesaecescacuussocestessacacnscnevacevedtes ste TER AAE E E E i 64 Table 7 Site and Equipment Preparation 0 0 ee eee eeceescesscesecesecsecsaecaeecseseneeeeeeeeesseesecaecsaecsaecsaessaeeaaeeneeeas 65 Table 8 Mount Racks ocre nieee iaecesca caves ounstecsscacusenesaceuedtey ste TEA E AA ceventenatecoponeuenns 67 Table 9 Assemble C30 C50 C70 Controller Rack eseseseessseesssreesssrrerssestesresteeresrerrssertrnrestenresrerrnserrrsserrenesee 69 Table 10 Assemble C75 Controller Rack corneei nnn eere ie EEEE EE E E E A a 72 Table 11 Assemble I O Expansion Racks essseessseeesesreerssrsresresresrssrrrrssesteerestesteseeissestentestentestertsserrrererrreresrt 73 Table 12 Minimum Recommended Wire Sizes escceseceesseceseceeseceeneeesseceeneeenseceeneecsaeceeeeecsaeceeneecsaeceene
97. able e If possible bring the process to a safe and orderly shutdown Table 35 Controller Module Replacement Step Action 1 If a process is currently in operation bring it to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply in the Controller rack from the site AC power source 3 Observe where communications cables are plugged into the Controller Module and if necessary tag them to identify their functions Unplug all communications cables 4 At the top and bottom of the module loosen the captured screws that secure the module in the rack and remove the Controller Module from the rack 5 Ensure that you set the S1 S2 and RS 485 terminal dip switches as applicable 6 Ensure that the new Controller Module is properly aligned with the slot guides insert the new Controller Module in the rack and secure it in place with the captured screws at top and bottom of the module 7 Re install communications cables 8 Using the user supplied switch re connect site AC power to the rack 9 If using the Ethernet port for configuration use the Designer software to set the proper network address 10 Download the configuration 11 Set the Real Time Clock 12 If all status indications are green power may be restored to the I O modules per the application s procedures Revision 4 0 HC900 Process amp Safety Controller User a
98. able which includes a standard template for creating batch reports SpecView32 SpecView Corporation Matrikon OPC Server works with redundant and non redundant networks e Other software available from third party sources The following software which incorporates Modbus TCP connectivity is available from third party sources The Fix Family Intellution Incorporated Wonderware Wonderware Corporation Citect CI Technologies OPC server client software various available from Kepware and others Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 39 June 2015 Inter Connection to Other Networks In many cases an HC900 Controller application will include a single free standing controller that involves no connections via the Ethernet Open Connectivity network In other cases the HC900 Controller will be a member of a Local Area Network LAN as indicated in Figure 22 The HC900 controller LAN may be very simple or it may include many devices in a complex and very sophisticated structure In any case it must always be regarded as a single modular entity that can be protected from intrusion by any other networking device to which this LAN is connected Various types of networking devices that enable selective connection to other networks are available A Router is commonly used for this purpose Routers can examine and filter message packets permitting passage of
99. aeeeeaaesaceeceaeeeseaesgeaeeseeeeseaeeseaaesseneesenees 30 VO Network isens avid a ihe ee aes ee 33 I O implementation requirements include cccccceeeceeeeeceeseeceeeeecaeeeeaaeeeeeeeeaeeesaaesseaeeseeeeseaeessaeeseneessaees 35 Ethernet Open Connectivity N twork c cccsccceeceeceeeeeeaeeeeneeceeeeecaaeeeeaaeseeeeseaeeesaaeseeaeeseeeescaeeesaeeseaeeseaees 35 SElial POMS eHsceieetecerettee E E A E teeta tbbeatee Mh pad Meade EESAN 42 Pre Installation Planning fogs sgs see cccece pevneassSeccet seeecdatevessegee tue aces utaex ans seecdens gverecurecysccecetet 44 OVENVIOW nteni a aaa st is Mid arate eden I een RGU dee eee 44 AC Power Supply Selection for racks With N O cccccccseesseeeeeeeeeeeeeeeeaeeeeneeseeeesaaeeeeaaeseeeeeseeeesaeeeeeeeeeeeees 45 DC Power Supply sininen Meeiel th nina Media aden hae eel ited a 47 Rack Orientation and Mounting cccceeeeeeeeeeeeeeeeeeeeeaeeeeneeceaeeecaaeeeeaaeseeeeseaeeesaaeeseaeeseeeeseaeeesaeeseneeeenees 47 Remote Termination Panels ccccccccecescccceeeeccceeseeeceeeeeeeaceesaseaeeesasaaaaesaaaaeeesaeaeeesaeaaeesneeaaeeseeeaeeeseeeaeennses 50 EALES AUL ATERT E T E A E T E OE OTE ETA E E S 50 Hear Rise Deranger aan AE E E E EES EEE cats cls RAAE AE ENE E TRAE E TE oly carted 51 Cable Wiring Distance Planning a ssesiiinersiiiiiiiciiiiiiiii diaii i eiii iiia e a E 53 Electrical Considerations spinin a ra a a a a a a a a aa a aa AA aa RE E 55 Hardware and wiring requirements fo
100. age 133 Refer to device s port instructions Refer to device s port instructions Refer to device s port instructions Terminal connector of operator interface Refer to Table 18 Connect from each CPU A and B to the Ol Refer to device s port instructions Refer to device s port instructions For Wiring details of Null Modem cable see Table 19 SIL applications require shield drain wire to be connected to grounding bar SIL applications require shield drain wire to be connected to grounding bar SIL applications require shield drain wire to be connected to grounding bar 126 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 E110 100 Base T RJ45 E210 100 Base T RJ45 E110 100Base T RJ45 E2 10 100Base T RJ 45 Shielded CAT5 cable up to 100 meters Host Peer and Internet Devices Shielded CAT5 cable up to 100 meters Host Peer and Internet Devices Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Designer configuration software Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Designer RJ45 connector on Host Peer or Internet Device RJ45 connector on Host Peer or Internet Device Default IP address is 192 168 1 254
101. allation Manual 75 I O Module Installation and Wiring Overview This section contains descriptions of and procedures for installing I O Modules in controller racks C30 C30S C50 C50S C70 C70S models and in I O expansion racks S50 S50S S75 S75S only Module Placement in Racks Each input or output module is placed in an I O slot in a rack as shown in Figure 39 Each slot in a rack includes a set of guides that locate the circuit board in the rack and a 20 pin 4 x 5 socket in the backplane that receives the associated 4 x 5 pin plug at the back of the I O module At the front of each I O module a 20 or 36 pin plug receives the associated socket on the back of a terminal block When the I O module is inserted into the rack and the terminal block is placed on the circuit board two captured screws in the terminal block are fastened to metal tabs on the rack amsa x 5 Pin connector f to Backplane omc x 20 or2x 18 i Pin connector to Terminal Block SSssoscsossssssss Figure 39 I O Module Installation A WARNING Ay e Do not use an input output terminal block if the terminal block is damaged if the door is missing or if one or both mounting screws are missing e Always tighten both terminal block screws to proper torque settings before applying field power to the module Torque to 0 4 0 5 Nm 3 5 4 4 Lb In e Do not apply energized live field wiring to an input output module th
102. ansfers the configuration file from flash memory to RAM and reinitializes all dynamic data The Cold Start procedure is flowcharted in Figure 86 The controller initiates the Cold Start procedure e After a power outage when diagnostics indicate that the controller hardware and software program are intact but the content of the RAM database is incorrect See Figure 85 e Ona Mode transition from PROGRAM to RUN This Mode transition can be initiated by operating the Mode switch on the controller or RSM or by exiting the Program mode at a Control Station e When initiated by the user after download with Cold Start selected or any transition from PROGAM Mode to RUN Mode 154 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Build empty database invalid database Initialize Process Values Operate in RUN Mode wi initialized process values Operate in PROGRAM Mode w all outputs off Figure 86 Cold Start Operation Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 155 Execution sequence e The type of control functions executed during a scan is determined by the system configuration Controller configurations contain a series of algorithms in the form of function blocks that get executed in a fixed sequence The first 100 function blocks are pre assigned by the system to handle communication tasks alarm
103. ase Depending on the results of the diagnostic the controller will execute either a Warm Start or a Cold Start Warm Start A Warm Start is a restart of the control strategy using dynamic data that is stored in battery backed RAM to allow control action to resume exactly as it was before the restart In the Warm Start procedure flowcharted in the main flow of Figure 85 diagnostic testing proves the integrity of the hardware software and configuration database resulting in an automatic Warm Start of process control Control action is resumed exactly as it was before the outage This flowchart also indicates actions that would be taken by the controller in case of fault Notice that if primary diagnostic testing determines that RAM or firmware is faulty all process control functions cease and the Status LED red color strobes one blink periodically If RAM and firmware tests pass but the database in RAM is faulty the controller initiates the Cold Start operation Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 153 June 2015 Hot Start Copy new configuration in RAM Initialize all control blocks data Controller goes to Initialize modbus RUN mode and PDE tables a Start copying config data to Flash in background Figure 85 Warm Start Operation Cold Start A Cold Start clears the data in battery backed RAM turns all outputs off tr
104. at is not installed in one of the racks in the HC900 Controller e Do not operate the controller without a Protective Earth connection Failure to comply with these instructions could result in death or serious injury 76 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Terminal Block Styles The terminal block is available in the barrier style shown at left in Figure 40 and the Euro style shown at right Not shown a Euro style with 36 connections is also available for certain high capacity modules Terminal blocks have an embossed numbering key that shows the numbering pattern of the 20 36 connections The frame associated with the terminal block has a transparent hinged door The hinged door is a tool secured cover To open the door insert a flat screwdriver into the slot at the top and bottom of the door while pulling out The door has molded in tabs that hold labels which are uniquely color coded to identify each module type Each label is printed on both sides On the front visible when the door is closed are I O channel numbers with spaces in which tag names can be written On the back visible when the door is open are wiring patterns for the type of module located in the slot Figure 40 Terminal Block Styles The 20 pin inline connectors at the back of the terminal blocks are universal that is any type of I O module can be used with either the Barrier
105. ation files setpoint profiles and recipe files can be uploaded for storage and archiving in a PC and or to a disk in the Control Station Using the PC the Upload function is accessed from the Designer Software For details of uploading configuration items refer to Designer Software and Control Station manuals Firmware Download Firmware Download provides a mechanism to upgrade the firmware in your CPU and Scanners It is available in Program or Program Locked modes only Specific instructions are provided with the upgrade files 162 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Redundant Operating Characteristics Overview This section describes operating characteristics specific to redundant controllers In a redundant HC900 system the Lead Controller performs all primary tasks including interfacing with remote I O racks communicating with a local HMI exchanging data with peer controllers interfacing with Modbus slave devices and communicating with a Host PC application Detection of a fault or removing power from a Reserve Controller will initiate a diagnostic prompt in the Lead Controller but will have no impact on the process under control The detection of a fault or removing power from a Lead Controller will initiate failover that is transfer all primary tasks to the Reserve Controller establishing this controller as the new Lead Following a failover the new Lead Controller
106. atus LEDs on I O modules Other functions NOT permitted e Al calibration e AO calibration PROGRAM I O scanning Controller and expansion Racks is performed but function blocks are not executed and all outputs digital and analog are set to OFF See Note 1 Monitoring of Diagnostics Controller and Expander Racks Detection of I O Modules Other functions permitted e Al calibration e AO calibration e Downloading of configurations e Downloading controller firmware Program Locked or Program Other functions NOT permitted e Indications of Forces at Status LEDs at I O modules OFFLINE IO scanning Controller and Expander Racks is performed but function blocks are not executed and all outputs digital and analog are Frozen see Note 2 at the states they were in when the OFFLINE mode was selected Monitoring of Diagnostics local and expanded racks Detection of I O Modules Other functions permitted e Al calibration e Indications of Force at Status LEDs of I O modules Other function NOT permitted AO calibration Note 1 The Off state of the module outputs are defined as e Digital output low state e Time proportional Output TPO 0 duty cycle e PPO and TPSC Outputs Both Fwd and Rev are Off e Analog output 0 0 mA Note 2 The Frozen states of module outputs are defined as e Digital output same state as previous last active state e Time Proportional Output TPO Same duty cycle as
107. ault Subnet Mask is 255 255 255 0 You can use these network parameters initially for testing or configuration use In the Current PC to Controller Connection Settings area of the dialog box click on the Network button to bring up the Network Port Properties dialog box and Add the default IP addresses Be sure both PC Ethernet NICs have fixed IP addresses on the same subnet as the controller 192 168 1 x and 192 168 2 x where x 2 to 253 Note 900 Control Station uses IP 192 168 1 253 as default 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network 5 Device Name Honeywell HC900 Controller gt Address 192 168 1 254 bd Protocol Modbus R TCP Speed bps N A PC Port Setup for Controller Access m Network COMI COM2 COMS COMA COMS COMB COWM7 COMB 6 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Also ensure that the PC Network Interface Cards have an IP address that allows access to the controller on the subnet after changing the controller s network parameters 7 You may change the controller s IP a
108. be compensated in each individual thermocouple calibration cold junction calibration may be skipped e After connecting the thermocouple extension wire to the terminals you must wait for the terminal temperature to stabilize e If using a compensated calibrator input the equivalent simulated temperature values corresponding to the REFERENCE mV values These will be the hi and low range values for the particular thermocouple configured Figure 94 is an adaptation of the wiring diagram given in the installation section of this manual This figure indicates how a calibration device can be connected to the appropriate terminals of an analog input module The calibration device s must have the following precision characteristics e TC mVolts Volts inputs 1 microvolt resolution e Ohms RTD inputs 01 ohm resolution e 4 20mA inputs 4 microamp resolution Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 189 June 2015 Peceeseccens MV or 3 mV or Vee al Source Sane n Seeccccccess See note ecscleccs 4 20 mA H Xmtr input Sesenqeces PEPE LALELS 9 24 Vde a Ter Note The following Al types are not available for High Level Analog Input modules RTD Thermocouple Ohms mV Figure 94 Terminal Board Connections for Al Calibration 190 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Analog Output Cal
109. board to allow mating with the module See page 83 e Connect terminal block end of desired cable assembly to 32 point Digital Input module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 32 point DC DI label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 2 Mount RTPs to DIN rail e Latch to rail See page 251 e Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 16 RTP B to Inputs 17 32 You can write on the RTPs labels to distinguish them 3 C OC Cm CO See page 250 for RTP internal schematic 248 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 32 Point DC Digital Input Connect field wiring RTP A for inputs 1 to 16 DC Supply RTP B for inputs 17 to 32 DC Supply Note SDC refers to switched positive side of the DC supply Note Terminals 9 and 11 DC are connec
110. c blocks 35ms for up to 315 25ms for up to 500 fast 25ms for up to 660 fast 35ms for up to 780 fast fast logic blocks logic blocks logic blocks logic blocks 50ms for up to 400 35ms for up to 780 fast 35ms for up to 1040 50ms for up to 1040 fast logic blocks logic blocks fast logic blocks fast logic blocks 50ms for up to 1040 fast logic blocks 60ms for up to 1300 fast logic blocks 50ms for up to 1380 fast logic blocks 60ms for up to 1700 fast logic blocks 125ms for up to 3300 fast logic blocks 60ms for up to 1300 fast logic blocks 125ms for up to 2500 fast logic blocks Detection Failover Time from Lead to Reserve CPU N A Up to 4 analog scan cycles Run Mode Edit Transfer Time 3 normal scan times 1 5 sec typical for all configuration edits not including I O changes Operating Modes Run No configuration download in this position Run Program Download allowed Program Outputs Off initialization on download Offline mode is available via software selection for Al calibration Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 203 Features C30 C50 C70 C75 Maximum user configurable Function Blocks 400 2000 5000 Maximum Control Loops Quantity based on available memory System Blocks Not user configurable 100 not part of 400 2000 or 5000 for Alarm Group blocks Syst
111. can contribute to delays in processing outputs and or improper or unexpected operation e The HC900 controller samples all inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The sequence order of the function block determines when in time the actual value will be updated It is important that algorithms that need updated input values for their calculations have the inputs execute first in the sequence e Except for Time Proportioning Output TPO Three Position Step Control TPSC and Position Proportional Output PPO function block types that update their physical output values while the function blocks are being executed all physical outputs are updated at the end of a scan Lead Reserve controller synchronization e Lead Controller automatically synchronizes the Reserve with the configuration database During download of a configuration from a Host to the Lead During process operation to bring a Reserve Controller from the Unavailable state to the On Line state e Lead Controller automatically synchronizes the Reserve with run time data during each function block execution cycle e Both the Lead and Reserve Controllers execute the function blocks in the control strategy but only the Lead Controller writes the physical outputs to the I O Racks See e Figure 90 e The Lead and Reserve controllers exchange system status to determine conditions for
112. cedure Reference 2 Install or verify correct installation of enclosures for HC900 Mount Racks Controllers and ancillary equipment Table 8 Mount Rack e Mounting rails or flat panels e for cabinet with multiple HC900 Chassis grounding bus barrier strip for AC power e Master control Relay 3 Install or verify correct installation of enclosures closets See Pre installation planning for networking devices sections Note Some networking devices may share enclosures with HC900 Controller components 4 Install or verify correct installation of See I O Module Installation and Wiring on page 75 e External disconnect switches e Fuses at the power source associated with input sensor or output devices for I O modules 5 Arrange and organize items to be installed at or near enclosures 66 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Mount Racks Rack assembly information is given in Table 8 Table 8 Mount Racks Step Procedure Comments References 1 Mount the Rack in the enclosure as follows e Using the diagrams below as a guide mark the locations for rack mounting in the enclosure for the top holes in the rack See CAUTION and Note at right e Drill and tap for 10 or M4 screws e Start the mounting screws supplied by the user in the drilled holes e Hang the Rack on the screws at the top e
113. ch each eight bit byte is sent as 2 ASCII characters and RTU in which each byte is sent as two four bit hexadecimal characters Each Modbus message frame is embedded into a TCP IP datagram as indicated in Figure 23 Transaction Protocol Length Modbus Identifier Identifier Field Frame J l x or s s r 1 Function vaoress Buon oaa checksum Figure 22 Modbus TCP Framing The HC900 Controller uses either Modbus TCP or Modbus RTU not ASCII The fixed Modbus mapping structure for the HC900 Controller is based on the mapping structure employed in Honeywell s UMC800 Controller and the function codes and methods for parameter access are also virtually identical Modbus Maps In your controller s configuration certain parameters are each automatically assigned a Modbus address These include certain types of function blocks such as loops and set point programmers signals and variables among other items Through their addresses these parameters can be accessed or displayed remotely such as by a third party operator interface Collectively these Modbus addresses and parameters are known as the Modbus map Two Modbus Mapping options exist Fixed map and Custom map Using HC Designer you can use a pre defined fixed map where common parameters are mapped out automatically at fixed addresses or you can configure a custom map for configurations rev 4 0 or higher Function blocks added to the contro
114. ct power to the power supply Using a meter and the test points on the face of the power supply ensure that voltages measured on the backplane are within specifications 194 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Replacing the Controller Module Removing and replacing the Controller Module requires that that the source of AC power is removed from the rack Removing power from the Controller rack has the following consequences e All control action stops e All power to all I O modules in the rack is lost hence all control outputs to the process are lost Because external power connected to terminal boards from or to field devices will still be present it is essential that field devices are maintained in a safe condition during replacement procedures e Control to all I O expansion racks is lost If power is available to the expansion racks outputs go to configured Failsafe values C75 module e Does not impact the other C75 CPU module which will continue to control the process e Contains start up diagnostics after replacement to verify proper operation e If there is a Lead Controller the configuration database is automatically copied from the Lead to the newly replaced C75 CPU module Before replacement e If possible upload and SAVE a copy of the configuration or ensure that a previously saved copy of the current configuration is avail
115. d RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs 3 Cm Cs Cm Cm See page 241 for RTP internal schematic 242 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 Point Analog Output Connect field wiring RTP A for Outputs 1 to 8 9 and 10 RTP B for Outputs 11 to 16 9 and 10 EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN to 9 External 24VDC supply 24VRTN to 11 16 Point Analog Input Step 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP labeled DI DO AO RTP ASSY with jumpers J2 J9 is the correct one for 16 point Al Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect terminal block end of desired cable assembly to 16 point Analog Input module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 16 point Analog Input label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in t
116. d CPU If using a single network connection during initial setup verify connection is made with the Lead CPU Two redundant systems with PC supervision OPC Serwer to PC Software 10400 baseT Peer to Peer D ata Exchange Controller A Rack Controller Rack Up to 100m 100 baseT Ethernet Ppr Switch i Mee EE 1 100 bas eT Epp ai iiit VO Rack vy TINE ER Ein TELE WO Rack Figure 81 Two redundant systems with PC supervision 146 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 C Direct Ethernet Connection to one HC900 controller Defaults IP Address 192 168 1 254 Subnet Mask 255 255 255 0 Default Gateway 0 0 0 0 Ethernet 10 Base T Host 10Base T Ethernet port RJ 45 connector ATTENTION Always observe the wiring cabling guidelines on page 53 Step Procedure 1 Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled 2 Connect an Ethernet 10 100 Base T crossover cable to the HC900 controller s Open Ethernet RJ 45 port top RJ 45 port 3 Connect the other end of the Ethernet 10 100 Base T crossover cable to the PC s network port 4 On the PC use the Utilities Worksheet in the Designer software to connect to the controller over Ethernet Every HC900 controller is shipped with the default IP address of 192 168 1 254 and Subnet Mask
117. d Installation Manual 219 June 2015 8 Point Analog Input Note You must set switches 1 8 for RTD Input 2 Input 3 Input 4 Input 6 Figure 103 Three wire RTD input connections Input 5 Input 7 Note You must set switches 1 8 for Ohms is OD OQOOQOOOOOOHHOOOOOE Install jumper wires 3 23 6 26 8 28 12 32 13 33 16 36 17 37 20 40 Input 1 Input 2 Input 3 Input 4 Input 6 Figure 104 Two wire RTD or ohm input connections 220 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 8 Point Analog Input Note You must set switches 1 8 for Ohms Input 2 Input 3 Input 4 Input 6 Input 8 Figure 105 Slidewire feedback connections for actuators Analog Input accuracy specification Range Al Module Accuracy RTP Cable Accuracy Al Module RTP Accuracy 0 1 of Range 0 04 Range 0 357 C 0 1 of Range 0 12 Range 0 824 C 0 1 of Range 0 57 Range 1 540 C 0 1 of Range 0 07 Range 0 1409 0 10mV LINEAR 0 1 of Range 0 04 Range 0 004mV Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 221 June 2015 Analog Input RTP Internal schematic HC900 Terminal Block J1 l 6 O 2 SW 1 2 250 Ohm al 3 8 Pi i 9 O SW 2 2 250 Ohm 5 10 6 20 O SW 3 2 250 Ohm 7 19 18 17 O SW 4 2 250 Ohm 10 16 11 15 SW 5 2 250 Ohm 12 14 13 13 14 12 O SW 6 2 250 Oh
118. d RS 485 serial communications ports connect Base Stations to the HC900 controller as shown in Figure 82 HC900 Controller Modbus Modbus Modbus Slave 1 Slave 2 Slave 3 s s s 120 ohm Termination Figure 82 RS 485 Modbus slave wiring 150 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 If the RS 485 network to slave devices is intermittent or fails completely over short durations and recovers after the controller is power cycled use an external isolator with additional port biasing See Figure 83 Note Legacy Controllers do not provide biasing 120 ohm Termination Locate on physical last device on network Modbus Slave Devices HC900 Controllers B amp B electronics or equivalent 4850PDR 120 ohm Terminatio y VDC GND Figure 83 RS 485 Modbus slave wiring with isolation For XYR 5000 base stations if the RS 485 network is intermittent or fails completely over short durations and recovers after the controller is power cycled the need for additional port biasing may be required Figure 84 shows recommended installation procedure for using an external isolator and additional port bias Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 151 June 2015 Locate on physical last device on network XYR 5000 HC900 Controllers Base Stations _ Stations L T THRX B amp B electronics or
119. d off 2 Check connectors diagnostic 2 If configured as a Modbus 3 Check cable polarity iS masier 4 Isolate cabling from electrical e e AREARE p meteore pins are Possible causes are turned on 5 If RS 232 y RS 485 converteris used check its power switch jumper e Ifthe port is e Slave and read blocks settings and polarity configured as a associated with the slaves i Modbus or ELN experiencing the failure have 6 If configured as a Modbus master slave the data link their read pins frozen to the last use the slave status screens to layer is reporting vali read determine which slaves are that at least 75 of f experiencing the problem For those the last characters e Slave blocks associated with slaves check the slaves experiencing the iis oo failure have their BAD COMM Power the UART or at and NO SCAN pins turned on e Connections least 75 of the e IN SCAN STATUS is set to e address last messages NO for all slaves experiencing e baudrate received have the failure i been invalid e COMMSTATUSissettoBap Pay l e Ifthe portis for all slaves experiencing the number of stop bits configured as a failure e for electrical interference Ee a Theslaves with the data link e grounding e o of the last requests to a eee zero data e termination resistor if at end particular slave ee of link resulted in no es slaves sohe the The diagnostic is cleared by response or a reply allure are moved to the clearing the port s sta
120. d personnel should perform the procedures in this section e Disconnect all sources of power associated with these components before removal or insertion Failure to comply with these instructions could result in death or serious injury 192 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I DIVISION 2 A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN NOT TO BE HAZARDOUS Replacing the Power Supply The power supply for the HC900 Process Controller is available in two models and is used in the local controller rack and in the remote I O expansion racks in 4 8 and 12 module sizes This reduces required inventories of spare parts and also simplifies removal and replacement procedures Removing the power supply from a rack will remove all DC voltages from the rack that powers the Controller Module or Scanner Module and from all I O modules within the rack NOTE The power supply includes an internal fuse rated at 5 amperes This fuse is not replaceable in the field If desired the user can provide an external fuse that has a current rating lower than that of the internal fuse See page 70 Table 34 Power Supply Replacement al
121. ddress and related network parameters from its default using the Utilities Worksheet in the HC Designer software This may be done using either the RS 232 serial port legacy systems via a null modem cable connection or the Ethernet connection from the PC to the controller If the RS 232 connection is desired make sure the proper PC serial Com port to be used has been set up See Direct Serial RS 232 Connection page 131 Attention IP addresses for E1 and E2 must be on different subnets Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 145 June 2015 Step Procedure 8 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Note Network communication will only occur with the Lea
122. de of the smaller compartment see 1 in figure above See Table 9 steps 1 and 2 for details Insert the PSM between the 2 power supplies Fasten it in place with screws at top and bottom See 1 in figure above See Table 9 steps 1 and 2 for wiring details Revision 4 June 2015 0 HC900 Process amp Safety Controller User and Installation Manual 73 Step Procedure Comments References Set scanner address for the I O rack using the Scanner Module DIP switches on SW3 shown at right For C50 C70 use addresses 1 4 For C75 use addresses 1 5 DIP switches 6 8 must be OFF Only one DIP switch may be ON DIP switch 1 ON Scanner 1 DIP switch 2 ON Scanner 2 DIP switch 3 ON Scanner 3 DIP switch 4 ON Scanner 4 DIP switch 5 ON Scanner 5 A small slotted screwdriver or paperclip works well avoid pencils Honeywell E i Repeat steps 1 through 3 for each I O expansion rack Then for each I O expansion rack insert the Scanner Module immediately to the right of the Power Supply and secure it in place with the two captured screws in the faceplate I O will be installed later See Page 76 74 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 This page has been intentionally left blank Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Inst
123. ded HC900 Controller Configuration C50 C70 CPU only oo eee cee ceeecesecssecseeceeeseeeeeeeeeeeeeees 10 Figure 3 Single process with redundancies eceeceeccesscesecesecenecseecseeeaeeeaeeeeeeeseaeeeeeeeeesecesecsaecsaecsaecsaeeneseneeeas 11 Figure 4 Configuration with Multiple Controllers ec cec ec ceecseecseeeeeeeeeeeeeseeeeeeeecsseeesecesecaecsaecsaecseeeaaeeneeees 16 Figure 5 Redundant Configuration with multiple I O racks 00 eee eee eeeceeeeeeeeeeceeecesecesecsecsaecsaecsaeeneeeneeees 18 Figure 6 Controller Rack Component 00 00 00 ececeescesecesecesecesecenecaeecaeeeseseaeeseeeseseaeeeeesseceseesaeesaecsaecsaecsaeeaeeeneeeas 20 Figure 7 Redundant Controller Rack Components 0 ec ec ceecesecesecssecesecaeecneeeeeeeeeeseceseceseesecsaecnaecsaecsaeeaaeeaeeeas 21 Figure 8 I O Expansion Rack Components 0 cceeceecesecesecesecesecececseeeneeeaeeseeeseseaeeeeeeeeseessecsuecsaecsaecsaeeaaseneeeas 22 Figure 9 Rack Options wei ssseccaseectiss he e th stod I dedi hare hei Rodin ee aise ede ieee 23 Figure 10 Power SUpphy niieoee norisi eoor eie S EEE EOE E E S EEE E E ET 24 Figure 11 Power Status Module PSM cesssesscsesecesecessceceseeesneeceseeessaecesceeesaecesceecsaecseeecsaeceseeeesaeceeeeessaeeees 25 Figure 12 Controller Module 3 ioc so cescs sop sees stk fat sh sete ce e ao eS eE E EE EEE EEr EEE dosh evressebusbeuscbaueespesuts 26 Figure 13 Redundancy Switch Modu
124. e You may change the controller s IP address and related network parameters from its default using the Utilities Worksheet in the HC Designer software This may be done using either the RS 232 serial port legacy systems via a null modem cable connection or the Ethernet connection from the PC to the controller If the RS 232 connection is desired make sure the proper PC serial Com port to be used has been set up See Direct Serial RS 232 Connection page 131 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Network Access to one or more controllers 10 100BaseT LAN 165 125 163 25 165 125 163 26 ATTENTION Always observe the wiring cabling guidelines on page 53 Step Procedure Mak
125. e 5 April 2014 51452734 Revision C HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 INDEX A D AC Input Module Wiring ccssccsscessesssesseesseeeseeeees 103 DC Input Module WiIring cscccsscssessteceseesseeseeeaes 100 AC Input terminal block cecceesceesseeeteeeseessseeeseeesseesees 24 DC Output Module WiriNg c ccescecesessseesseeeseesseeeees 109 AC Output Module Wiring ceceesecsseeesessteeeseeeseeees 113 Designer SoftWare girne E A 29 AO ESS Stn E R See Controller access Diagnostics and Troubleshooting ccsccseseeseeseeees 169 Alarm GtOU PSaren r E E E 40 Dist nc planning ainsana a ERE 53 Alarm Event messages ccccessesseesesscessesssssssseseesesseseess 40 Download Upload cccccccsecsecsseesseseessessseessssesersesesenees 161 Analog Calibration cccccccsccssesscessseecssecseesseessseessneess 188 DSi sissies eit ale ee ul thie Ge 40 Analog Input Calibration ccccessssecssessseesseesneeeseeees 189 Analog Output Calibration cccccseessesesesseeeseeeseeees 191 E Analog Output Module Wiring cccccscsssesssesseesssesees 97 Appendix Installation of Remote Termination Panels EMail raar E E A AN E Mail Communications Emergency Stop SWitChES cccsccsssesssessseesseeesssesseeeenees CNClOSUNGL i aeee rea a e E E AER eerendst B equipment enclosureS sessessesesis
126. e HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP 230 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 Point DC Digital Input J2 J4 C C J3 J5 J7 J9 sw C CZ Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc Please see page 81 for more details ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 238 for RTP internal schematic Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 il Install jumper wires DC Supply Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 231 June 2015 16 Point AC Digital Input ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP combines the two groups of 8 inputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect desired cable to 16 point AC DI module at controller
127. e Jumper 102 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 32 point DC Input Module Wiring The 32 point DC Digital Input module Figure 57 provides two groups of 16 inputs each with a pair of terminals for connection to common DC power applied between the common terminal and an input cause the input to turn ON A green LED on the module provides indication of an ON state Logic in the controller allows the state to be inverted when necessary Requires Low Voltage Euro style 36 terminal terminal block AC Input Module Wiring zay rh lt nnner A YV N 2 caoga COVO OCOOQOQOCOOCOQOQOQOOQOQOQO QOS Legend cemal 9 n Disconnect s z apn i User supplied Safety Davicas Figure 57 32 point DC Input Module Wiring The AC Input Module has sixteen inputs An example of AC Input Module wiring is shown in Figure 58 Specifications for this module and for other modules are given in the Specifications section of this manual Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 103 Common Terminals Two common terminals are provided for each group of eight inputs Terminals 9 and 10 are connected in the input module and terminals 11 and 12 are connected in the module Jumper Comb An optional two position jumper comb is available as an option for barrier sty
128. e PC s serial port attributes for use with the controller Make sure that the same baud rate is set up for the PC port and the controller In general the faster the baud rate the better the performance however your PC may not communicate reliably at the faster baud rates Refer to the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Utilities Worksheet Set Controller Serial Port for details on this step Current PC to Controller Connection Settings Port CoM OW COM g Loop Back and Protocol Honeywell Inc ELN Speed bps 38400 PC Port Setup Network COM1 On the PC use the Utilities Worksheet in the HC Designer software to select the Com port as the current port Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 131 RS 232 Direct Link to PC Configuration Tool Legacy Conirollers The Controller can be connected directly to the PC in which case a Null Modem Cable is required The Null Modem Cable can be ordered from Honeywell Part 50004820 501 Cable connections are shown in Table 19 Table 19 Null Modem Cable Connections 9 pin D female connector 3 plug connector ONGS oO D D G h D G G OG NOK Ga wn Signal Name Pin No Connection Signal Name Plug No DCD 1 None RXD 2 Connects to T
129. e and software As long as power is applied each major component of the controller will execute one or more diagnostic elements Diagnostics have two functions they e Automatically alter system operation to react appropriately to operating conditions particularly in the event of a system fault e Provide external indications that enable operating and maintenance personnel to react appropriately when external actions are required External Indications of Diagnostic Information The following diagnostic indicators are provided e Light Emitting Diodes LEDs included in controller hardware Locations of LEDs are shown in the following figures and tables The LEDs are useful when personnel are performing troubleshooting activities solely at the controller Also they are useful for verifying indications viewed as screen items LED indicators See page Controller CPU indicators 170 Scanner indicators 178 I O Module Indicators 183 Ethernet Switch indicators 186 e Screen items on The Operator Interface connected to the galvanically isolated RS 485 port See Operator Interface manual 51 52 25 108 A PC with Designer Software Process Control Utilities connected to the controller module via the RS 232 Converter or the Ethernet 10Base T Open Connectivity port See the Diagnostics section in the application s help Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 169 Janua
130. e module 184 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Numberof Failure Description Al AO DI DO PFQ User Action ae Contact AC DC Relay AC DC 8 HARDWARE General Hardware Failure y Replace module Al convertor not working 9 HW SW Key The software residing on the y V IV fv y Replace module module does not match the module type This diagnostic should only result in the factory 11 Shift Register The loopback test of the shift y Viv IV IV fv Replace module register failed Bad I O Channel Diagnostics Individual channels on I O modules indicate their diagnostics by 6 flashes on the Scanner and CPU the channel s LED does not indicate a diagnostic Table 32 is a list of conditions that can cause a bad channel diagnostic Table 32 Bad I O Channel Diagnostics Module Failure message Description User Action Type indicated on Honeywell Ol or Honeywell HCDesigner Utilities function block monitor Al Burnout Failure The sensor T C RTD or mV source is failing burnout checks Check terminal block connections Replace source element Replace module Under range The signal at the terminals is less than 10 below the range of the sensor Check the signal level being applied to the terminals Replace module Over range
131. e sure the PC has an Ethernet NIC Network Interface Card installed and enabled Be sure the NIC has an IP address fixed or DHCP served that allows access to controllers with IP addresses on the same or other subnet Consult your IT department or network administrator for allocating IP addresses to the controllers if required 2 You will need to set each controller s IP address prior to network connection since every HC900 controller is shipped with the default IP address of 192 168 1 254 Placing multiple controllers on the same network before they have been given unique IP addresses will cause problems 3 On the PC use the Utilities Worksheet in the HC Designer software to set up the serial RS 232 Legacy or USB RS485 connection to the controller at the desired baud rate see Direct Serial RS 232 Connection above This will require a null modem cable 148 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Procedure Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC COM port to be used then set the controller s new network parameters including IP address Subnet Mask and Default Gateway if required See your IT network administrator for proper entries Refer to the on line help provided with the HC Designer software Utilities Worksheet Set Controller s Network Parameters for further details on th
132. e the I O Modules and or the diagram shown next page i Example 777 Tabs Removed Ra for AC Output Module Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 83 June 2015 Step Procedure Comments Reference 4 NOTE In the diagram below the white cut outs represent the cut outs on the modules that cont d accommodate tabs on the Terminal Block That is all key tabs that line up with the white cut outs on the diagram should be retained and all other tabs should be removed The orientation of the diagrams below corresponds to the picture of the terminal block shown in the previous picture Diagrams for I O Module Key Tabs 120 240Vac 125 VDC IN 120 240Vac IN 120 240Vac OUT 24Vdc OUT 32 DO Relay OUT Contact IN 16Al PFQ 32DI Analog OUT 24 VdclIN Analog IN HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Procedure Comments Reference 5 If installing High Level 16 channel Analog Input module set its SW1 and SW2 DIP switches to ON This connects an internal 250 ohm resistor A small slotted screwdriver or paperclip works well avoid using pencils J Honeywell Do f N Qa Z Ww E gt A Ga oe b gt k a5 NA 6 If installing 8 or 16 channel Analog Output module set its DIP switch as follows Switch is located at edge of module mark
133. e until power is removed The operation of the system varies according to the following interacting factors e Power transitions Power DOWN Power UP Power DOWN transitions are usually planned and controlled but in some cases such as power outages are unintended To ensure proper operation in either case the HC900 Controller includes software that controls operation at power restoration The controller handles a Power UP transition as one of two types Cold Start or Warm Start e Operating Modes Program Locked Program Offline Run and Run Locked Operating Modes are selected by positioning the Operating Mode switch on the Controller Module or RSM by selecting parameters on displays Control Station Designer Software In some cases mode transitions also restart Cold Start or Warm Start controller operation e Results of diagnostics in case of system hardware or software fault the controller automatically alters operation as appropriate for the diagnosed conditions Power Down Power Up The HC900 Controller is designed to facilitate restoration of process operation after a power outage The active control configuration is maintained in battery backed RAM and the last configuration update performed in the program mode is also stored in Flash memory on the Controller Module When power is restored the system automatically enters a diagnostic procedure that checks the integrity of hardware software and the control datab
134. eT X to 100BaseFX multi mode fiber port with SC connectors require 24VDC power Fiber Cable Multi mode Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet FO Connector SC Type Figure 96 and Figure 97 are examples of Extended Distance configurations Moxa Switch 10 100 EDS 308 MM SC 10 100 HC300 Copper Main Rack Sopper pp Rack 1 Fiber Cable Distance 750M 10 100 Copper Fiber Cable Distance 750M Moxa Media Converter IMC 101 M SC 10 100 Copper Moxa Switch EDS 308 MM SC As a Repeater Fiber Cable Distance 750M Moxa Media Converter IMC 101 M SC Figure 96 Extended Distance Example 1 212 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Moxa Switch Moxa Switch EDS 308 MM SC 10 100 Hcgoor 10 100 EDS 308 MM SC Copper Redundant Copper ew Copper HC900R Copper VO Rack1 10 100 HC900R Copper VO Rack 2 Fiber Cable Distance 750M Fiber Cable Distance 750M Moxa Media Converter 10 100 IMC 101 M SC Copper Moxa Media 10 100 Converter HC900R Copper IMC 101 M SC VO Rack 3 Moxa Switch EDS 308 MM SC As a Repeater Moxa Switch EDS 308 MM SC As a Repeater HC900R Copper VO Rack 4 Moxa Media Moxa Media Fiber Cable Converter 10 100 10 100 Converter Fiber Cable Distance 750M IMC 1
135. eaeeeas 92 Figure 47 Analog Input Wiring Eight TCs ee eecesecesecesecssecsaecaeecneeeaeesaeeseeseeesecsecsaecnaecsaesseeeaaseaeeeas 93 Figure 48 Analog Input Wiring Eight Resistance Inputs cee eeeeeeeeeeeeeeeeceeeeeeeceseesecsaecsaecsaecsaesseeeaeeees 94 Figure 49 Analog Input Wiring Eight RTDS 000 ee ceeceseceeceseceecseecaeeeaeeeeeseeeseeeesecsecsaecnaecsaessaeeaaeeaeseas 95 Figure 50 Analog Input Wiring Slidewire Position Proportion Block eee eee cese cee cneeceeeseeeeeeeeeeeeees 96 Figure 51 16 point High Level Analog Input Wiring oo eee csc creeeeeeeeeeeeeeeeeeeeesceeseessecsaecsaecsaecsaecaaeeneeeas 97 Figure 52 4 channel Analog Output Wiring Diagram eee cseeeeeeeeeeeeeeeeeeeeeeeeeeceseesecsaecsaecsaecsaeeaeeeaeeeas 98 Figure 53 8 channel Analog Output Wiring Diagram eee ceeeeeeeeeceeeeeseeeeeeeecesecesecssecsaecsaecsaecsaecaeeeaeeees 99 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual xi June 2015 Figure 54 16 channel Analog Output Wiring Diagram ee ee eeceseceseceseceseceeecneecseeeaeseaeeseeeeeneeeseenseenaes 100 Figure 55 DC Input Module Wiring Diagram 0 eee ee ee ceeeceseceecssecenecaeecaeeesecaeecaeecseseaeseaeseeesseeseenseenseenaes 101 Figure 56 DC Input Module Jumper een s na e e a a E E E A een edasuign E 102 Figure 57 32 point DC Input Module Wiring eeeeeseesseeseseeesesreressrrreereseeerrseeresseerrsteteste
136. eater at the midpoint See page 212 With redundant CPUs when using 2 or more I O racks an Ethernet switch is required between each CPU and the I O racks Use Honeywell approved switches only see page 212 Maximum of 2 switches between each CPU s I O port and all I O racks Cable lengths specified in this manual are absolute When planning for routing of cables and wires be certain to include vertical and horizontal routing within cabinets raceways and conduits It is advantageous to minimize length of I O wiring However it is also a good idea to locate racks and wiring away from adverse environmental conditions such as sources of RFI EMI and away from areas with high levels of moisture dust and corrosive materials Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 53 How to make Ethernet cables no crossovers 1 Hold the cable ends and RJ45 connectors side by side as shown Straight through cable assembly Cable left end Left to right Wire color pin number 10Base T 100Base T Signal Description Cable right end Left to right Wire color pin number white orange 1 TX white orange 1 Orange 2 TX Orange 2 white green 3 Rx white green 3 Blue 4 Unused Blue 4 white blue 5 Unused white blue 5 Green 6 Rx Green 6 white brown 7 Unused white brown 7 Brown 8 Unused Brown 8 Ethernet cable shielded Cat 5 contains
137. ed SW1 e For internal rack power set DIP switch to ON e For external power 18 36V set DIP switch to OFF default Note 24VDC external power is required if using 6 or more 8 pt AO modules or 3 or more 16 pt AO modules A small slotted screwdriver or paperclip works well avoid using pencils 8 16 Analog output Channels require loop power for open loop detection Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 85 June 2015 Step Procedure Comments Reference If installing a PFQ module set its Input 1 Input 2 and Index DIP switches to differential or single ended mode Inputs mode need not match index mode See below for switch positions Switch location on PFQ module Honeywell HE sw 7 INPUT 1 SW2 INPUT 2 SW3 on Orr INDEX F Settings using Input 1 as example Single ended factory setting ON OFF IN1 Cast DIFF _ coo LIN SINGLE ES J 1 and 2 SINGLE ON 3 and 4 DIFF OFF SW 41 Differential ON OFF SINGLE INGLEIZ DN iH Oca int 1 and 2 SINGLE OFF 3 and 4 DIFF OSW 4 86 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Procedure Comments Reference Connect wire tie into the top and or bottom of the Rack Form a bend in each wire to provide strain relief and secure the wire bundle with
138. ed could result in death or serious injury This CAUTION symbol may be present on Control Product instrumentation A CAUTION and literature If present on a product the user must consult the appropriate part of the accompanying product literature for more information This CAUTION symbol indicates a potentially hazardous situation which if CAUTION not avoided may result in property damage WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury A ATTENTION Electrostatic Discharge ESD hazards Observe precautions for A handling electrostatic sensitive devices CAUTION HOT SURFACE This symbol warns the user of potential hot surfaces which should be handled with appropriate caution Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor LIN Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to protective earth at the T source of supply in accordance with national and local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective earth at the source of supply in accordance with national and local elec
139. ee status LED is MEMORY inthe indicating the Reserve CPU failure see Diagnostics Memory display Diagnostics in the Reserve Diagnostics Overview dialog box 4 Battery voltage is low e ASYS and FSYS blocks Replace battery LOWBTRY pins are tumed on e ASYS and FSYS blocks HW OK pins are tumed off e Firmware upgrade is inhibited until both the Lead and Reserve batteries are good 4 Flash failed to bum ASYS and FSYS blocks HW OK 1 Force a cold start pins are tumed off 2 If diagnostic does not clear replace CPU module 5 The Real time Clock 1 On power up time and date is Use HCDesigner HCUtilities or Ol to If the lead s status If the lead s status RTC is not initially set to 00 00 00 January 1 program the real time clock RTC LED is indicating LED is indicating programmed This is 1970 on both the lead and the the failure see the failure see usually a result of the reserve RTC inthe Lead Real Time Clock lead s battery failing fo asys and FSYS blocks HW OK CPU Diagnostics Diagnostics in when it was powered pins are tumed off display rb Lead a Note If the reserve s battery fails Ifthe reserve s Seer when it is powered down The lead status Laie 7 box will automatically program the indicating the reserve s RTC with the correct date failure see RTC in If the reserve s and time when the lead and reserve the Reserve CPU status LED is are synchronized Diag
140. eeaeeeses 78 Table 13 RIUP Potential Hazards and Recommended Actions c cesscceseeeeseceereeesseceeeeecaeceeeeecaeceeneeenaeeeees 81 Table 14 Connect Input Output Wiring oo eee eeeceeeceeecesecesecesecsaecsaecseecaeesseseaeeseeeseeeseessesaecnaecsaessaecaeeeaa 82 Table 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees Fu eee eee eeeeeeeeeee 89 Table 16 Connect Communications Wiring and Cabling 0 0 eee ceecese esse cseecseceeecaeecneeeneseeeeeeeesenseenseeseenaes 125 Table 17 Links to Controller Communication Ports eescceseceeseeceseeeesceceeeeeneeceeeseneeceseeeeneeceeeeseneeceneeeeneeens 126 Table 18 Parts needed to make RS 485 Cable cece ceeecceecceescesecesecssecaecsaecseecaeecseseaeseaeeeeeeseeseenseenseenaes 129 Table 19 Null Modem Cable Connections eeccessceceseceeseeceseeeeneeceseeesncecaceceaeecanesenceceeeeseneeceeeseneeceeeeeneeens 132 Table 20 Redundant Network connections in Figure 80 0 0 ec eeceeceecesecesecesecssecseecaeecseeeaeseeeeseeeeenseenseenseenaes 144 Table 21 Redundant network CONNECTIONS cescceesceceseeeesceceeeeeneeceseeeeaeeceaceseneeceseesenaeceseeeeaeeceeereneecetreeeneeens 145 Fable 22 Controller Operating Mod s ecciescceseeascecsevscseesdpsupevseneeseveceat eovecueostceenee ie E pE E Sa HES SEIRE si 158 Table 23 Mode Switch Functions pecine e n E a E e E EI TE N Ene i ikini 159 Table 24 Controller Behav
141. eees 77 test POINTS enr eaS NE NEEE SENEE 70 Tea T EEE TE E TEA 39 transmission d la yS peronra aiy s 53 U UDP EEEE A E 36 Universal Analog Input Wiring essssessssesssreesrererseese 91 97 User Datagram Protocol cccccssccesscesecsssessseesseesseeeenees 36 V Vertical Spacing Of RACKS ccscccssccsssessessteesseessteesneeeees 49 Voltage test points WwW WAN 25st ciate nena eel en E E 36 Warm Start aisant citric E RE 153 Wire Gasper EN EE AEE een AE E 78 TARIA AEEA S E aur le aden at Ble 78 S ANTEA S PAA AEE E E E E E EE EE 87 Wiring RUES stiic paa e E a E tise 78 SCADA s a A A ah ee iS Scanner 2 Module Scanner Diagnostics X Scanner Module C50 EVR STII Posh a an ALEN 151 SCanner rack ASSEMDIY ccssseseseesssesseesseecseeesteesseesenees Serial port ACCESSING ase e vec ecves Serial Ports xiao wee eae eee RS485RS232 irei voces sates garers test atin det STSP iana ee N E A Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 257 June 2015 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC Honeywell Process Solutions TAC hfs tac support honeywell com Australia Honeywell Limited Phone 61 7 3846 1255 FAX 61 7 3840 6481 Toll Free 1300 36 39 36 Toll Free Fax 1300 36 04 70 China PRC Shanghai Hone
142. eeni aerae ea Ea EAS TEENE Jumper Comb Jumper Combs Parallel proceSSing c cccssssssssssssssssssesssssscssesssssesessesteeees JUIN PETS tisi nA e aore EEE a ENEA E ES PHOST A AE T NA LON m o T E EE EO aid NEEE E E AE TE K PCM od m Cables i a eevee ts aiB SEEE A E Kepware EE E A eee ee 39 Peer Data ExChange cccccsccscssssssssssssscescsscsssssssesseneeesens key tabs TENO ENOTE EAREN AITE NOON OSAA E 83 Peer to peer communication Personal Computet 00 L PlantScape Vista Software ae a Power DOW N a nar e E ES babel a A a 82 Power Down Power UP cccscessessssseesscsseesesseessesseeeeees labeli innnan AA E 77 Power Status MOdUule ccccccccssccesssecceseeeessseeeesseees LANs araras a cenrechenecharcaue aire 36 Power SUPP yns E LED Indications on Ethernet HUD cccccsscccesseeeesseeee 186 Power transitions oiii eiiean LED Indications on I O Module seese 183 POWER UP EE eters Ne cote acta ete oad LED Indications ON Main CPU cc cccccccsessssseeeeeeessseeee 171 PROGRAM Mde ssccccesessssscceeesessseesecessessnneceneeens LED Indications on Scanner Module c cccscceereeseees 179 PV Input Types and Ranges ceeeseeeeneees LED IndiCatOrses 2 seiel hie ees E E T 178 lithium batt ry nenei an g ction E GR 26 R Local Area NetWork iniciaria ii aeia 36 rack address for O ccccscccsssccesssescssssssesssesessseeesssseneeaes Rack Dimensions rack installation
143. ees 108 Controller access Hardware and wiring considerations for safety how to access via serial port when port settings are COnfigUrAatiON sae ea a eas 61 UNKNOWN oo eeseeseeeees testes teeatesneesteententeentesneenteeneeny HC900 Process Controller eeeeecesseseceeeeseeeeeseeeeeeeeneeeas 9 Controller Modes Heat Rise De rating c c cscscescssescssesescssssscssssesesseseseestseees 51 Controller Module IMA eara decker dete roceden baled ate del det dees celta 38 Controller Module Diagnostics HUD a araa EE e RA A E AAEN RS 34 Controller Name giest iise a Controll r Racka s a eet CUSTOM Sra Dhics cc an A E R ENER a Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 255 June 2015 l M I O channel numbers sssesseesseseseeessiesssieesrieessiesrressrrrrerres 77 Master Control Relay ccccccssscsssecssseeseeesseesseesssesseeesnees 59 I O Expansion Network C50 CPU only e seseeeeeeeeees 33 Modbus mapping Structure cccccssesscsssseesstessseessneeenees 38 1 O Expansion Network C7OR ccccsesseessessesseeseseeeseees 35 MODE Switches te aie et E Rk 159 1 0 expansion POFt ccccscceccessssecesecsecssseseeesessessreees 27 28 Mode Transitions cccsssessssssssecsssscssessseeeeeeeeeeeeeeeeees 159 1 0 Expansion Rack cccscccssesscsseesecsscessesesssessessessseeeeens 22 Model number I O expansion rack assembly c ccsceseeeeeeeeeeeeeeeeeeeeees 7
144. efer to the HC900 Process amp Safety Controller Safety Manual 36 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 eoero i PC Host PC Host PC Host i 2 4 1 Networking Devices e g Hubs Switches etc Configuration File Configuration File Function Blocks Function Blocks PDE Read PDE Read PDE Write PDE Write PDE Control PDE Control Figure 21 Modular Network Structure Connection to PC Hosts For legacy systems connection to PC hosts for example PCs that include HMI supervisory software and or Designer Software configuration software can be via Modbus TCP as well as serial Modbus RTU over either the RS 485 or RS 232 communications ports Both ports support Modbus RTU and are configurable as master or slave For new systems connection to PC hosts can be via Modbus TCP as well as serial Modbus RTU over the galvanically isolated RS 485 communication ports The TCP hosts can be concurrent with Modbus hosts on one or both of the other ports Any given controller is capable of concurrent communication with up to 5 TCP hosts on C30 C30S controllers or up to 10 TCP hosts on C50 C50S C70 C70S or C75 C75S controllers The meaning of the term host varies but for this definition a PC host is any PC that is on the same LAN as the controller or on any LAN or WAN Wide Area Network that is network connected to the controller Each HC900 Controller
145. elay Output Module Jumpers eee cee eeeeeeeeeeeeseeeceesecesecsecsaecsaecseecaeecseseseseaeeseeseeeeseenseeseenas 119 Figure 70 Pulse Counting Wiring seio cus csscssccesntseesosyessdvessiss eare in r E EESE Eep oE ESSEE eSEE EEEE a e E E E 120 Figure 71 Pulse Output WINNS ie e r ees EE aS ep a EEEIEE AEREE oIa TE ee VEERE IT PER r EEE SENERS 120 Figur 72 Frequency Wining aesir e E EE E EEE EE AE E SE 121 Figure 73 Quadrature Differential External Power Wiring eseesseseseseeesrsrserssrerssrerrssesrenresrenresrenrnserrrnresreere 121 Figure 74 Quadrature Single Ended External Power Wiring eeseseesseeesrereeseseerssrerrssesrensesrenrssrerrnserrrnserreees 122 Figure 75 Quadrature Differential HC900 Power Wiring eee cece cseecreeeseceeeeeeeeseeeeeeceeeeeseensecseesaeenaes 122 Figure 76 Quadrature Single Ended HC900 Power Wiring 00 2 cece cee cseeeseeeeecseeeeeeeeeeeeeeeeeeseeeseensecsseeaeenaes 123 Figure 77 A Direct Serial RS 232 Connection 0 00 cece eceesceeceescesecesecesecssecsaecseecaeeeaeseaeeeeeseeeeseeeseenseeaeesaeenaes 131 Figure 78 RS 232 Remote Access via Modems 00 cceeccescesecesecesecseeceeecaeeeseeesecaeeeaeseaeeeeeseeeseesseenseesasenseenaes 133 Figure 79 Modem Connection ceeecesccesecesecssecssecseecseeeseeeaeeeeeeseeecenseceseceaecsaecsaecseecaeecaeseseseseeseeeeeeeeeseenseenas 134 Figure 80 Redundant Networks see Table 20 o0 ec ceeeeeeseceececs
146. em block Rack Monitor blocks Communications Loop Outputs Current time proportional position proportional 3 position step motor positioning dual output heat cool Control Loop Types PID A PID B Duplex A Duplex B Ratio Cascade Carbon Dewpoint Relative Humidity On Off Auto Manual Bias Auto tuning Accutune III fuzzy logic overshoot suppression applicable to all control loops Setpoint Programmers Ramp Types Ramp Rate or Ramp Time Time Units Hours or Minutes Segment Time 0 99 999 999 hours or minutes Program Cycles Up to 100 or infinite configurable segment range Programmer Events Assignable to DO or internal status Setpoint Profiles 50 segments per profile Number of stored profiles is user configurable Setpoint Scheduler Ramp type Time units Hours or minutes Segment time 0 001 to 9999 999 hours or minutes Cycles Per segment to 999 or infinite Ramp time Auxiliary Scheduler Setpoints Up to 8 setpoints soak only Schedule events Up to 16 assignable to DO or internal status Setpoint Scheduler Schedules 50 segments per schedule Number of stored schedules is configurable Sequencers States 50 State text 12 characters Steps 64 Time Units Minutes or Seconds Digital Outputs 16 Analog Output 1 configurable value step Step Execution On Time Event 1 Event2 or via Advance Next Step Any step Sequences Number of
147. equivalent 120 ohm aye 4850PDR VDC GND Figure 84 XYR 5000 RS 485 Modbus connections with isolator RS 232 Modbus Connections For Legacy controllers connect to the RX TX and ground pins of the controller s 3 pin RS 232 port See page 42 for RS 232 DIP switch settings Table 19 page 132 identifies the pins For connections on other device refer to its product manual For new 6 x controllers use an RS232 RS485 converter Use Designer software to Configure the legacy controller s RS232 port or New 6 x controllers RS485 port as a Master of Slave Use HC Designer software to configure the controller s RS 232 port as a master or slave 152 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Operating Characteristics Introduction This section applies to all controllers that is non redundant and redundant For operating characteristics unique to redundant controllers see Redundant Operating Characteristics on page 163 This section provides insights into system functioning that are useful in configuration in installation commissioning tasks and also in normal and abnormal operation For related information regarding diagnostic indications how they should be interpreted and determining appropriate actions refer to the Diagnostics section in this user manual Overview The HC900 Controller components begin operation as soon as power is applied and continu
148. er Powel cessseeseeseeeees 81 Removal and Replacement Procedures csceeseeereees 192 Replacing an 1 O Module ccscsesssesssssseeessesseeseeenes 197 Replacing the Controller MOGUIC cc cccsccseteesteeseeees 195 Replacing the Power Supply c cccssccssesseesesssseesreees 193 Replacing the Scanner Module ccsccsssessseesseeseeees 196 Reserve Power Supply Service ProOVid lve ea ae eens EE ER 40 Shielded twisted Paifssnesiinna ees eae erect 58 Signal Gro n dinganii i eace sees EE E 79 Simple Mail Transport Protocol cccccescesseesteeessesseeees 40 Site and Equipment Preparation cceeseeeeeteeeeeneeeees 65 SMTP scsceasssades aisantessiges sad sisazaia sap a a i a a ioa 40 SOCKETS ses casciesccspescisuaveisaa veers gazcnsencansneeney AEE SEa 37 Specifications i2Aseseic ese ie ieee ens 202 SPECVIEWS 2 nnno ils nish i i a E S 39 StatUS NEE REE A E dee ceteenastd igi netecees 153 Subnet Mask sirrin innoar a 36 System Monitor Function BIOCKS cccsceesseeeteeseesreeees 63 T tagn mMe Svene a e E E EE E a 82 TOP I P a A N OE NA 38 Telephone and Email Contacts cscccsccsscssseessteeeseeees iv telephoneilinkS nisana a E Ea 29 t rminal DOCK ici sic ssssassisssdoasectisheatesaseacesbipbededsaaiavaco essieas 76 Terminal Block COlOrs ecesesceeeeeeeeeeeeeeeeeaeeaeeeeeeaeeeees 77 Terminal Block Styles ccccecsecssessssesseeseeesseesseessseesse
149. er User and Installation Manual 197 June 2015 Table 38 I O Module Replacement Step Action A CAUTION Removal or Insertion Under Power of an I O module is an option but if operating circumstances permit disconnecting power from the rack is the preferred option Plan and develop an action sequence before beginning the replacement procedure Primary considerations include When replacing I O module the voltages to the modules must be disconnected at the field device before removing the terminal block from the module Loss of control monitoring in a running process Each signal at each of the terminals for an I O module has a specific function Any or all of the signals may be vital for safely controlling a process Determine the functions of all signals to the modules and know the potential consequences of losing each If possible transfer control to alternate mechanisms otherwise bring the process to a safe and controlled shutdown 1 A WARNING Disconnect all signals from power sources using user supplied switches at field devices Use a meter to ensure that all voltages are disconnected If a power down replacement procedure is opted also disconnect power from the rack using the user supplied switch in the site AC power source Loosen the captive screws at top and bottom of the module loosening the screws will cause the terminal block to be partly extracted from the module connector Remove the
150. ere until both Reserve lights are on then release key Table 24 Controller Behavior in Mode Transition Initial Mode New Mode Controller Behavior PROGRAM RUN Validate configuration database Reset all I O scanners Upon startup initiate Cold Start sequence Diagnostic Identify and configure all I O racks and modules All output modules are configured with Failsafe values Any modules not included in the configuration are configured with default values which cause outputs to be Off While in transition all output modules are Off when transition procedures are completed Function Block processing begins and output values are set to Function Block output values Any calibration process that was in progress is immediately aborted and the results are discarded PROGRAM OFFLINE Same as PROGRAM to RUN transition except that Function Blocks are not processed and outputs remain Off Any calibration process that was in progress is immediately aborted and the results are discarded RUN PROGRAM Set all channels of all output modules to Off Set all output module Failsafe values to the Off state Turn off the LED indications on all output modules OFFLINE PROGRAM Same as RUN to PROGRAM transition Any calibration process that was in progress is immediately aborted and the results are discarded RUN OFFLINE Freeze output module channels Freeze Force LED indications on all output modules
151. ernal Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 2 pin connector use a DB 9 male to DB 25 female modem cable If your PC s RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232 cable 2 Connect power to the modem 3 Power up the modem 4 Run a serial communication port program such as Hyperterminal 5 Within the communication program select the port to which the modem is connected 6 Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key 8 In the program s terminal window key in in the following command string AT El QO Then press the ENTER key The modem should give an OK response 9 Key in the following command string AT amp CO amp DO amp KO amp R1 amp SO amp Y0 SO 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp W0 The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem s serial cable to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900
152. es use power supply 900P02 0001 If the answer to 8 is No use power supply 900P01 0001 46 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 DC Power Supply The P24 DC power supply is for use with 24V input power applications The wattage rating is the same as the P01 60W Rack Orientation and Mounting Racks must be mounted as indicated in illustrations throughout this manual so as to provide for vertical airflow through the racks That is racks must never be mounted vertically and must never be mounted with the backplane horizontal for example flat on a horizontal panel or tabletop Environmental specifications apply only to the normal mounting configuration Rack dimensions including overall dimensions and patterns for drilling holes for mounting are given in Figure 26 and Figure 27 Vertical spacing of racks which is required for rack ventilation and for routing wires is shown in Figure 28 Rear mounting F Total Depth plate Chassis Rack height height components 54 For 32 DI DO amp 16Al 175 137 Reference Center E caia E eae for Drilled Holes _ lea ste cS at Top of Rack i on 153 15 153 Figure 26 Rack Dimensions Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 47 June 2015 Reference Center for Drilled Holes D Figure 27 Rack Dimensions with reserve power supply
153. esrerirrerrsrsrrsrsrrsresens Ethernet Devices sseeesesrsierseierisrsrierrrrsrisrerrerere backplane snn E 70 76 Ethernet Open Connectivity Network ssssessssesseese 30 35 barrier Stylea eraai aeea E a a Eai 77 Euro Stylea ineeie ana avai E Eaa a Ea aiaia 29 77 B rtierstylensin i a s 29 Event Gro PS a Meter a aE 40 Battery Installation c cccsesssessseeesseesteesseeeees 71 72 199 Battery Installation ReplaceMent ccccceseseeeeees 71 72 F Battery Replacements 201 Field Signal Wiring C Filler BIOCK cesses Flash s C30 C50 controller rack assembly ccceeseseseeseeeeeeaees 69 Form A relays T E ence sei ates ei ese C7OR controller rack ASSEMDIY cecceeseeesteesteeeseeeseeess 72 Form C relays te aiein hana nee ens Cabinet Wiring e263 cnt Steen peti Bee 55 FUSOS 20st A E A ee OU ee a Cable lengthivas igncinitetisencnndiatiasiieguntendt eau 53 FUSING E E E E A E se cable segmentasyon r ah nian nee 34 Cable Typene A E AE N 126 G Cables how to make shielded CATSE ccccscssssseseseeeesesesesens 54 ground voltage potential cccccccscsessseseescssssseseeeeeeees 79 captured ScCreWS niiina AE E EAE 76 grounding balisi erensia ineine inii Eaa CE C NfornMitY e eeren E EE N 58 grounding bars Ea lo I E EEE E ETEEN ENEE S 153 Grounding lug COM Traer nate aen a E Gar tee 29 Communications Installation s es 125 H Contact Input Module Wiring cccsccsesessessteestsee
154. g amplitude 2 5 mm amplitude 2 5 mm peak to peak peak to peak 14 Hz to 250 Hz 14 Hz to 250 Hz acceleration 1 g acceleration 1 g Applies up to 40C Table 41 HC900 PV Input Types and Ranges Type Range Range High EU Reference Corresponding Low UMC800 Input type and range None n a B 18 1815 C B 40 1820 C 58 B 0 3300 F B 104 3308F 59 E 270 1000 C n a E 454 1832 F n a E 129 593 C n a E 200 1100 F n a J 18 871 C J 200 870C 4 J 0 1600 F J 328 1598 F 5 J 7 410 C J 0 400C 2 J 20 770 F J 32 752F 3 K 18 1316 C K 01200C 16 K 0 2400 F K 322192F 17 K 18 982 C K 0 800C 14 K 0 1800 F K 321472F 15 K 29 538 C K 0 400C 12 K 20 1000 F K 32 752F 13 Ni NiMo 0 1371 C NiMo 01400C 50 Ni NiMo 32 2500 F NiMo 32 2552F 51 Ni NiMo 0 682 C n a Ni NiMo 32 1260 F n a NiMo NiCo 0 1371 C MoCo 01400C 110 NiMo NiCo 32 2500 F MoCo 322552F 111 NiMo NiCo 0 682 C n a NiMo NiCo 32 1260 F n a NiCroSil NiSil 18 1300 C N 01200C 24 NiCroSil NiSil 0 2372 F N 322192F 25 NiCroSil NiSil 18 800 C N 0 800C 22 208 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Type Range Range High EU Reference Corresponding Low UMC800 Input type and range NiCroSil NiSil 0 1472 F N 321472F 23 R 18 1704 C R 20 1760 C 28 R 0 3100 F R 43200F 29 S 18 1704 C S 01
155. h rack in your system 68 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Assemble Controller Rack C30 C50 C70 Controller Rack assembly information is given in Table 9 C75 Controller Rack assembly information is given in Table 10 Table 9 Assemble C30 C50 C70 Controller Rack Step Procedure Comments References 1 Carefully place the Power Supply in the leftmost slot in the Rack ensuring that the connector at the back seats properly Insert a slot screwdriver in the slots at the top and bottom of the power supply cover while pulling backward to open the cover Fasten the screws captured in the face of the power supply into the tabs at top and bottom of the rack Torque to 0 4 0 5 N m 3 5 4 4 Lb In A WARNING Ay Hazardous Voltage e Ensure that wiring to the Power Supply is disconnected from the site AC source before installing wiring e Do not remove Yellow Green wire from grounding stud on the power supply Failure to comply with these instructions could result in death or serious injury Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 69 Step Procedure Comments References Ensure that wiring to the Power Supply is disconnected from the site source and then connect AC wiring to the power supply as shown at right N
156. he I O port on the controller to the switch Two cables go from the switch to 2 scanners A third cable goes from the switch to a second switch which connects to a third remote scanner HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 I O implementation requirements include e Constructing a configuration file and loading it into the Controller Module This file includes I O numbering assignments for each I O Function Block regarding Rack Number Module Number slot number or position in the rack starting from the left and Channel Number e Physically assigning Rack Numbers by positioning DIP switch settings in the Scanner Module for each rack e Placing the appropriate module type in each slot in each rack The I O expansion network uses Honeywell private protocol that optimizes I O performance and security The configuration and operation of the I O expansion network is automatic it is entirely under control of built in private software that resides in the Controller Module and in each Scanner Module included in the HC900 system The controller examines the control strategy stored in its memory verifies that the physical configuration Rack Numbers and I O Module type by Module Number matches the stored control strategy and establishes communication with each of the I O modules in each of the I O racks I O Expansion Network C75 C75S T O for redundant controllers is the same
157. he modem 4 Run a serial communication port program such as Hyperterminal 5 Within the communication program select the port to which the modem is connected 6 Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp F0 Then press the ENTER key 8 In the program s terminal window key in the following command string AT El QO Then press the ENTER key The Modem should respond with OK 9 Key in the following command string AT amp YO amp CO amp DO amp R1 amp SO amp KO S0 1 Then press the ENTER key The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp W0 Then press the ENTER key The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller 140 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Best Data 56SX Data Fax Ext
158. he rack adjacent to the Power Supplies Fasten them in place with captured screws at top and bottom Torque to 0 4 0 5 N m 3 5 4 4 Lb In ATTENTION The CPU baitery comes installed with a plastic tab protruding from the battery cover This tab breaks the battery circuit Do not remove this tab at this time Removing the tab before the controller is configured can substantially shorten battery life Remove the tab under power after the controller configuration is complete For more information refer to Battery Installation Replacement page 199 See figure in step 1 Insert the RSM in the middle slot and attach with screws at top and bottom See figure in step 1 72 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Assemble I O Expansion Racks T O Expansion Rack assembly information is given in Table 11 Table 11 Assemble I O Expansion Racks Step Procedure Comments References 1 Insert power supply into left most slot in the I O rack See Table 9 steps 1 and 2 for wiring details If using redundant power your I O rack will contain a second smaller compartment see 1 in the following figure Insert first power supply in the larger compartment as shown to the immediate right of the plate dividing the two compartments Redundant Power optional Insert the second power supply in the left si
159. he shield grounding section page 79 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 243 June 2015 16 Point Analog Input Mount RTPs to DIN rail Latch to rail See page 251 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs voltage is still present on the positive side at RTP and module terminals 3 C Om Cm Cm Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is possible but See page 250 for RTP internal schematic 244 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 RTP A for inputs 1 to 10 RTP B for inputs 9 to 16 Notice that Inputs 9 and 10 are connected across RTP A and RTP B Figure 106 Voltage input connections RTP A for inputs 1 to RTP B for inputs 11 to 16 Not shown recommended external current loop fuses Additionally on RTP A connect the following terminals 3 22 4 23 7 24 8 25 15 26 16 27 19 29 20 30 On
160. hods e A Direct Serial RS 232 connection See page 131 Direct with RS 485 and RS 485 to USB converter with supplied instructions e B Modem connection See page 134 e C Direct Ethernet connection See page 147 e D Networked Ethernet connection See page 148 These methods are described below ATTENTION Always observe the wiring cabling guidelines on page 53 130 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 A Direct Serial RS 232 Connection Legacy Controllers PC Null Modem cable Figure 77 A Direct Serial RS 232 Connection ATTENTION Always observe the wiring cabling guidelines on page 53 Step Procedure Prepare a null modem cable Refer to RS 232 Converter Direct Link to PC Configuration Tool page 132 for specific instructions on the null modem cable Connect one end of the null modem cable to the HC900 controller s RS 232 configuration port Connect the other end to an available serial port COM1 through COM8 on your PC Refer to RS 232 Converter Direct Link to PC Configuration Tool page 132 for specific instructions on the null modem cable If a configuration is not available start a new configuration in HC Designer by selecting File New After selecting controller type and revision select OK From the Utilities Worksheet Utilities tab in the main window in the HC Designer software set up th
161. ibration Analog output modules have essentially one output type A diagram of a precision ammeter connected to the terminals of a 4 channel Analog Output module is given in Figure 95 The specifications of the meter must be consistent with calibration requirements See page 99 for terminal connections for 8 and 16 channel AO sussecuouccoqoonrs oa Sevecee OUT 1 A ft LTETETEETETEEEETT Milliameter OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 95 Terminal board Connections for AO Calibration Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 191 June 2015 Removal and Replacement Procedures Overview This section contains procedures for removing and replacing the active components of an HC900 Process Controller It also includes recommendations suggestions and hints as they apply to the circumstances under which the procedures are used Safety Considerations PLAN AHEAD When using the procedures in this section plan the sequence of procedural actions so as to ensure e The safety of personnel e The protection of property e The integrity of operating processes The first consideration is safety of personnel While there is always an inclination to preserve the materials and time invested in a running process no action should ever be taken that would risk injury to personnel Protection of personnel property is an important consideration that a
162. ications Installation This section contains descriptions procedures and recommendations for installing communications systems and components Wiring and cabling Table 16 Connect Communications Wiring and Cabling Step Procedure Comments Reference 1 for communications links See e Ethernet e For legacy system e Cabling Wiring Distance Determine requirements Devices Considerations on page 30 serial Ports RS 232 and RS 485 on page 42 For new system two RS 485 serial ports on page 42 Planning on page 53 connection details All ports are shown controller model see cabling or peer HC900 controllers Refer to the diagram at right and to Table 17 Links to Controller Communication Ports for 2 RS 485 port pear To Operator Interf Availability depends on Te E ge ee Figure 12 page 26 Connect communications E2 To PC applications For Modbus connections see page 150 RS485 connectors top to bottom Shield TXIRX TX RX S1 RS 485 To PC Configuration Tool ee E1 To PC applications 91 peer HC900 co To single O Rack or hub cnccncc 0tnoemeame enes 0 ani Communication Ports all ports shown Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 125 Step Procedure Commenis Reference Default IP addresses C30 C50 192 168 1 254 and Subnet Mask of 255 255 255 0
163. iguration C50 C70 CPU only The HC900 Controller design enables users and OEMs who are adept in system integration to assemble a system that fits a broad range of requirements Any configuration can be readily modified or expanded as requirements dictate In initial configuration and in subsequent modifications the HC900 Controller affords an optimum balance of performance and economy Configurations such as those shown in Figure and in Figure 2 as well as many variations can be assembled from modular components Many of the components are available from Honeywell and some are available from third party suppliers These modular components are available in any quantity and mix that make the most sense for a given application As indicated in Figure 3 the HC900 Controller includes provisions for communication via Ethernet with host systems such as the Honeywell Experion HMI and other HMI software that supports Ethernet Modbus TCP protocol Also the communication structure of the HC900 Controller enables remote placement of input output components allowing significant economies in cabling and wiring 10 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction Redundancy Experion or 34 party SCADA 900 Control Station Redundant HC900 PEE Remote I O Expansion Qualified Ethernet 7 Racks un managed Switches Te Leepey ee mime SE MO RTT Figure 3
164. in last active state e PPO and TPSC Outputs digital outputs are Off to freeze the motor position e Analog output same current as previous last active current level 158 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Controller Mode Transitions Mode changes are controlled primarily by positioning of the MODE switch Figure 87 on the controller module or RSM and secondarily by selection of mode names on operator interface displays That is the Mode switch takes precedence In the RUN Locked position or in the PROG Locked position selecting a mode name at the operator interface has no effect on the operational mode In the RUN PROG position the mode may be changed from any mode to any other mode The effects of the Mode switch operator interface selections are described in Table 23 The effects on controller operation for each mode transition are described in Table 24 Run Pgm Pg Run Run Pgm Run Run Pgm Fail Pgm Over l Figure 87 Mode Switches Controller left RSM right Table 23 Mode Switch Functions Mode Name Mode Selections at Operator Interface Switch Function RUN Locked None locked in RUN In this position the Controller is locked in the RUN mode of operation Run mode configuration changes are disabled and mode cannot be changed at any operator interface SIL application must operate in this position SIL require
165. indicating the Ifthe reserve s e Software interrupt This diagnostic will cause the 3 Upgrade the firmware failure see CPU in status LED is HWOK pins of the AYSY and FSYS 4 Replace the CPU board the Reserve CPU indicating the e Undefined blocks to be tumed off c H IP Diagnostics failure see CPU instruction error 5 Contact Honeywell Personnel display Diagnostics in the Reserve Diagnostics Overview dialog box 3 One of the exception The exception vector was vectors located in RAM automatically corrected in the became corrupted controllers RAM and the controller continues to operate normally This diagnostic will cause the HWOK pins of the AYSY and FSYS blocks to be turned off Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 173 June 2015 Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 4 Estimated battery life is e ASYS and FSYS blocks HW Replace battery If the lead s status If the lead s status less than 5 days OK pins are tumed off LED is indicating LED is indicating i the failure see the failure see ll upgrade is still MEMORY inthe Memory Lead CPU Diagnostics in Diagnostics the Lead display Diagnostics If the reserve s Overview dialog status LED is box indicating the If the reserve s failure s
166. ined by DIP switch setting on see the following figure To change either port s setting use the switch settings in Table 3 Use a small slotted screwdriver or paperclip to gently move the DIP switches If you push too hard you could damage the switches or nearby circuitry Avoid using pencils because the point could break and cause damage Table 3 Serial port DIP switch settings RS 485 unterminated RS 485 terminated last link in network Figure 25 Serial Ports DIP Switch default settings Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 43 June 2015 Pre Installation Planning Overview Methodical pre planning of an installation will preclude false starts and errors that can cause costly hardware re configuration and or poor system performance Factors to consider in your pre installation planning include e C75 CPUs require two Power Supply Modules 900P01 or 900P02 power supplies C70R CPU requires 900P02 power supplies e I O Rack can use AC Power Supply 900P01 900P02 see page 45 or 24DC Power Supply 900P24 see page 47 e Limit of ten 4 channel five 8 channel or two 16 channel if powered from backplane Analog Output modules can be installed per rack Limit of 4 PFQ modules e Power Supply rack space if using redundant I O power see page 48 e Rack orientation and mounting see page 47 e Remote Terminal Panels see page 50 e Environmental condi
167. ing gt 50 Vdc Vac e Earth ground wiring e Control relay output wiring e Line voltage alarm wiring Signal Analog signal wire such as lt 15 Vdc e Input signal wire thermocouple 4 mA to 20 mA etc e 4 20 mA output signal wiring e Slidewire feedback circuit wiring Communications Low voltage e Low voltage alarm relay output wiring lt 50 Vdc Vac e Low voltage wiring to solid state type control circuits 58 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Master Control Relay A Master Control Relay MCR structure is a safety mechanism for shutting down the process control system in emergency conditions This mechanism which is hard wired provided and installed by the User can include several Emergency Stop switches strategically located near process equipment An example of an MCR structure is given in Figure 34 Operating any of the Emergency Stop switches opens the holding path for the MCR When the MCR de energizes the MCR contact opens disconnecting all AC power that is supplied to AC Input Modules and to AC Output Modules Notice that AC power is disconnected only from the AC input output modules Power is still available to Power Supplies at the Controller Rack and at each I O expansion rack The Controller Module and the Scanner Modules in the racks continue to execute diagnostics and other programs A WARNING Ay The Master Control Relay does
168. initialized Step Action 1 A CAUTION Improper application of site power can cause damage to equipment Ensure that the controller rack is ready and safe for application of AC power Apply site AC power to the Power Supply that is associated with the controller Module Press the latch on the battery cover 1 to release the battery holder and pull on the handle 2 to remove the battery holder Note the orientation of the battery holder assembly battery toward the left The battery is retained in the holder by spring tension of the plastic holder itself Insert the negative end of the battery into the back end of the holder and press on the battery see arrow so that it snaps into the holder To ensure that the battery is seated properly rotate it in the holder using finger or thumb pressure toward the positive front end of the battery While maintaining proper orientation battery toward the left slide the battery holder into the slot in the Controller Module until it snaps into place HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Battery Replacement Procedures Table 40 Replacing a Backup Battery CPU Powered Step Action 1 A CAUTION If the battery is removed from the Controller Module when AC power is not applied the content of RAM will be lost Before beginning this procedure upload and SAVE
169. ins information and instructions for connecting calibration devices A WARNING Hazardous voltages exist at the Power Supply and at the terminal boards on I O Modules Only trained and authorized personnel should perform the procedures in this section Failure to comply could result in death or serious injury H ATTENTION For calibration procedures refer to the Control Station manual or Process Control Designer manual 188 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Analog Input Calibration Analog input modules can accommodate five input types e RTD e Thermocouple e Ohms e Volt e millivolt e 4 20 mA Not available on high level analog input modules Calibration values for each channel are stored in the module as numeric values paired with A D conversion counts corresponding to those numeric values The numeric values are those identified as REFERENCE on the OI or HCD calibration displays apply these values to the input terminals during the calibration procedure For AI channels configured as thermocouple inputs the stored calibration values are compensated by the measured temperature of the terminals Because of this observe the following rules e If you plan on calibrating the 2 cold junction compensation devices perform this operation first before performing any thermocouple calibrations However because cold junction measurement inaccuracies will
170. ion racks except C30 and C30S CPU Direct connection to each C70R Legacy and C75 C75S new model CPU For more information For complete feature summary and specifications see Specifications on page 202 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 13 June 2015 Introduction This page is intentionally left blank 14 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Components and Architecture Overview Components and Architecture Overview This section provides a description of each of the major components that can be included in an HC900 Controller physical configuration and indicates some of the methods by which they can be combined Components The Honeywell HC900 Process Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications Some of the modules are required in all configurations Others are optional they are selected as appropriate to provide optional functions and or to size the system either in initial planning or in modifying and or expanding the system to meet changing requirements An HC900 Controller configuration with multiple controllers is illustrated in Figure 4 This illustration includes key numbers that identify components that are described in Table 2 CAUTION Communications lockout is possible in high net
171. ior in Mode Transition ssessseeseseeeeseesesesereseseessesstesstesseesreseesseesressrssresseesseeetet 160 Table 25 Configuration file downloading eee cseeseeeeeeceeseeeeeeesecesecsecsaecsaecseecseecsaseaeseaeeeeeeeeestenseenseseaes 162 Table 26 LED Indications on Controller CPUS 00 eeceesccesneeesseceeceecaeceseeeceaecesceceeeeeneeceeeeeeaeecseeeseneeceneesenaeens 171 Table 27 Controller Status LED Diagnostics eee eeeeeeeceesceeccesecesecesecsaecsaecaeecseecnaseaeseeeeseeeeeeseenseenseenaes 172 Table 28 LED Indications on Scanner MOodulle eeecescceesceceseeeesceceseeeeneecsceeenceceeeseneeceeeeeaeecseeeseaeeceeeeeeneeens 179 Table 29 Scanner LED Dia snOstics eisoes oei ee benta eap orere UE EEEren S ES pE e EE e ONE N E SEE he ESSE BIRERE SEANS 179 Table 30 LED Indications on I O Module uu cee ceeceeseecssecesececsseceeeeecaccesceecsaeceececeseeeeneeceeeeeaeeceeeseneeceneeeenaeens 183 Table 31 1 O Module LED Diagnostics 0 0 ee cee eseeseeeeeeeecessceseessecssecssecnaecnaecsaecseecseseneseneeseeesesseenseesseesaes 184 Table 32 Bad T O Channel Diagnostics ee nr enmena sapeo oe eara Oesen Ea PEE Ea e SEENE S EETHEN IRERE Enne 185 Table 33 LED Indications on Ethernet Switch eeseesccesccecssecesececesceeeeeeceaceesaceceaeeecaeecaeeeeaeeceaeeeeaeecaeeeeneeees 186 Table 34 Power Supply Replacement all except C75 eee eeceecesecesecesecssecaeecseecseeesessaeeeseesesssenseesseesaeenaes 193 Table 35
172. is connected Switch directly to a Controller Module the Switch is not required 6a Ethernet Enables inter connection of several 10 100Base T Third party suppliers 10 100Base T Ethernet devices in an Ethernet network Devices Switch or include other HC900 Controllers HMIs and can also Router Firewall include routers servers and other devices in wider networks 7 Ethernet CAT5 Connects I O expansion racks C50 C70 CPU only to Third party suppliers or shielded cable controllers and or to 10 100baseT Ethernet switches Honeywell 10 or 20 3 04 or 6 08m Fiber Optics Controller to remote rack distance up to 750m 2460 Cable ft with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint 8 Ethernet CAT5 Connects devices in Ethernet Open Connectivity Third party suppliers or shielded cable network to 900 Control Stations and PC SCADA Honeywell applications 10 Serial Interface For legacy system Null modem cable up to 50 Third party suppliers or Cable 15 24m PC modem cable if used with Modems Honeywell For new system RS 485 to USB converter connects galvanically isolated RS 485 port to USB port Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 17 June 2015 Redundant components Sa m es 3 Figure 5 Redundant Configuration with multiple I O racks CAUTION The HC900 expansion I O link is a private net
173. is step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Repeat step 4 for each controller on the same network Select the Network button at the bottom of the dialog box and Add any or all of controller IP addresses configured to the list This will allow selection of any of these Addresses for downloading or uploading configurations You may now connect the controllers to your network for access by the Designer software For the Networking Example shown connect one end of the Ethernet 10 100 Base T cable to the PC s network port Connect the other end of the Ethernet 10 100 Base T cable to the Ethernet switch Connect an Ethernet 10 100 Base T cable to each HC900 controller s Open Ethernet RJ 45 port top RJ 45 port Connect the other end of each Ethernet 10 100 Base T cable to the Ethernet switch or router firewall You may now access any controller on the network for configuration access by assigning Network as the Port and the respective IP Address as the Address of the controller ATTENTION When multiple controllers are on the network be careful to check for the correct IP address of the destination controller prior to download of a new configuration or when downl
174. ized state the current draw on the battery is approximately 6 ma for C30 C50 and 9 ma for C70 C75 CPUs However if the battery is installed before power is applied and the CPU initializes the SDRAM will draw approximately 40 milliamps At the 4 microamp level the battery will retain energy over an extended period At the 6 to 9 mA level the battery will retain sufficient energy to maintain the content of SDRAM for 30 days for C30 CS50 and 20 days for C70 C75 controllers of backup service At the 40 milliamp level battery life is severely reduced The battery could be rendered useless in less than 60 hours CAUTION Installing the backup battery when the CPU is not initialized will cause undue battery drain Do not install or replace the backup battery until after site power is applied Note Upon power up of a controller which had been powered down with a marginal battery the initial battery test result will latch and hold for three minutes This is done so that subsequent battery checks will not falsely indicate Good should the battery voltage recover after removal of the load After the 3 minute wait period battery removal and replacement with a new battery will restore the battery diagnostic to Good and reset the battery life accumulator Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 199 June 2015 Battery Installation Procedures Table 39 Installing Backup Battery CPU not
175. k s scanner module 10 Ensure that the Scanner and Controller CPU software versions are compatible If not perform a firmware upgrade 11 Replace the expansion rack s power supply 12 Replace the expansion rack 13 Replace the main CPU 3 One of the following Scanner restarts The main CPU detects that Cycling power to the scanner will microprocessor exceptions the Scanner restarted and places the clear the diagnostic occurred Scanner back into the scan mode If the problem reoccurs try the e Watchdog timer timeout following e Address error 1 Ensure the system is properly rounded e Prefetch error 2 2 Ensure the system is properly e Data abort error isolated from external noise e Software interrupt sources e Undefined instruction error 3 Upgrade scanner firmware Replace scanner module 5 Contact Honeywell Personnel 3 One of the exception vectors The vector is restored to the proper value and located in RAM became corrupted the Scanner continues to operate normally 4 Flash failed to burn properly when The boot code is the only software running Perform a code download the firmware was being upgraded This software waits for a request to burn the flash It does no scanning of modules Module outputs remain in their off state 180 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Number Possible Cause Scanner Action User Action of Strobes 5 C75 only The co
176. ked to the controller via the Ethernet 10 100Base T Open Connectivity Network port Redundant controllers PC communicates with Lead Controller only NOTE For specific PC requirements and for specific software requirements refer to the Designer Software Users Manual RS 232 Modem Devices In Legacy systems the PC configuration tool can connect from the RS 232 serial port of the Controller Module to a serial port on the PC For new system the PC Configuration tool connects to the galvanically isolated RS 485 port on the Controller Module using an external Honeywell qualified RS 485 to USB converter The PC can be located remote from the Controller by using Modems and telephone links Modems and suitable cabling are available from third party vendors Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 29 June 2015 PC Configuration Tool Controller i jE pc ss J Modem Cable Poz a PC Modem P 3 Modem _ Cable j Telephone _ Cable i Telephone Cable Figure 17 RS 232 Modem Devices Ethernet Devices Considerations Ethernet device requirements vary with specific applications Regarding intended use they fall into two categories CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices or communicatio
177. l block Wiring Rules and Recommendations In general stranded copper wire should be used for non thermocouple electrical connections Twisted pair wiring with shielded cable is recommended and will improve noise immunity if wire routing is suspect Wire Gage Observe all local codes when making power connections Unless local electrical codes dictate otherwise the recommended minimum wire size for connections is given in Table 12 Table 12 Minimum Recommended Wire Sizes Wire Wire Application Gauge 14 Earth ground to common power supply 14 to 16 AC to power supply 10 to 14 Earth ground wire 20 DC current and voltage field wiring 22 DC current and voltage wiring in control room Routing and Securing Wires Typically field wiring is routed to connections at a terminal panel near the controller and then from the terminal panel to the terminal blocks on the I O modules Whatever method of routing is used wiring must be mechanically supported along its length and must be protected from physical damage and electromagnetic noise interference See Electrical Considerations page 55 Also all wires must be securely terminated using appropriate wiring practices 78 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Signal Grounding Figure 41 The shield for each input should be grounded at the grounding bar optional at the top or bot
178. l except C75 Step Action 1 ATTENTION This procedure does not apply to C75 power supplies If the power supply to be replaced is powering a rack that is currently controlling a running process then Either e Ensure that powering the rack down will not have adverse consequences on any running process Or e Bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply from the source of site AC power Use a meter to ensure that power is off 3 Depending on the type of wire lugs used loosen or remove the three screws on the terminal board and remove the three wires from the terminal board NOTE DO NOT remove the nut that secures the lug for the PE Ground wire green to the grounding stake at the bottom of the rack 4 At the top and bottom of the module loosen the captured screws that secure the module in the rack and remove the power supply from the rack 5 Place the new power supply in the rack cont d Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 193 June 2015 Step Action Secure the lugs for AC wiring to the terminals on the new power supply e L1 top terminal Black USA or Brown Europe e L2 N middle terminal White USA or Blue Europe e Ground bottom terminal Ensure power can be applied safely and use the external user supplied switch to re conne
179. lable port of the Controller Module using an external from Honeywell Honeywell qualified RS 485 to USB converter 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMIs other HC900 Controllers and supplier Interface other networks including Internet HMI software is Typically includes HMI operating software available from Honeywell Experion May also include Designer Software configuration Hs or SpecView32 or tool and utility software from third party supplier 6 Qualifies un Required if using 2 or more I O Expansion racks Qualified third party managed Provides connection of the I O Ethernet 100Base T devices available from Ethernet port on a Controller Module to the Scanner Honeywell 100Base T modules Switch not required for connection to a Switch single I O rack 6a Ethernet Enables inter connection of several 10 100Base T Honeywell or third party 10 100Base T Ethernet devices in an Ethernet network Devices suppliers Switch or include other HC900 Controllers HMIs and can Router Firewall also include routers servers and other devices in wider networks Use of a properly configured firewall provides a more robust network limiting exposure to uncontrolled network traffic 7 Ethernet CAT5 Connects I O expansion racks to controllers and or Third party suppliers or shielded cable to 10 100baseT Ethernet switches It also connects Honeywell to 900
180. le 0 cece eceecessceseceecesecesecseecaeeeaessaeseeeeaessaesseeseseeeeesessecsaecaeesaesaeeeaa 27 Figure 14 Scanner 1 Modules viinien ea th sate cnet ledetecnaele o eE EE EAE e EOE EEEE EEEE EEE ar 27 Figure 15 Scanner 2 Mod le ennet e ren Anoe n r eao eE EEE EAE EROS EEEE EEEE E E E 28 Figure 16 I O Module Terminal BloCk seesseeseseeessseeeseseserssesresresterrssrrressesrestestenteseertssertentestenteseertsserrrererreereste 28 Figure 18 RS 232 Modem Devices siipiin te ren ieor on ior eeo ooren EN EEK EnS NS EEOSE EEEE EEEE EEE EEE S 30 Fig te 19 Fire Walls cererii eee E ae ee E AEE EE EEA RE O E EEEE EES 32 Fig re 20 Firewall RO TET sheena onene oe chante ches r EE AEE dus EE A e ROEE SEE EEEE EE T 33 Figure 21 HC900 Controller Configurations seseseseseeeseseeeeseerrsstsreesestesssstrrseetsstetrsertentertesteseerrssenrreresreereset 34 Figure 22 Modular Network Structure eseeseesseeesessereeereseeerestereserresreseeetrseetessreteseetesertestertestrseetensenreseerresreset 37 Figure 23 Modbus TCP Framing esise eseon epearen eeen pee S oE PEE eE DEEE EARE E ESES REE ESEE an s 38 Figure 24 Typical installation using a Cable Modem esseseessssesssreesssresssstsesrestesrrsterrsserrensesresresrenrnserrrsserrenesee 41 Figure 23 Controller Sera POT Sree e Ta aae aeaaaee E E EA Ea E a eE E EEES SE E PERENE EE SES 42 Figure 26 Serial Ports DIP Switch default settings 0 00 eee ceecseec
181. le terminal blocks only for connecting digital common wiring at terminals 9 and 11 or terminals 10 and 12 See Figure 59 A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 0geood Com 1 IN 1 8 Com 2 In 9 16 DDODADO Ek Legend External N Disconnect y m User Supplied Safety Devices O CGOOEDOOOOOS Figure 58 AC Input Module Wiring Diagram 104 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 AC Input Jumper either 10 12 Connect ANY Of 9 12 pem to L2 N Figure 59 AC Input Module Jumper Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 105 June 2015 AC DC Isolated Input Module Wiring The AC DC Input Module has sixteen isolated inputs An example of AC Input and DC input Module wiring is shown in Figure 54 Specifications for this module and for other modules are given in the Specifications manual Requires Low Voltage Euro style 36 terminal terminal block Isolation Inputs must be powered from external voltage sources Inputs are isolated from each other and from controller power IN 2 INJ IH d IN d IN IN INd IM 4 IN IM 2 IN IN t IM 14 TENCE S le
182. ler User and Installation Manual Revision 4 0 June 2015 ATTENTION Always observe the wiring cabling guidelines on page 53 Step Procedure 1 Connect a modem to the HC900 controller s for a list of approved modems their settings and the connection specifics 2 On the PC check on the Utilities Worksheet in the HC Designer software to see if the PC modem is properly installed A modem icon on the associated COM port button indicates the PC modem is properly installed internal or external If the modem icon is not visible on the associated COM port button use the modem supplier s instructions to properly install the modem and verify the installation using the Windows Control Panel Modem property page to confirm proper installation 3 Set up the phone book in the HC Designer software This list includes the phone numbers for each of the HC900 controllers that can be connected using a modem The phone book can be accessed from the Main Menu View Phone Book or from the Utilities Worksheet by selecting the modem port as the current port Refer to the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Remote Access for details on this step Phone Number 215 822 3001 Aoise Nara Remove from List Cancel JHC300 Furnace 1 Comments Plant 3 Location Phone Number List 4 On the PC
183. ler may typically not be used to connect the PC to the modem or to connect the modem to the controller If your modem requires command string configuration you will need an interface cable to connect the modem to your PC Refer to your modem and computer documentation to determine this cable s requirements HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Modem configuration Before connecting a modem to the controller s RS 232 port marked CONFIGURATION the modem must be configured with the following settings e Baud Rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller e Parity None e 1 stop bit e 8 data bits e No handshaking e Ignore DTR e Suppress result codes e Suppress echo e Auto answer e Disable command recognition only necessary if the modem has this capability Some of these settings may be settable via switches Others may require command strings to be written to the modem using a PC terminal program such as Hyperterminal You will need to refer to your modem s documentation to make this determination Those settings that are configured using command strings must be saved to the modem s non volatile RAM NVRAM and the NVRAM must be configured as the profile that gets loaded when the modem is powered up Most modems are equipped with auto recognition to set the baud rate parity stop bits a
184. llation Manual 121 June 2015 Encoder 5to24Vdc as Single ended A B Encoder to 6 0V Differential 200mV HSN F Differential Internal jumper SV Encoder power from HC900 5 to 24Vdc Altention For Inputt Input 2 and Index reverse polarity to Attention For Input Input 2 and Index reverse polarity to IN 1 sii Lal D m IN 2 a O ai E IN 3 rO wie ae on as INDEX m INDEX ca 7 SENSE ab SENSE at a PF OUTPUT2 gt OUTPUT3 S a s OUTPUT4 Sy D M 2 ENCODE lt ee F P IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUT3 OUTPUTS COM Figure 75 Quadrature Differential HC900 Power Wiring 122 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Encoder At IN 1 Y Single ended a IN 4 IN 1 ba BH IN 2 z 8 IN 2 IN 2 a a en a n p 3 INS S IN4 IN 4 Pe INDEX P7 INDEX INDEX z SENSE SENSE Internal jumper oe SENSE E e a OUTPUT UT2 4 OUTPUT2 OUTPUT2 OUTPUT3 OUTPUT3 POT OUTPUT4 COM E ENCODE Encoder power ENCODE a ENCODE Ly Figure 76 Quadrature Single Ended HC900 Power Wiring Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 123 June 2015 Communications Installation Overview Overview Commun
185. ller in release 4 0 and higher are not automatically included in the Fixed Modbus Map To access the registers of these function blocks the Custom Modbus Map must be used and the block data manually inserted into the custom Modbus map HMI Supervisory SCADA software is available from various suppliers and functionality and setup requirements vary with suppliers and with specific products In all cases the software selected must be compatible with Open Modbus TCP protocol 38 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 The user can use the standard Modbus command set to generate a custom set of drivers for his specific application or may purchase additional software for example OPC with Modbus TCP protocol to reduce or virtually eliminate development tasks HMI software HMI software available for use with the HC900 Controller includes but is not necessarily limited to the following packages eavailable from Honeywell Experion HS Software which operates under Windows 7 operating software provides PC based supervisory control and data acquisition This package includes a large selection of standard operating display templates which can reduce development time significantly Experion HS includes a full graphic display development environment enabling development of custom graphics that include animated responses to changing process conditions A batch reporting option is avail
186. lways requires comprehensive knowledge of the entire control process the control equipment the process control strategy and the conditions and circumstances that exist when the removal and replacement procedures are taken The procedures in this section include notices of potential hazard as they apply to various components in the controller Because each control process and the set of conditions and circumstances at each user site are unique it is the user s responsibility to know the potential consequences of each action as it relates to a running process It is recommended that the user becomes familiar with the significant aspects of each set of circumstances and has a plan for execution of the proper action sequence A CAUTION All of the modules input output RSM PSM available for use in the HC900 Controller have a RIUP designation That is they can be Removed and Inserted Under Power where power refers to DC power at the backplane of the rack It does not refer to power for field wiring at the terminal board associated with the I O module which must be disconnected using a user supplied switch at the field device before removing or inserting the module For all other components of the controller AC power to the controller must be removed before removal or replacement of the component A WARNING Ay Hazardous voltages exist at the Power Supply and at the terminal boards on I O Modules e Only trained and authorize
187. ly isolated RS 485 communications RS232 port can be used for link to PC for 900 Designer configuration tool up to 50ft 12 7 Meters or via modem Also can be configured for Modbus RTU master or slave RS 485 port used for 2 wire link to legacy operator interface ELN protocol or can be configured for Modbus RTU master or slave communications up to 2000 Ft 600 Meters New Controllers Two isolated RS 485 communications ports USB to RS485 cable must be obtained to support link to PC for 900 Designer configuration tool Can be configured for Modbus RTU master or slave communications up to 2000 Ft 600 Meters 12 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction Ethernet 10 100 Base T connection Port s configured to Auto Negotiate default to half duplex C30 C30S controller up to 5 PC hosts via Modbus TCP protocol C50 C50S C70 C70S and C70R Legacy and C75 C75S new model support up to 10 PC hosts via Modbus TCP protocol Peer to Peer UDP communication with up to 32 other HC900 Controllers C70 C70S and C70R Legacy and C75 C75S new model have 2 Ethernet ports for connection to up to 10 PC hosts They also support Modbus TCP Initiator function over both ports and automatically switch between ports to maintain Peer to Peer communications with other C70 C70S or C70R C75 C75S redundant CPUs Private Ethernet 100 base T connection to I O expans
188. m 15 11 16 1 O SW 7 2 250 Ohm 17 2 19 SW 8 250 Oh 20 5 a ji 7 O sw S 8 1 7 18 19 20 40 21 24 25 30 31 34 35 39 222 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Relay Output Relay Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 84 e Remove appropriate key tabs from terminal block to allow mating with the module See page 83 e Connect desired cable to relay output module at controller Choose from 900RTC H010 Remote Terminal High Voltage Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 9OORTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F Install relay output module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP Fuses 6 3A Time Lag Littelfuse part 37416300410 UL CSA approved for 250V Module Removal Insertion Under Power R
189. ments may not occur in other operational modes This RUN locked mode is the Safety mode for Safety controllers and the proper normal operational mode for All controllers RUN PROG PROGRAM RUN OFFLINE In this position the mode can be changed at any operator interface using screen selections PROGRAM RUN or OFFLINE The Run Program mode should be used only when changes are anticipated The Run Locked mode is the preferred operational mode to prevent any unintentional changes PROG Locked None locked in Program In this position the Controller is locked in the PROGRAM mode of operation Mode cannot be changed at any operator interface While in PROG position the S1 serial port is set to Honeywell ELN protocol This temporarily overrides the configured settings for S1 port With your PC s serial com port connected to S1 use Designer Software s Utilities to view any setting of any controller port such as network IP address and change if needed Refer to Designer Software documentation for details Placing the Run Program switch in RUN or RUN PROG mode returns S1 to its configured protocol and settings Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 159 Failover N A Transfers all primary tasks to the Reserve Controller RSM only establishing this controller as the new Lead Does not affect controller mode Turn key to Failover and hold it th
190. minal Low Voltage Cable Assembly 5 0 meters long Install AO module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 227 June 2015 4 Point Analog Output Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 238 for RTP internal schematic Connect field wiring LOADS ARE 0 to 750 ohm 228 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 16 Point Contact Digital Input ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect desired cable to 16 point Contact DI module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point contact DI module label into the module connector cover Co
191. mmunications C75 only This problem may cause on C75 only with the reserve is failing for the following reasons There is a problem with the connection between the scanner and the reserve 2 The scanner port used to communicate to the reserve has a hardware failure demand failover attempts to be unsuccessful pry Verify that the CPU A cable is connected to the A port and the CPU B cable is connected to the B port on the Scanner 2 2 If a switch is used check that all cables are properly connected to the switch proper crossover cables are used that the switch is powered and it supports 100 Base T 3 Check cable shielding for proper grounding and noise immunity 4 Make sure the cables have the correct pinout Cycle power to the Scanner 2 Cycle power to the switch Cycle power to the reserve DSN AO OF Replace the expansion rack s scanner module 9 Ensure that the Scanner 2 and reserve software versions are compatible If not perform a firmware upgrade 10 Replace the expansion rack s power supply 11 Replace the expansion rack 12 Replace the main CPU The modules installed do not agree with those required by the configuration No action is taken Verify that the correct modules are installed for the configuration The Scanner cannot communicate to a module or the module is experiencing a diagnostic condition No action is taken For each module with a red
192. n each group An example of Digital Input Module wiring is shown in Figure 55 Specifications for this module and for other modules are given in the Specifications manual Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section Common Terminals Two common terminals are provided for each group of eight inputs Terminals 9 and 10 are connected in the input module and terminals 11 and 12 are connected in the module Jumper Comb A two position jumper comb is available as an option for barrier style terminal blocks only for connecting digital common wiring at terminals 9 and 11 or 10 and 12 See Figure 56 A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 100 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 DC Input Com 1 IN 1 8 Com 1 IN 1 8 Com 2 In 9 16 Legend External g N Disconnect Fuse User Supplied Safety Devices Figure 55 DC Input Module Wiring Diagram Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 101 June 2015 DC Input Jumper either 10 12 me or 9 11 s Connect any of 9 to 12 pn to DC Figure 56 DC Input Modul
193. n traffic other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings as well as failover in redundant systems e Components of the Ethernet Open Connectivity Network are those which link an HC900 Process Controller to Peers to HMI Supervisory Stations and to other Ethernet 10 100Base T devices that support TCP IP The Ethernet Open connectivity Network is potentially more complex than the I O expansion network and in some cases may require the services of an IT networking professional e Although the HC900 E1 E2 ports provide protection against Cyber security DOS type attacks additional protection is required for safety applications using a firewall device configured to prevent uncontrolled messages into the controller e Firewall settings to include gt Close all Ethernet ports into controller except TCP UDP port 502 30 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 SMTP port 25 ONLY if email is used SNTP port 123 ONLY if NTP server is enabled Disable unused Ethernet ports Rate Limiting In general one host should not be allowed to occupy unlimited bandwidth For example broadcast storms could be caused by an incorrectly configured topology or a malfunctioning device Firewalls can prevent storms seen by the H900 E1 E2 port
194. nd Installation Manual 195 June 2015 Replacing the Scanner Module Removing and replacing the Scanner Module from an I O expansion rack C50 C70 C75 CPU controllers only requires that the source of AC power is removed from the rack Removing power from the Expansion rack has the following consequences e All power to all I O modules in the rack will be lost hence all control outputs from the rack to the process are lost e Redundant controllers will operate with the affected I O in failsafe state during Scanner2 module replacement e Does not impact other I O Racks in the same configuration Table 36 Scanner Module Replacement Step Action 1 If a process is currently in operation then Either ensure that powering down the expansion rack will not have adverse consequences on any running process or bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply or supplies in the expansion rack from the site AC power source 3 Unplug the cable s from the scanner port s 4 At the top and bottom of the Scanner Module loosen the captured screws that secure the module in the rack and remove the module from the rack 5 Configure the scanner address jumpers DIP switches on the replacement module to match those of the removed module 6 Ensure that the new Scanner Module is properly aligned with the slot guides insert
195. nd data bits If your modem has no means of setting these using switches then most likely it is equipped with auto recognition To configure the port settings of a modem with auto recognition do the following Step Action 1 Connect the modem to a PC Power up the modem 2 3 Start up a PC terminal program such as Hyperterminal 4 Configure the PC COM Port for 1200 2400 4800 9600 19200 38400 57600 baud must match Baud Rate configured in HC900 Controller no parity 1 stop bit and 8 data bits recommended 5 Establish communications with the modem A common way of doing this is simply entering the AT E1 Q0 command and seeing if the modem responds with OK Once you establish communication to the modem its port settings are configured 6 Save the port settings to the profile that gets loaded on power up Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 137 June 2015 Modem configuration examples Below are procedures for setting up the following commercially available modems e 3Com US Robotics 56K Data Fax External Modem e Zoom 56K Dualmode External Modem page 140 e Best Data 56SX Data Fax External Modem page 141 e SixNet VT MODEM Industrial External Modem page 142 3Com US Robotics 56K Data Fax External Modem Step Action 1 Ensure that the switches are set to the factory settings Switch
196. nect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 108 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Contact Input mn D N 1 T NG y N3 m5 N4 7 NE BE ING aes X ir E IN8 D COM COM 0 COM COM E D COM COM COM COM EEr IN9 Q IN 10 o a IN 11 Oo b IN 12 e D er ab uae ae P at TS i IN 16 lt OOOOOC Figure 61 Contact Input Wiring Diagram DC Output Module Wiring The DC Output Module provides 16 current sinking outputs in two groups of eight points per group The two groups are isolated from each other outputs are non isolated within each group Current sinking means that a positive voltage potential is continuously applied to one side of each DC output load and the negative side of the load is switched internally in the module SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Specifications for this module and for other modules are given in the Specifications manual Examples of DC Output wiring are shown in Figure 62 DC Output Module Wiring Diagram Over Current Protection Electronic high current and high temperature limiting provides overload protection resets after cycling powe
197. neneeeeaees 192 SSC IC ATOMS saioen e a a Ea a a aa aa eaaa 202 General Specificato S saniterar ita aian aeaaeae eed pene ar aae fas Jenene iao taas eria edi a tina 202 System Sizing and Availability SUMMALY c ccceeeeece cece ee eeeeeeeeaeeeeeeeseeeeeceaeeesaaeeeeaeeseeeeesaaeeeeaaesseneeenaes 211 Fiber Optics Recommendations ecececeeeceeeceeeeeee cae eeeeaeeeeneeceaeeesaaeedeaaeseeeeseaeeesaaeedeaeeseaeeescaeessaaeeeeeeeeaes 212 Appendix Installation of Remote Termination Panels RTPS ceeesesseeeeeeesnteeeeeeeeaes 215 ON OIVICW S E tute ehi ens beiedhas EAE PA E el ellie witht what EE 215 Analog MPU aise ei enya ey ties ee i ee ey ee eee 216 PIENEEN IT ol iR E n E E EO A T A soesec ssaseeuatebngescteases 223 Analog Input Digital Input Digital Output Analog OUutpUt c cceecceeeeeeeeeeeeeeeeeeaeeeeaeeseeeeeseaeeesaeeseneeeeaees 227 Declaration of Conformity 42 2226 tac ccenstadicti do mnededl ededicl mdiectaade ede cadadndtendaded baa dace ones 253 ATEX CGTIMC Atl ics cesiascs ssa vests tau ssate nas ree aca at Cana ddd ence anda Sancaands en ad ots Une ance Bona ione Lanahatdlannee 254 INDEX cexeg sonata ces ceeta nenin ate ta scene eet ceeec tate ean a cee ce sea a ete eee 255 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual ix June 2015 Tables Table 1 Descriptions of Major Components Figure 4 ee ee ceeecesecssecneecseeeeeeeeeeseceecesecssecaecsaecsaecseec
198. nnect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 2 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP 3 C C Com Set jumper positions as shown for the 16 point contact digital input module Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 238 for RTP internal schematic Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 229 June 2015 16 Point Contact Digital Input Connect field wiring 16 Point DC Digital Input Step 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP combines the two groups of 8 inputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect desired cable to 16 point DC DI module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DI module label into the module connector cover Connect shield drain wire to the grounding bars at the base of th
199. nostics indicating the display failure see Real Time Clock Diagnostics in the Reserve Diagnostics Overview dialog box 174 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Number of Red Strobes Possible Causes Lead and or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication One of the following RTC conditions occurred RTC was previously programmed but when it was last read its date and time were deemed invalid An attempt was made to program the RTC but it was unsuccessful The RTC is unable to be read Usually indicating a serious hardware failure Same actions as described above 1 Use HCDesigner HCUtilities or Ol to program the real time clock RTC 2 If problem persists replace the CPU module One of the following remote I O conditions exist Communications between the CPU and a Scanner 2 is failing Scanner 2 is unable to communicate to a module or a wrong module is installed A module in the I O rack is reporting a diagnostic C75 and Scanner 2 firmware versions are incompatible Scanner 2 I O rack or power supply is defective C75 module is defective A bad channel has been detected on one of the modules 1 Associated blocks set their fail pins on their warn pins off and their output pins to the failsafe value 2 Associated
200. not remove power from the Controller rack or from any of the I O expansion racks e Before performing service tasks such as installation of terminal connections or fuse replacement use the appropriate switch s to disconnect power from the power supply at each module e Ensure that wiring design precludes over riding of the MCR by operator actions Failure to comply with these instructions could result in death or serious injury A WARNING A Class 1 Division 2 Installations e DO NOT REMOVE OR REPLACE MODULES WHILE CIRCUIT IS LIVE UNLESS THE AREA IS KNOWN NOT TO CONTAIN FLAMMABLE VAPORS Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 59 June 2015 L2 Power Supply in HC900 Controller Rack Power Supply i in HC900 1 O Expansion Rack e Multiple I O Expansion Racks Power Supply in HC900 I O Expansion Rack Emergency Stop orn AN a Input Modules Input Sensor P a Q elelelelelelolelere wleLeleleIlelelere e MieLeleperierers E opopogood Output Modules Figure 34 Master Control Relay Wiring Example 60 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Hardware and wiring requirements for safety configuration For the function blocks for safety a special hardware configuration and wiring is required Below high level diagram explains the wiring concept for u
201. ntroller Up to 32 Up to 1024 max per controller Selectable per device 1 second fastest load dependent Peer to peer 10 100Base T via Network port No of Peers Controller Update rate Peer Data Supports UDP protocol and Peer Data Exchange function blocks for peer data exchange 32 500 ms to 5 sec selectable Digital and Analog Signal Tags Variables up to 2240 parameters Ethernet Ethernet Network Connection Host Network Protocol 10 100 Base T RJ 45 Modbus TCP Maximum distances per Ethernet specifications Controller rack to I O Rack Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Fiber Optic cable with switch 750m Fiber Optic cable with switch and repeater 1500m see page 212 Controller to Ethernet Switch Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Ethernet Switch to I O Rack Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Controller to Network Switch Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Network Switch to PC Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Controller to 1042 Operator Shielded Twisted pair 610m 2000 ft Interface 206 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Approvals CE Conformity This product is in conformity with the protection requirements of the following European Council Directives 2006 95 EC the
202. oading edits to a configuration while in RUN mode Otherwise you may inadvertently download a configuration to the wrong controller Setting Up the Controller Network Parameters See the Designer Software Users Guide Doc 51 52 25 110 or respective HC Designer Help Files for setting up following network parameters e IP Address Subnet Mask optional Default Gateway IP Address optional e Network Name optionally used in Peer Data Exchange e Local Name optional user identifier for controller e E mail Server IP Address required if e mail alarms are configured H ATTENTION This setup will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 149 Connecting the HC900 Controller to Modbus device s S1 RS 485 terminals RS 485 Modbus connections Use Designer software to configure the controller s galvanically isolated RS 485 port as a master or slave Install resistor as shown for terminated devices except HC900 For terminating HC900 do not install resistor Instead set internal DIP switches for termination page 42 When using the HC900 XYR5000 transmitter function blocks an
203. ocess amp Safety Controller User and Installation Manual 171 June 2015 Coniroller Status LED Diagnostic indicators When the Controller has a flashing amber status LED after power up a critical power on self test error has occurred that requires controller module replacement When the Controller Status LED Figure 91 on page 170 item 1 is flashing red consult Table 27 A WARNING Ay Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources e Disconnect power before servicing More than one switch may be required to disconnect all power Failure to comply with these instructions could result in death or serious injury Table 27 Controller Status LED Diagnostics Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 1 RAM or ROM failed on Executes an infinite loop that toggles 1 Cycle power Not available Not available power up the LED Communications and 2 Replace CPU because the C75 because the C75 control are disabled communication communication 3 Replace power supply ports are disabled ports are disabled 4 Replace rack 5 Check grounding 6 Ensure system is properly isolated from noise 2 Atleast one function The block s output s is are forced to If it is not desirable to have forced See SYSTEM in See System block ha
204. of 255 255 255 0 You can use these network parameters initially for testing or configuration use In the Current PC to Controller Connection Settings area of the dialog box click on the Network button to bring up the Network Port Properties dialog box and Add the default IP address Be sure the Ethernet Network Interface Card in the PC has a fixed IP address on the same subnet as the controller 192 168 1 x where x 2 to 253 Note 900 Control Station uses IP 192 168 1 253 as default 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network Device Name Honeywell HC900 Controller X Address 192 1681 254 z Protocol Modbus R TCP Speed bps N A Q Statistics PC Port Setup for Controller Access Network COM1 6 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Also ensure that the PC Network Interface Card has an IP address that allows access to the controller on the subnet after changing the controller s network parameters Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 147 June 2015 Step Procedur
205. of the Mode Switch are described in Table 23 and the procedures that the controller performs in transitions between modes are described in Table 24 PROGRAM Mode In the PROGRAM Mode active control processing is suspended This mode is used for safe execution of utility functions such as configuration download and calibration of analog inputs and outputs All outputs are Off RUN Mode The Run Mode is used for normal operation of the controller that is for running the control configuration that was previously downloaded Configuration download and other utility functions can be performed in this mode when the physical mode switch is placed in the Run Program position See the Designer Software User Guide for precautions restrictions and procedures Functions placed on the Safety worksheet may not be forced or written to in this operational mode when the physical mode switch is placed in the RUN position The mode switch must be placed in the RUN position for runtime on Safety applications The physical mode switch while in the RUN position prevents unintentional configuration changes and is the recommended operational position when modifications to the configuration are not anticipated 156 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 OFFLINE Mode The OFFLINE Mode can be entered only from the RUN Mode and is intended primarily for performing AI calibration A CAUTION Because
206. ommunication is based on fail safe and data expiration mechanisms that provide for fault and loading considerations without requiring reserved network bandwidth allocation Peer to peer is designed to be easy to configure as part of a device s standard configuration and does not require the distribution of a global database With redundant controllers peer to peer communication always stays with the Lead controller Implementing peer to peer communications involves e Interconnecting controllers with Ethernet media and networking devices cables switches etc e Configuration via Designer Software Controller configuration which includes entry of an IP address and a Subnet Mask and a Controller Name for each controller The Controller Name is used only by the Honeywell proprietary software for network access between controllers it should not be confused with a Network Domain Name or Workgroup Name Peer Data Exchange PDE function blocks which are included in the control strategy configuration file PDE function blocks include PDE Control PDE Write and PDE Read Refer to the HC900 Process Controller Function Block User Guide for additional information An illustration of HC900 Controller Peer to Peer on a Local Area Network LAN is given in Figure 22 Typically a Router is used for interconnection to another network LAN WAN or other However Peer controllers must all be on the same subnet For additional details r
207. ossible when sharing bandwidth with other devices We recommend putting the controller on a private network segment Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 35 June 2015 Use of properly configured managed switch is recommended to mitigate potential cyber security DOS problems Safety applications must include a properly configured Firewall See Ethernet Devices Considerations on page 30 for suggested settings Redundant Networks Honeywell Matrikon OPC Server supports redundant networks Up to 10 connections may be distributed in any combination across the controller s 2 network ports E1 and E2 PC hosts may include for example HMI supervisory software and or Designer Software configuration software Redundant ports may be used in a simplex mode non redundant Peer to Peer Communication Peer to peer communication enables any given HC900 Controller to request a peer relationship with up to 32 other HC900 Controllers on the same subnet other controllers can request a peer relationship with the controller The total number of peers that a controller can have a relationship with is 32 Peer to peer communication uses the Ethernet Open Connectivity network and employs standard User Datagram Protocol UDP for fast and efficient transfer of information Peer to peer c
208. ote The Yellow Green wire is supplied with the power supply The nuts w star washers for the grounding stud are on the stud The power supply has an internal fuse that is not replaceable A second external fuse may be added if desired For P01 power supply use 3 0A slow blow for 115VAC operation 2 5A slow blow for 230VAC operation For P02 power supply use 2 5A slow blow for 115VAC operation 2 0A slow blow for 230VAC operation For P24 power supply use 7 0A slow blow CAUTION The P24 is a 24V DC Power supply Do not apply AC voltages of any kind to this power supply or you will destroy it Apply power For P01 only test voltages at the test points provided on the face of the Power Supply Note Test points are electrically connected to the backplane of the rack If the power supply is not properly seated in the backplane connectors no voltage will be measured at the test points It is measured from the backplane ATTENTION Do not connect PE Ground Green Wire directly to terminal on Power Supply Brown Black Eure USA 14 AWG L2 N 2 1 mm Copper 75 C wma mnnmanps s Blue White Eure USA Image shows strain relief Yellow Green 14 AWG 2 1 mm Copper 75 C 70 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Step Procedure Comments References A WARNING Ay Ensure
209. output blocks Quantity based on available memory Profiles in Pool User Configurable Ramp blocks Quantity based on available memory Recipes in Pool User Configurable Redundancy capability No No No Yes Redundant host comms No No Yes Yes Schedules in Pool User Configurable Segments per profile 50 50 50 50 Sequencer blocks Quantity based on available memory Sequences in Pool User Configurable Setpoint programmer blocks Quantity based on available memory Setpoint scheduler blocks Quantity based on available memory Signal tags Quantity based on available memory Soft Wire bytes Quantity based on available memory Stage blocks Quantity based on available memory Steps per schedule 50 50 50 50 Steps per sequence 64 64 64 64 Support of dual port scanner No No No Yes Tag descriptor Quantity based on available memory Text bytes Quantity based on available memory Variables 2000 2000 2000 2000 Variables in a Recipe 50 50 50 50 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 211 Fiber Optics Recommendations Honeywell recommends that you use the following equipment for extended distances Table 43 Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 100Bas
210. ower is potentially hazardous to property and to personnel Circumstances that dictate prudent actions depend on conditions and specific process applications at each user facility It is the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 37 provides some general guidelines for establishing appropriate procedures at a given installation Table 37 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s A CAUTION Each signal at each of the Either L Econtrol terminals for an I O module has a oss OF Control or view OF a specific function Any or all ofthe Using trained personnel and damage to equipment controlling a process transfer to manual control of each and or to process product signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING Potentially lethal voltages on Disconnect all signals at terminal Terminal Blocks blocks from sources of power Human contact with high before removing the terminal voltage sources will result block from the I O module in death or serious injury Ensure that the Protective Earth PE ground is properly connected and properly functioning Revision 4 0 HC900 Process amp Safety Controll
211. own 7 16 1 Black 17 2 Orange 8 19 4 Red 20 5 White 9 3 8 Red 8 18 Green 10 13 13 Red 18 3 Blue RTP Internal schematic Applies to 4 AO 16 DI 16 DO 8 DO HC900 Terminal Block COMONOORWN Baas SS Ni NA ONDARON RTP CON40 238 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 8 Point Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal board to allow mating with the module See page 83 e Connect terminal block end of desired cable assembly to 8 point Analog Output module at controller Choose from 900RTC B810 Remote Terminal Cable assembly 1 0 meters long 9OORTC B825 Remote Terminal Cable assembly 2 5 meters long 900RTC B850 Remote Terminal Cable assembly 5 0 meters long Install 8 point Analog Output label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 2 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP Set verify jumper positions on each RTP as shown J4 A C C C Cm J3 J5 J J9 sw C C CZ Jumper open Jumper closed
212. r Conventional external fuses may be used if desired Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 109 June 2015 Reverse Polarity Protection A potential of 34 Volts will cause no damage to the module a reverse polarity power supply connection allows continuous current flow to the loads that are not controlled by the On Off state of the output circuits Jumper Comb Two position jumper combs are available as an option for barrier style terminal blocks only for connecting digital common wiring between terminals 10 and 12 and for connecting 24Vdc between terminals 9 and 11 See Figure 63 V Terminals The V1 terminal 9 and V2 terminal 11 are the positive power supply input to power the output circuits for the two groups of eight inputs per group The V supply must provide minimum 24 Vdc at 65 mA min per group A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 110 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 DC Output OUT 1 OUT 2 T3 OUT 4 V2 External s Disconnect ea User Supplied Safety Devices 2 e O D E Oo e ooann O T OUTS akcii E ONO te o tn OUT 12 Oe jail f a OUT 13 a
213. r safety configuration 20 0 eee eeeeeeee tence ee eeeeeeeeteeeeeeeteeeeeeteeeeeeeeeenaees 61 system Monitor Function BIOCKS iieri earannan aeaa aa raaa a aa a a aa aaa atin aaa aaia aaa a aiai 63 Rack lNStallalOnstn 2 ta ata tonne Bae taste hen ste ere ee NRO Si BOR eA ese 64 DIAA AN 25 ee Des sere ecole ae E vu had sek Rae A rue adaaneds doscy E E E 64 MOUNE RACKS einar rn ETEA TERA ieee bce tied en la EAE elt des td eal A AE TEORA leet EERENS 67 Assemble Controller RaCKr inins reini ie eei eee nae ce a sae ne ae gees 69 Assemble I O Expansion Racks c cccccccceceeceeneeceeeeecaeeeeaaeeeeeeeceaeeeeaaeeseaeeseaeeesaaesesaaeseeeeeseeeeeaeeseaeeeeeeeee 73 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual vii June 2015 I O Module Installation And Wiring ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeceeaaeeeeeeeeeeeeeeeeeneeeeeeees 76 COVEIVIC Wises cts Aosta AA E E e A T 76 Module Placement in RACKS i esrden arana eris reaa ra rink irine Ri oLan Ridin EE eiF A Rika AR Ee PREEK AER Caia PAE einki dA iain KARA ES 76 Remote Termination Panel RTP secscsceeecteteteesatdeves E N T E E E EEEE E EEAS 78 Terminal Block to Field Signal Wiring cccceeeeeeeceee cesses eeeeeeeeaeeeeeaeeeeaeeseeeeeseaeeeeaaeseneeeseeeesaeeseeeseeeees 78 Removal and Insertion Under Power RIUP ecccceeeeeneeeeeeeneeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaaeeeeeeaeeeeeeaeeeene 81 V O Module Installation Procedures
214. re isolated from each other Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring form power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 97 June 2015 E ter t a u e OUT 1 OUT 1 LOAD ae OUT 1 OUT 1 0 Y O degen 8 OUT 2 see OUT 2 Se ourd OUT 2 OUT 3 OUT 3 S e OUT 3 OUT 3 te A S O S x 8 om OUT 4 OUT 4 fe f a OUT 4 eH Figure 52 4 channel Analog Output Wiring Diagram 8 and 16 channel Analog Output Module Wiring A WARNING Ay Hazardous voltages exist at terminal blocks AO8 and AO16 modules require at least one channel to be configured prior to a cold start for the module to work properly Subsequent channels then may be added with a hot start Failure to comply with these instructions could result in death or serious injury Examples of high level Analog Output Module wiring are shown in Figure 53 and Figure 54 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900
215. rence only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library support Public Downloads HC900 SafetyControllerModulesRevisions zip Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 Introduction ATTENTION For the Legacy systems it is specifically mentioned in the guide wherever applicable The other text is applicable to the new HC900 system Modems are not qualified with the new HC900 system Checking HC900 Model Numbers for Compatibility ATTENTION Be sure to check your model numbers for compatibility before installation For a HC900 system to be fully compatible all components must have matching model numbers Each component s model number format is XXXXXXX XXYY ZZ For example HC900 CPU is 900C71R 0000 40 For redundant CPU systems component model numbers ZZ numbers must match For non redundant CPU systems component model numbers YY numbers must match See examples below Example of a compatible redundant system Component Model Number XXXXXXX XXYY ZZ HC900 CPU 900C71R 0000 40 Scanner 2 900C73R 0000 40 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 Example of a compatible non redundant system Component Model Number XXXXXX XXYY ZZ HC900 CPU 900C51 0040 00 Scanner 1 900C53 0040 00 HC Designer Software 900W01 0040 40
216. rminal block to allow mating with the module See page 83 e Connect desired cable to Al module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install Al module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP 216 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 8 Point Analog Input Set DIP switch positions SW1 through SW8 Set each input s DIP switch positions according to the input type For Input n use Switch n For example for Input 1 use Switch 1 for Input 2 use Switch 2 etc If an input is not used set its DIP switch positions to OFF Fuses 80mA Time lag Littelfuse part 37400800410 UL CSA approved Transmitter Loop Powered Volt millivolt Milliamp i Transmitter Externally Powered SW9 is the red po
217. roller handles communications with Modbus RTU slave devices 164 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 e Lead and Reserve exchange system status data to determine conditions for failover e T O Scanners relay system status data between each Controller to determine conditions for failover Execution time HC900 Controllers are designed to execute control functions within fixed scan cycles for analog data types and logic data types In redundant controllers the default scan time is 500ms for analog data types and 53ms legacy 25 mS for new controllers for logic data types Execution sequence e The type of control functions executed during a scan is determined by the system configuration Controller configurations contain a series of algorithms in the form of function blocks that get executed in a fixed sequence The first 100 function blocks are pre assigned by the system to handle communication tasks alarm processing system monitoring functions etc and cannot be changed by the user Starting with function block number 101 the user may select the type of function to be executed e The sequence of function block execution is initially determined by the sequence in which the function blocks are placed on the graphic diagram in HC Designer Final desired sequence must be set by the user to achieve proper and optimum performance CAUTION Incorrect execution sequences
218. rom 900 Control Station e Via input to RSTAT Function Block to initiate failover User can configure logical conditions such as loss of communication handshake between Host and Controller to initiate failover Failover Performance Failure condition detection and failover from Lead to Reserve CPU executed in 4 analog control cycles or less Redundancy Diagnostic Monitoring e From HC Designer and HC Utilities PC Software Redundant System Status current status of Lead Reserve Controller CPU s On Line Monitoring Controller Diagnostics Communications Loop Back tests Redundant Link Status status of communications between Lead and Reserve controllers Lead CPU status Reserve CPU status Scanner status File Download Upload Functions See page 161 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 167 June 2015 This page is intentionally left blank 168 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Diagnostics and Troubleshooting Overview Diagnostics and Troubleshooting Overview The HC900 system incorporates a comprehensive set of diagnostic tools that test hardware and software operation Diagnostic software elements are contained in each system component The diagnostic elements that are executed at any given time depend on operating conditions such as current operating mode and the current status of hardwar
219. rs at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 79 Set verify jumper positions as shown J2 J4 J6 J8 o_o Eo J33 J5 J7 J39 Sw Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 238 for RTP internal schematic 2 Mount RTP to DIN rail e Latch to rail See page 251 e Connect cable to RTP 236 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 8 Point AC Digital Output Connect field wiring CAUTION S L1 terminals in the wiring figure below are live when switch SW1 is on 1 Note AC Outputs are individually fused in the module but adding a fuse here protects the wiring Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 237 June 2015 RTP Cable wire positions and colors Applies to 4 AO 16 DI 16 DO 8 DO Twisted Pair Number HC900 Module TB Position RTP J1 Plug Connector Color 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 9 17 Black 10 16 Blue 5 11 15 Black 12 14 Yellow 6 14 12 Black 15 11 Br
220. rt B Private Ethernet 10 100 Base T Port Connects directly to I O port on CPU B or indirectly through a switch 4 LED status diagnostic indicators for communications functions 3 5 Figure 15 Scanner 2 Module Input Output Modules T O module types 16 point high level analog input module each point is configurable for V or mA Point to point galvanic isolation chassis to input galvanic isolation 4 point galvanic isolated analog output module Supports from 0 to 20mA each chassis to output galvanic isolation 8 or 16 point analog output module Supports from 0 to 20mA each Galvanically isolated in groups of 4 channels galvanically isolated chassis to output channels 16 point digital input modules Contact closure type DC voltage and AC voltage types Galvanically isolated chassis to input 32 point digital input module DC voltage Galvanically isolated in two groups 1 16 17 32 Galvanically isolated chassis to input channels 8 point AC sourcing type or 16 point DC digital output modules sinking type Galvanically isolated output channels to chassis and channel to channel in two groups 32 point digital output DC voltage sourcing type Galvanically isolated output channel to chassis and output to output in two groups Figure 16 I O Module Terminal Block 8 point relay output module four form C type and four form A type relays Galvanically isolated output to chassis and output to output
221. rteresteerssrrresserteeteseeeteseetessertestereeeteseetessreresrerreeeset 62 Figure 37 Common Series DO COMMeCHiONS ee eceeccesecesecesecsecneecosecneceneveneeseeeneceaeesaeeseeseessessaecssecnaecnaesaaeeaa 62 Figure 38 Series Relay for Analog OUtputs see ee eceeceeccesecssecesecnecsaecaeecaeeeseeeaesseeeeeeseesessaeesaecsaessaesaeeeaa 63 Figure 39 V O Module Installat ON 2 ossssscoscssesssetssesteeteessssetiee suze toot aa aese Ekora TS SESE r a eat sabaiasdsasbvessdeupeesveesgeeasgees 76 Fig re 40 Terminal Block Styles sscsssecscctscasssesscessessecusttebsseseeesscusessssnsstes oesstetsveubersavaasssbavesdebsvessgedpseaveesgeeasgeess 77 Figure 41 Signal W ire Grounding is ereere cosh sesesestestecasstebssesegesseessssdenscdevcsvesesetsseeosvoavaes OE EEEE ES EET CEEE EEE a kaes 79 Fig t 42 Wire Shield Grounding scssses cciscesscesssesces tech sotesssesveistussevsassctescspesetetssecoessavqasssbavesdsbsvvessgedsseaveesgeessgeses 79 Figure 43 Terminal Block Jumper Installation ee eee cee ceeecseecneeeaeeeeeeseeeaeeeaeeseeeeeeseesseeaecsaecsaessaeeaeeeaa 80 Figire 44 RUD Un puts ses EE se sucd seuss Gas casbes Sach abte ds sesnesd stash EE 90 Figure 45 Universal Analog Input Wiring Diagram ou eee cee cseeeneeeeeeeeeeeeeeeeeeeeeccesecsecsaecsaecsaessaecaaeeneeees 91 Figure 46 Examples of RTD Input Wiring 0 eee ee ee ceseceeceeeccecaeeeneseeeeseeeseseeeeseeeeesseessecsaecsaecsaessaesaae
222. rtesteseeetesrerenseeresereeetes 103 Figure 58 AC Input Module Wiring Diagram 0 eee ee cesecesecesecnsecesecaeecaeecaecaaecneecaeseaeseeeseeeeseseenseeaeenaes 104 Figure 59 AC Input Module Jumper veso sssesen Sesscceecesue So pantageresccen ds e e e teaves E EA E S E R 105 Figure 60 AC DC Isolated Input Module Wiring 0 eee ee eeceeecesecesecnsecseecaeecaecaeecaeecseeeaeseaeeseeesesseenseenseenaee 107 Figure 61 Contact Input Wiring Diagram cee ceeeeeeeeeeeeceeeeesecesecesecsaecsaecseecaeecseseaeseaeseeeeseeseenseenseenaes 109 Figure 62 DC Output Module Wiring Diagram eee eecesecesecnsecseeceeecaeeesecsaecseecseseaeseaeeeeseseeeenseenseenaes 111 Figure 63 DC Output JUMPefS ssr sirien reeet eaeoe EErEE TEE EE Eep E ETETEN r ET EEE asee rE ESS 112 Figure 64 32 point DC Output Module Wiring esseseesssessseeesssreereseseesestenrssterreetssentssestenresrentesrerrssentenresreetes 113 Figure 65 AC Output Module Wiring Diagram cece eecesecesecnsecssecseecaeecsecseecaeecaeseneseaeeeeeeeeeeenseeaeenaes 115 Figure 66 AC Output Module JUMper iiis eee eee eescesecesecesecesecesecsaecsaecsaecsaecaecsaecaeecseseneveneesesesseeeenseenseesaes 116 Figure 67 Schematic Example Relay Output and External Wiring 000 cele cece cee cseeeeeeeeeeeeeeeeeeeenseenseenaes 117 Figure 68 Relay Output Module Wiring Diagram eee ecceeceeeceseceseceseceaecseecaeecseseneseaeeseeeeeeeseenseenseenaes 118 Figure 69 R
223. ry 2014 Controller CPU indicators Figure 91 LED Indicators on Controller CPUs See Table 26 170 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Table 26 LED Indications on Controller CPUs CPU Figure LED LED State Color Description model 79 item All models 1 Controller Status Off No power Solid Red Failed Blinking Yellow Failed Blinking Red Diagnostic Code refer to Table 27 Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode while Flash RAM programming All models For legacy systems RS 232 RS 485 S1 port 2 For new systems RS Yellow Green Yellow when transmitting green when 485 S1 port receiving XMT RCV All models For legacy systems RS 232 RS 485 S2 port 3 For new systems RS Yellow Green Yellow when transmitting green when 485 S2 port receiving XMT RCV All models E1 port 4 Upper LED Yellow On Off On for 100Base T Off for 10Base T 5 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C70 E2 port C75 6 Upper LED Yellow On Off On for 100Base T Off for 10Base T 7 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C50 I O port i 8 Upper LED Yellow On Off On for 100Base T Off for 10Base T 9 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity Revision 4 0 HC900 Pr
224. s Upper LED Lower LED Link Yellow Speed Green On while the as long as electrical connection host is detected Flashes during message transactions OFF for 10Base T connections ON for 100 Base TX connections NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by software 186 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 This page is intentionally left blank Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 187 January 2014 Analog Calibration Overview All calibration data for Analog Input Modules and Analog Output Modules is stored in non volatile memory in the I O modules Calibration data is stored for each channel of each AI or AO module Calibration data for each channel can be either e Factory calibration which is stored permanently in the module and e Field Calibration which is entered from an HMI OI on the galvanically isolated RS 485 Port and or a PC on the RS 232 Port and or the Ethernet 10 100 Base T Port using Designer Software A field calibration procedure consists of two parts e Connecting a calibration device to each channel of an AI or AO module and e Using the Control Station HC Designer or HC Utilities to select actions and enter custom calibration data values calibration into the I O module This section conta
225. s Limit rate of all traffic Ingress egress to E1 E2 lt 3 MB s gt Denial Of Service DOS settings should also be enable in the Firewall device if possible These settings may include the following scan types Null XMAS NMAP XMAS SYN FIN FIN NMAP ID SYN RST SYN Flood and others e Firewall device s should be introduced above the network at the control network level prior to the supervisory control network level See Figure 19 and Figure 20 provides protection to the control system layer HMI and servers maybe placed above or below firewall per application requirements Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 31 Configured as Firewall Supervisory Control Network Layer Control Network Layer Qualified Switch IO Layer Non Redundant Control System Redundant Control System Figure 18 Firewall 32 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Supervisory Control Network Layer Configured Firewall Router Control Network Layer Qualified Switch IO Layer Non Redundant Control System Redundant Control System Figure 19 Firewall Router I O Network I O Expansion Network C50 and C50S C70 and C70S CPU only Examples of HC900 Controller I O expansion configurations are shown in Figure 21 Revision 4 0
226. s an output the value s specified block outputs use HCDesigner to the Controller Diagnostics in that is forced locate and remove the forced outputs Diagnostics the Diagnostic Overview display Overview dialog box 2 The RAM and FLASH An empty database is created and Use HCDesigner HCUtilities or Ol to copies of the the lead and reserve will not download a valid configuration configuration database synchronize The reserve s RSM were corrupted and LED is flashing to indicate it s not are now set to a valid synchronized with the lead empty database Usually this is a result of a firmware upgrade 2 One of the following The lead uses its own switch 1 Install RSM if none present NOTE RSM failures was reading and dictates to the reserve WHEN PLUGGING INTHE RSM detected what the mode is If the lead s switch INTO ALIVE UNIT YOU MUST _ The RSM module is position is invalid then the lead uses MAKE SURE THE SWITCH IS IN not installed the last good known position prior to THE PROPER STATE PRIOR TO the failure INSERTION 2 The RSM switch p _ position is invalid If failover occurs the new lead will 2 If the key is installed in the RSM assume the mode prior to failover remove it to make sure the switch is 8 The lead and until a good switch reading is seated properly If the key does not branes acquired pull out turn it slightly to the proper ae If after the power is cycled to both position until i
227. seceseeeceaeceeeeecsaecececseesenaeceseeseaeecseeseneeceereeeneeens 143 Figure 81 Two redundant systems with PC supervision ce ee cescesecseecseeceecseceeecaeecneeeseseeeeeeseeesseenseenseesaes 146 Figure 82 RS 485 Modbus slave wiring ceeceeecsecseeeseeeeeeeeeeseceeeesecsecesecsaecsaecseecseecseseaeseaeeeeeeesenseenseeseenaes 150 Figure 83 RS 485 Modbus slave wiring with isolation 00 cece eeeessceseceseceseceeceeecaeecaeseaeseeeeseeeeseneeeseenseenaes 151 Figure 84 XYR 5000 RS 485 Modbus connections with isolator eee ese ceeecneeceeeeeeeeeeseeeeseeseenseenseenaes 152 Figure 85 Warm Start Operation ononon en ee ees nnee aeS EEE AES EE EAEE EEE SEE E NESSES 154 Fig re 86 Cold Start Operation sieneen erne ives EEE E EEE E AE E N E 155 Figure 87 Mode Switches Controller left RSM right cee eescceeeceeseeceseeeenceceereeeneeceseeeeneecseeeeneeceereeeneeens 159 Figure 88 Pathways for Upload Download Transactions 0 cecescesecesecseecseeesecoeecaeecneeeaeeeeeeseeeseeeenseenseenaes 161 Figure 89 Modes of operation On RSM 00 0 eee ceeeeseeceescessceecesecesecsaecsaecsaecseecsecsaecaeecseseaeseneeeeeeeeeeeneeseenaes 164 Figure 90 Lead Controller synchronization cece ceecseeeeeeeeeeeeeseceecesecsecsaecsaecseecaeecseseaeseeeeseeesenseenseeseenas 166 Figure 91 LED Indicators on Controller CPUs See Table 26 0 0 eeeceescecsseceececeseeeenceceeeeeneeceeeeeneecerereneeens 170 Fig
228. seeeeceeeeseeeeeeeeeeeeeeeeeseensecaecsaecsaecsaesaaeeneeees 43 Figure 26 Rack Dimensions soca cioccssecs r a aaraa eoa aaa e ER A seveuncesaeyapes SE E E OET en SE I PERENE EE ns 47 Figure 27 Rack Dimensions with reserve power supply eesseseeseerssresrsreerssrerrsseeresrerrserrensesrenteseenrssenrrnresrenesee 48 Figure 28 Vertical Spacing of Racks all models ee eee eee cee cscecseeeeeeeeeeseeeeeseeeeseeseeeeseesecaecsaecsaecseeeaaeeneeees 49 Figure 29 AC Input Module de Rating oo cece eecececeescesecesecesecsaecsaecsaecseseaeseaeeseeeeeeseeseesaecsaecsaecaeecaaseneeees 52 Fioure 30 Power Supply d Ratui yes icececk esdesse beori aerer oree eSa o eaaeo I Eapen Eneo N EEES enS ES PERENE EEn S 52 Figure 31 Cabinet Wiring Single Chassis soreer hees ea oSer Eea eapi EE E EEES EES RSS ES PE RENESANS iF 55 Figure 32 Cabinet Wiring Multiple Chassis 2 0 0 0 ee eecesecesecssecseecseeeeeeeeeeseeeseseeeeseeseeesecaecaecsaecsaecsaeenaseneeeas 56 Figure 33 Redundant power supplies each with external fuse and SWitch iw eee eee eeceeeeeseceeessecaecssesneeees 37 Figure 34 Master Control Relay Wiring Example 0 ee eececceseceecseecneeeeeeeeeeeeeeaeeeaeeeeeeeeneessesaecaecnaessaesaeeeea 60 Figure 35 IO V function block COMMECTIONS 00 0 ee ee eeeceeeceeeceeecseceseceaecsaecaeecseeeaeseaeseeeeaeeeseesecsaecsaecsaessaesaeeeaa 6l Figure 36 Individual Series DO connections sssessseessesreeesser
229. sing the validation function blocks Independent Relays hooked in Series jem Single Ouput E Channel 142 Module 4 1 _ NewDOV BeChannel nod Function Block Figure 35 IO V function block connections Figures 34 35 and 36 demonstrate the connection of a series output relay s normally OPEN contact to protect against outputs that are stuck ON This relay may be added individually as shown in Figure 34 and 36 or common for multiple channel outputs as shown in figure 35 and 36 The series output must be configured to operate when the DO V s or AO V s Fail pin or VFail pin goes ON Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 61 June 2015 24VDC 24VDC Sourcing DO 32 900H32 Relay Output AC 900HO1 Ta Relay Output 900H01 DI 16 900G02 Relay Output Relay Output OR DI 32 900H01 900HO1 900G32 pes 900H03 Q S DI 16 a a 900G03 900G04 9 5 V gt VALID HIGH lt 32 0 V 0 0 V gt VALID LOW lt 3 5 V 24VDC 24VDC Relay Output Q DI 16 DI 16 900H01 Q 900G02 200 COE 32 Relay Output OR DI 32 or SHOS 900G32 900G32 DI 16 Relay Output 900G03 900HO01 Relay Output s0000 900H01 Sinking DO 16 DI DI 900H02 Relay Output 900H01 Note DI
230. style or the Euro style terminal block The 36 pin Euro terminal blocks must be used with High Level AI High Level AO 32 DI and 32 DO modules H ATTENTION Before mounting terminal blocks in the rack be sure they are properly keyed to the module type they will be used with See I O Module Installation Procedures page 82 Terminal Block Colors and Keying Both the barrier style and the Euro style are available in two colors red and black Black terminal blocks which have gold contacts are used for low voltage low energy signals such as analog inputs contact inputs and low DC voltages Red terminal blocks which have tin contacts are used for higher voltages such as 120 240 Vac Colors of each Terminal Blocks must correlate to that of the mating header on I O modules with which they are used that is e Black terminal blocks which have gold contacts are for use with I O modules that have black headers and gold pins in the 20 pin connector these include Analog Input 4 channel Analog Output DC Input DC Output Contact Input Pulse Input Pulse Output Frequency Input Quadrature Input e Red terminal blocks which have white tin contacts are for use with I O modules that have red headers and white tin contacts in the 20 pin connector these include AC Input AC Output and Relay Output e 36 pin black Euro terminal blocks which have gold contacts are for use with 8 point AO 16 point AO 16 point AI 32 point DI
231. sult in death or serious injury Out1 No Out1 No cou Out Ne Out Ne Sai Form C sl Out 2 No OVO LOAD 3 Form C Ou COM wmm Out 2 CO al Form A UNN Out No Out 3 No o o 30 Sd Forme Ould No mmm Gf No Out COM n FormsA hated C z Out 5 No m Out 5 No aa O O LoaD Form Out COM 7 m Form A m Out No Out 6 No 7 ea joo Outa COM E Out 7 No m a a oa a as a a a a Out 7 No S Form C Oul 7 Comm Out 7 Com A Out Ne O Out No omememcmemns Form C 8 Oul B No S OVO LOAD 8 Out 8 No C N O Out 6 Com Ou8 Com ii S Ou8 Ne Out Ne Forme oo Legend TT External N Disconnect Tag User Supplied Safety Devices Figure 68 Relay Output Module Wiring Diagram 118 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Relay Output Module y One half F 10 position f jumper To Relay Loads via external disconnect a switches pi fuses 30 Vdc i either Figure 69 Relay Output Module Jumpers Pulse Frequency Quadrature Module Wiring Figure 70 through Figure 76 The 4 Channel Pulse Frequency Quadrature Module provides four different functionalities in the form of Pulse Input Frequency measurement Quadrature encoder input and Pulse Output Each of the 4 channels can be configured for any one of these four functionalities with the exception that quadrature encoder input
232. t can be removed the lead and reserve and the lead is 3 Replace the RSM unable to acquire a valid switch 4 Replace reserve CPU position the system will default to the run program mode of operation 9 Replace lead CPU This diagnostic will cause the 6 Replace rack HWOK pins of the analog and fast logic System Monitor blocks AYSY and FSYS to be turned off 172 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 2 There are slave blocks e MSTRFAIL pins onASYS and 1 Use the Ol HCDesigner or in the configuration FSYS blocks tum on HCUtilities to configure one of the a no e Tianan e All Modbus slave and Modbus serial ports S1 or S2 as a master port iS contigurea as a read blocks freeze their output 2 Use the Ol HCDesigner or Modbus master pins to the last value HCUtilities to download a Al slave blocks have theirBAD Configuration that has no slave COMM pin on e All slave blocks have their NO SCAN pin on e INSCAN STATUS is set to NO for all slaves e COMM STATUS is set to BAD for all slaves in the function block diagram e Statistical counters for all slaves are 0 2 Controller mode is e Controller will not goto RUN To clear the diagnostic In HCD System changed to
233. t is necessary to adjust wire length so as to ensure adequate flexibility of the twisted wires and to provide clearance sufficient to remove the I O module Figure 42 Wire Shield Grounding Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 79 Terminal Block Jumper Combs Two styles of terminal block jumper combs are available for use with the barrier style terminal blocks ten position and two position Figure 43 The ten position jumpers are used with AC output modules to inter connect L1 AC Hot of all channels The two position jumpers are used to connect Common DC negative or AC neutral for the DC input module the DC Output Module and the AC Input Module Each of these module types has groups of eight channels with the two groups isolated from each other The two position jumper connects Common terminals 10 and 12 making one group of sixteen non isolated channels The two position jumper can also be used to connect the V terminals on the DC Output Module Refer to the wiring information on each module given in this section of this manual Figure 43 Terminal Block Jumper Installation 80 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Removal and Insertion Under Power RIUP A WARNING Read and understand all of the following information regarding RIUP before attempting to remove
234. tallation Planning Rack Installation 64 Procedures for installing the major components of the system controller rack I O expansion racks and communication interconnections I O Module 76 Procedures for installing I O modules in the controller rack and I O expansion Installation and racks and for wiring field devices to the terminal block associated with each Wiring I O module Communications 125 Guidelines for installing RS 232 RS 485 to USB cable RS 485 and Ethernet Installation cabling and associated components Operating 153 Characteristics of the HC900 Process Controller as they relate to configuration of Characteristics a control strategy and to operation of an installed and running system Redundant 163 Characteristics of redundant operation Operating Characteristics Diagnostics and 169 Mechanisms that detect and react to faults in the operation of HC900 Process Troubleshooting Controller hardware and or software components Analog Calibration 187 Hardware configuration required for calibrating Al and AO modules from the configuration software Removal and 192 Guidelines for replacing system components includes Cautions and Warnings as Replacement applicable Procedures Specifications 202 Details of HC900 Process Controller design and functioning Appendix 215 The Remote Termination Panel RTP provides an easy way to connect the Installation of HC900 controller to the field wiring The RTP integrates some of the
235. ted by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 81 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is possible but voltage is still present on the positive side at RTP and module terminals 3 Set verify jumper positions on each RTP as shown C Ca C See page 250 for RTP internal schematic 246 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 32 Point DC Digital Output Connect field wiring 2 fo 3 g 9j 9 gt o avon avon avon avon a lt O a Q lt O a RTP A for outputs 1 to 16 GSI EE EGY SSSI EES S tll Install jumper wire Al fa fo fo fa lt fs Js is lt Of JOT FO JO JO Lo Lo Le 6 AAA DC Supply a lt O S Q lt O a lt Q ie par RTP B for outputs Install jumper wire DC Supply refers to the switched negative side of the DC supply Note SDC Note Terminals 9 and 11 DC are connected through the RTP cable Same for terminals 10 and 12 DC 247 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 32 Point DC Digital Input ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal
236. ted through the RTP cable Same for terminals 10 and 12 DC Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 249 June 2015 RTP A Cable wire positions and colors for cable assembly drawing applies to 16 Al 32 DI 32 DO Twisted Pair Number of HC900 Module TB Position RTP A J1 Plug Connector Color Cable A 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 18 17 Black 17 16 Blue 5 18 15 Black 17 14 Yellow 6 10 12 Black 11 11 Brown 7 12 1 Black 13 2 Orange 8 15 4 Red 16 5 White 9 3 8 Red 8 18 Green 10 9 13 Red 14 3 Blue RTPA HC900 Terminal Block 1 2 3 4 5 6 7 8 18 17 15 16 9 10 1 14 13 12 18 17 CON40 250 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 RTP B Cable wire positions and colors for cable assembly drawing applies to 16 Al 32 DI 32 DO Twisted Pair Number of HC900 Module TB Position RTP B J1 Plug Connector Color Cable B 1 19 6 Black 20 7 Red 2 22 9 Black 23 10 White 3 24 20 Black 25 19 Green 4 36 17 Black 35 16 Blue 5 36 15 Black 35 14 Yellow 6 28 12 Black 29 11 Brown 7 30 1 Black 31 2 Orange 8 33 4 Red 34 5 White 9 21 8 Red 26 18 Green 10 27 13 Red 32 3 Blue RTP B
237. that AC power to the rack is disconnected Set controller module s communication ports to desired settings page 42 Carefully place the Controller Module in the rack immediately to the right of the Power Supply Fasten it in place with two captured screws at top and bottom Torque to 0 4 0 5 N m 3 5 4 4 Lb In ATTENTION Do not install the battery at this time Installing the battery s before the controller is configured can substantially shorten battery life Install under power after the controller configuration is complete For more information refer to Battery Installation Replacement page 199 I O will be installed later See Page 75 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 71 Table 10 Assemble C75 Controller Rack Step Procedure Comments References Carefully place the Power Supplies in the slots in the Rack ensuring that the connector at the back seats properly See Table 9 steps 1 and 2 for power supply wiring details Note It is recommended each power supply should be powered from a separate power source and a power switch should be installed to allow for servicing of each Processor Supply separately Set controller communication ports See page 42 A WARNING Ay Ensure that AC power to the rack is disconnected Carefully place the Controller Modules in t
238. the new Scanner Module in the rack and secure it in place with the captured screws at top and bottom of the module Ts Re install the cable s 8 Using the external user supplied switch connect the power supply or supplies in the expansion rack to the site AC power source The Scanner Module should resume communications with I O modules in the rack and with the Controller Module with which it is connected 9 Check status indications at the Scanner Module at the Controller Module and at the OI HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Replacing an I O Module CAUTION Read and understand all of the following information regarding RIUP before attempting to remove and or replace any I O module particularly in a system that is actively controlling a process All of the I O Module types in the HC900 Controller System include the Removal and Insertion Under Power RIUP feature That is while the rack is powered any of the I O Modules can be removed or inserted e With no physical damage to the module to the rack or to other modules in the rack e Without disturbing the functions of other I O modules in the rack or in the system Under carefully controlled circumstances this feature enables the user to remove and insert an I O module without completely shutting down a running system However it must be recognized that removing or inserting an I O module under p
239. the tie Euro Terminal Block Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual 87 occupied by an I O module install a Filler Block cover Part number 900TNF 0001 Step Procedure Comments Reference 9 Install I O modules in racks Be sure to follow placement guidelines under Heat Rise De rating page 51 10 Install I O module install appropriate terminal block Seo g2 Ep amp Si a 11 In each slot location not Note The Filler Block Cover looks much like an I O Terminal Block assembly except that it does not include the wire terminating block screw terminals The Filler Block mounts in the same manner as a Terminal Block with captured screws at top and bottom Blank labels are provided for mounting in the hinged door 88 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 I O Terminal Block Wiring Diagrams Universal Analog Input Module Wiring The Universal Analog Input Module has eight inputs which can include any combination of the following input types RTD TC Ohms Millivolt Volt or Milliamp Figure 45 shows wiring examples of each of the analog input types An example of wiring for eight TC inputs is given in Figure 47 Specifications for this module and for other modules are given in the Specifications section of this manual H ATTENTI
240. tions see page 50 e Heat rise de rating see page 51 e Cabling wiring distance planning see page 53 e Electrical considerations controller grounding CE conformity grouping wires master control relay for emergency shutdown see page 55 e System monitor function blocks see page 61 44 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 AC Power Supply Selection for racks with I O To determine which I O rack AC power supply to use PO1 or P02 calculate power requirements below H ATTENTION Using inadequate power supply will cause the controller to cycle power on and off A B c D E Max Max Enter Current Current Calculate 5V current Calculate 24V current Module type Quantity 5V 24 V D A B E A C 820 mA 0 mA legacy 1100 mA Controller C30 and C30S New 1 0 930 mA 0 mA legacy 1100 mA Controller C50 and C50S New 1 0 1150mA OmA legacy 1350 mA Controller C70 and C70S New 1 0 1500 mA OmA legacy 1500 mA Controller C75 C75S New 1 0 670 mA 0 mA legacy 750 mA Scanner 1 Port S50 S50S New 1 0 770mA OmA legacy 950 mA Scanner 2 Port S75 S75S New 1 0 Power Status Module PSM 22 mA 0 mA I 0 Analog Input 8 pts 40 mA 25 mA
241. tions and procedures for the installation operation and maintenance of the HC900 Process Controller hardware References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title ID HC900 Process Controller Technical Overview Specification 51 52 03 31 HC900 Module Specification 51 52 03 41 HC900 Controlware Specification 51 52 03 42 Designer Software Specification 51 52 03 43 Legacy HC900 Process Controller Installation and User Guide 51 52 25 107 HC900 Process Controller Operator Interface User Guide 51 52 25 108 HC900 Designer Software User Guide 51 52 25 110 HC900 Process Control Utilities User Guide 51 52 25 126 HC900 Process Controller Function Block Reference Guide 51 52 25 109 HC900 Process Controller Communications User Guide 51 52 25 111 HC900 Controller Redundancy Overview amp System Operation 51 52 25 133 900 Control Station For use with HC900 Process Controller 51 52 25 148 Station Designer Software manual 51 52 25 149 HC900 Process amp Safety Controller Safety Manual 51 52 25 153 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual Revision Information Document Name 51 52 25 154 HC900 Process amp Safety Controller User amp Installation Manual Revision Number Publication Date First release 2 1 January 2014 Redundancy updates 2 2 June 2014 Cyber Security updates 3
242. tions see page 132 For RS 485 connections see page 150 For new systems either of two ports S1 and S2 can be configured as RS 485 For SIL applications communication cable shield connection must be made to IO grounding bar instead of the connector shield connector Ports configurable as ELN default or Modbus RTU e Controller can act as Modbus master or slave through either port e Controller can be slave to masters such as On Legacy systems Operator Interface 1040 559 Must be on galvanically isolated RS 485 port S2 Honeywell HC Designer PC software Third party PC HMI software Third party Operator Interface e Controller can be master to slaves such as Any Honeywell Modbus device e g recorders controllers flame safety Any non Honeywell Modbus device e Only one master port at a time can t have both serial ports as master ports e Modbus master ports default to slave ports ELN protocol when CPUs are in Program mode e Baud rates to 115 200 42 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Setting serial ports S1 and S2 to RS 232 or galvanically isolated RS 485 For legacy systems S1serial port default setting is RS 232 S2 serial port default setting is RS 485 Each port can be set to RS 232 or RS 485 not shown For new systems the serial ports S1 and S2 are galvanically isolated RS 485 unterminated See Table 3 below Functionality is determ
243. tistics that failed the data background scan rate link protocol 2 The UART failed its See above Replace CPU module power up tests 10 Ethernet port tests 1 E1 or E2 port diagnostic is set to Replace CPU module If the lead s status If the lead s status failed during power up FAILED LED is indicating LED is indicating ni the failure see the failure see ie EEPE NETWORK Lead Port E1 PORT E1 or Network Port NETWORK Diagnostics or PORT E2inthe Lead Port E2 Lead CPU Network Port Diagnostics Diagnostics in display the Lead Ifthe reserve s Diagnostics status LED is Overview dialog indicating the box failure see If the reserve s NETWORK status LED is PORT E11 or indicating the NETWORK failure Lead Port PORT E2inthe E1 Network Port Reserve CPU Diagnostics or Diagnostics Lead Port E2 display Network Port Diagnostics in the Reserve Diagnostics Overview dialog box Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 177 June 2015 Scanner indicators Figure 92 LED Indicators on Scanners 1 port left 2 port right See Table 28 When the Scanner is flashing an amber Status LED after power up a power on self test error has occurred that requires scanner module replacement 178 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Table 28 LED Indications on Scanner Module Figure 8
244. to which this declaration relates is in conformity with the provisions of the European Community Directives including the latest amendments as shown in the attached schedule Assumption of conformity is based on the application of the harmonized standards and when applicable or required a European Community notified body certification as shown in the attached schedule The CE Mark was first applied in April of 2002 The authorized signatory to this declaration on behalf of the manufacturer and the Responsible Person is identified below A Owen J Product Safety amp Approvals Engineer Issue Date 26 March 2014 Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 253 June 2015 ATEX Certification son eyweee ll CERTIFICATE OF MANUFACTURER CERTIFICATE NUMBER HON 08 0201 ISSUE NUMBER Revision C EQUIPMENT AND PROTECTIVE SYSTEMS INTENDED FOR USE IN POTENTIALLY EXPLOSIVE ATMOSPHERES DIRECTIVE 94 9 EC EQUIPMENT HC900 Modular Control System Low Power Modules Per Attached List MANUFACTURER Honeywell International Inc 512 Virginia Drive Fort Washington PA 19034 3260 United States of America MARKING OF THE EQUIPMENT SHALL INCLUDE THE FOLLOWING 113 G Ex nA IIC T Ge AMBIENT TEMPERATURE 0 C to 60 C ELECTRICAL DATA SUPPLY INPUT COMPLIANCE WITH THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS HAS BEEN ASSURED BY COMPLIANCE WITH IEC 60079 0 2011 EN 60079 15 2010 Issue Dat
245. tom of each rack as indicated in Figure 42 Low Frequency Noise Rejection Shield wire For low frequency noise rejection I O wiring shields should be grounded only at the controller end For high frequency noise rejection shields should be grounded at the controller and at the field device If the ground voltage potential at the field device is different from that at the controller a DC isolation capacitor High Frequency should be used between the shield and the Noise Rejection grounding bar on the rack Shield wire DC isolation Capacitor Shield wire Figure 41 Signal Wire Grounding Aluminum grounding bars for I O wiring are available as options When selected for use they are fastened to the top and or bottom of each rack as indicated in Figure 42 To enable connection of multiple ground wires with a single screw the wires can be twisted together and secured with a wire lug To facilitate module replacement it is advisable in most cases to route all wiring through either the top or the bottom of the terminal block This allows the terminal block to pivot up or down allowing ready access to the module and is the preferred method for a limited number of wires For a larger number of wires or for wires of a heavier gauge it is advisable to route some wires through the top of the terminal block and some through the bottom as indicated in Figure 42 In this case i
246. tor Interface to the galvanically isolated RS 485 port on the controller for legacy systems For new systems the parts in Table 18 connect to either of the two galvanically isolated RS 485 ports on the controller See page 42 for port location Typically the cable that interconnects this port to the Operator Interface must be made during installation because it will probably be necessary to run the cable through conduit On C75 connect cable from each CPU s galvanically isolated RS 485 port to the Operator Interface See Operator Interface manual 51 52 25 108 for connection details Table 18 Parts needed to make RS 485 Cable Belden 9271 or equivalent Variable Commercially available communication with 120 ohm resistors 2 000 cable feet Maximum Or Belden 9182 or equivalent with 150 ohm resistors 4 000 feet maximum 10 terminal connector Supplied with the operator interface Phoenix 1840379 or Connector 3 pin Supplied with the equivalent for C30 C50 controller CPU module Phoenix 1803581 for C75 047260 1 Ferrite cable clamps Supplied with the operator interface 089037 Nylon cable ties Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 129 June 2015 Connecting the HC900 Controller to a PC with the Designer Software To establish communications between the HC900 controller and the Process Control HC Designer configuration software use any of the following met
247. trical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual June 2015 This page is intentionally left blank vi HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Contents Ta ligers Whey ea aA A E ome eat ene arnt at eRe nae eon tr ane tan eente oat Ema e OT I AE DR Aone OM COPECO IE EONS ON PRES 1 PUNPOSG nagae onde te phidteie olde ae E T E A ated visa eidvag ES AS 1 Model Selection Guide cccccccececcceeeeeeeesaeceeneeceaeeecaaeseeaaeeaaeeeseaeeseaaeseaeeseaeeecaaeeseaaeseeaeeseeeescaeesaesssaeeeanees 2 Functional Descriptionia t 4 cei adit waitin dk intel eit a tone a aid iin a iia 9 Feature SUMMAarY iinan i ia a aria aaa adaa a aa adada ara da Va tan ai a ania iaia 12 Components and Architecture cs casesesccn veers civetiiadavecevetss iss nd sce dcie ees Reece eS 15 OVEIVICW A E TE ttt lees iiceveltat whuteetaleee Ste attenuates EA yyy E E TATE 15 Gomponent ani in Oates aie ini oe a esd vate eee A 15 Redundant COMPONMEMS aaar nA EA NAE ARA pease ER AA AANA 18 Hardwate Components m isiriitrenr aatia e te aa e e a inne aaas ai aaeain 20 Ethernet Devices Considerations ccccceesceceeeeeceeeeeeaeceeneeceaeeeca
248. ty Controller Safety Manual for additional details Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure 68 Fuses appropriate for load and for wire used i are provided by user o Fuses appropriate for load and for wire used are provided by user Figure 67 Schematic Example Relay Output and External Wiring Contact Rating Maximum current output 4A at 250Vac 30Vdc with resistive load Maximum current per module No de rating per module but ensure compliance with maximum ratings for each output Note specified relay life is 1 000 000 cycles For applications requiring constant cycling of output Honeywell recommends using a solid state AC or DC output module Required Output Fusing Outputs are not fused in the Relay module Install a fuse for each output at the field device that is appropriate for the load and the wire used Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 117 June 2015 Jumper Comb A ten position jumper comb available for the AC Output Module can be cut in half and used as shown in Figure 69 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could re
249. typical Remote externally connected components reducing wiring and setup time It also Termination Panels minimizes the need for multiple wires under a single screw connection by RTPs expanding the connectivity of the shared terminals of the I O modules Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 1 June 2015 Introduction Model Selection Guide Legacy System Racks o S SoS S S Controller C50 CPU 900C52 02XX 00 we No No No No eo a we ConvolercsocPu eooosze ORK ooo S 0 eooc zono o SSS S S Convolerczarcu eooorzazonaa no Oo O O OSOS Redundancy switch modde eooRsm 00 o o TO Scanner 2 Pon 0 per Oreg ooocraR ona no O Oy E VO Scanner for remote rasy 00053 0900 no Redundant Power Status Mode 900PSM 0001 no o Powersu O S S SS aoeaovac ew ooo SSS CZO E T woo o ooa S omas S SS f S SSS Analog Input channe eooo ooo S SO S S S High Level Analog Input 6 charme e00a16 20001 no Analog Output 0 1o 20mA 4 channe e0080 z020 no o Analog Output 0 to 20mA E sharre e00808 20001 no Analog Output 0 to 20mA 16 channe 8008160001 no Digital Input Contact type 16 channe 800601 0102 no Digital Input 240C 16 channe e0602 0102 no Digital Input 24VDC 82 channe eo0es2 0001 no Digital Input 1207240 VAG 16 channel 000608 0102 no Digita Input T2O240VAG 126V0C 6chso 900G04 0001 no
250. ule TB Position RTP J1 Plug Connector Color 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 9 17 Black 10 16 Blue 5 11 15 Black 12 14 Yellow 6 14 12 Black 15 11 Brown 7 16 1 Black 17 2 Orange 8 19 4 Red 20 5 White 9 3 8 Red 8 18 Green 10 13 13 Red 18 3 Blue 226 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Analog Input Digital Input Digital Output Analog Output A single DI DO AO RTP and cable is used with the following modules See page e 4 point Analog Output 227 e 16 point Contact Digital Input 229 e 16 point DC Digital Input 230 e 16 point AC Digital Input 232 e 16 point DC Digital Output 233 e 8 point AC Digital Output 236 e 8 point Analog Output 239 Dual DI DO AO RTPs and cables are used with the following modules See page e 16 point Analog Output 242 e 16 point Analog Input 243 e 32 Point DC Digital Output 246 e 32 Point DC Digital Input 248 4 Point Analog Output 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 98 e Remove appropriate key tabs from terminal block to allow mating with the module See page 83 e Connect desired cable to AO module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Ter
251. ure 92 LED Indicators on Scanners 1 port left 2 port right See Table 28 cee eeeceeeeeeeseeceereeeneeees 178 Figure 93 I O Module LED indicators ee cee cece ereeeeeeeeeeeececensecsecaecsaecsaecsaecaeecaeseaeseaeeeeeeeeensenseeseenaes 183 Figure 94 Terminal Board Connections for AI Calibration cssecseeeseceecaeecseseeeeeeeeseeeaeenseenseeseenaes 190 Figure 95 Terminal board Connections for AO Calibration 0 eee ec cececseeseeeeeeeeeeeeeeeeeesecesecaecsaecnaecseeenaeenes 191 Figure 96 Extended Distance Example 1 00 cece eeeeeseeceecceeeceseceseceaecsaecsaecaeecseesaeseaeseeeseseseesasenseesseaecnaes 212 Figure 97 Extended Distance Example 2 esisi ci ceccecssseesseeeeeeeeeeseeccesecesecsecsaecsaecaeecseecseseaeseeeeeeeeeeeseenseeseenaes 213 Figure 98 Example installation not shown 2 RTP amp cable for high capacity AI DI DO c ssccscesseeseeesees 215 Fisure 99 Analos input terminals poses nesenie enoo o ae ent deste suyevees leeds cp svevbeogeesunde SPESA ER iaioa ipi 218 Figure 100 Two wire transmitter connections with common 24 VDC supply sseessssessesssresesreesssreersserreesesreees 218 Figure 101 Milliamp input connections with 250 ohm shunt resistance eeseesesseeeesesesererrsreerssreereserrrnsesrese 219 Figure 102 Volt millivolt input connections 2 0 eee ee eeeceeeceescesecesecesecsecsaecseecseesaeseaeseeeeesseeesasensecaeeaeenaes 219 Figure 103 Three wire RT
252. us injury Controller Grounding PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National Electrical Code ANSI NFPA 70 and with local electrical codes Shields Grounding Bar Field Wiring L1 H L2 N PE Power Source Figure 31 Cabinet Wiring Single Chassis Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 55 June 2015 Grounding Baran g 14 AWG 2 1 mm L1 H L2 N PE Power Source Figure 32 Cabinet Wiring Multiple Chassis 56 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 14 AWG 2 1 mm ws L1 H L1 H L2 N PE PE L2 N L1 H Power Source Power Source For P01 power supply use 3 0A slow blow for 115VAC operation 2 5A slow blow for 230V AC operation For P02 power supply use 2 5A slow blow for 115VAC operation 2 0A slow blow for 230VAC operation For P24 power supply use 7 0A slow blow Figure 33 Redundant power supplies each with external fuse and switch Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 57 June 2015 CE Conformity Electrical noise produces undesirable effects in measurements and control circuits Digital equipment is especially sensitive to the effects of electrical noise You should use the following methods to reduce these effects e
253. ver 900TNF 0101 Yes Analog Input Remote Terminal Panel 900RTA L001 No Relay Output Remote Terminal Panel RTP 900RTR H001 No DI DO AO Remote Terminal Panel RTP 900RTS 0001 No Power Supplies 120 240 VAC 60W 900P01 0201 Yes 120 240 VAC 28 W 900P02 0201 Yes Redundant Power status module 900PSM 0101 Yes Redundant Switch module 900RSM 0101 Yes Conventions Throughout this guide where the text Legacy systems is used the following model numbers are applicable Legacy systems Model Numbers 900C51 00XX 00 900C52 00XX 00 900C31 00XX 00 900C32 00XX 00 900C71 00XX 00 900C72 00XX 00 900C71R 0000 XX 900C72R 0000 XX 900RSM 0001 900C73R 0000 XX 900C53 00XX 00 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Introduction Throughout this guide where the text New systems is used the following model numbers are applicable Note Model number change 900 xx where if C designates Controller module and S designates Scanner module e New System SIL and Non SIL Model Numbers 900C30 0360 00 900C50 0360 00 900C70 0360 00 900C75 0360 00 900875 0360 00 900S50 0360 00 900C30S 0360 00 900CS50S 0360 00 900C70S 0360 00 900C75S 0360 00 900S50S 0360 00 900S75S 0360 00 Refe
254. wer switch for 24 volt supply Module RIUP is not affected by using the RTP See page 222 for RTP internal schematic Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 217 June 2015 8 Point Analog Input Connect field wiring Refer to Figure 99 through Figure 105 for field wiring Any input type can be wired to any of the 8 inputs After wiring double check DIP switches settings for each input type Step 3 amne N8 WX GLX 3NI 11 B 5 5 S power gt switch Red 1 0 Figure 99 Analog input terminals E POOPHOOE f You must set switches 1 8 for transmitters sate enI amp QO OGOOHOO DOAA 25 Gs Input 1 2 Input 3 Transmitter Input 2 Transmitter Input 4 Transmitter Input 6 INDUE 7 Transmitter Transmitter Transmitter ansmitter Input 8 Input 5 Transmitter Figure 100 Two wire transmitter connections with common 24 VDC supply 218 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 8 Point Analog Input DODOOHOGOGHGSOHSE O QO O O O OO O O O mA Input 1 mA Input 2 Figure 101 Milliamp input connections with 250 ohm shunt resistance YOOOOOOVDOOOOOOOOOOOO Note You must set switches 1 8 for Volts Millivolts V mV Input 1 V mV Input 2 Figure 102 Volt millivolt input connections Revision 4 0 HC900 Process amp Safety Controller User an
255. will remain the Lead even if the condition that caused the failover is corrected Start Up e Assignment of Lead and Reserve status is determined at start up First available C75 assumes Lead In case of a tie CPU mounted in the left position of the rack will Lead No user configuration or manual operations required to establish Lead Reserve status e Lead Controller assumes control of I O and all external communication interfaces e Reserve Controller receives the configuration from the Lead Controller Modes of operation Figure 89 The modes of operation are e Run e Run Program e Program You can change modes with e key switch on the redundancy control module e HC Designer software e HC Utilities software e 900Control Station e acommand from a supervisory host Both Lead and Reserve Controllers maintain the same mode Placing the Lead Controller into the Program mode will also place the Reserve Controller in the Program mode Revision 4 0 HC900 Process amp Safety Controller User and Installation Manual 163 June 2015 Reserve lt C gt Run Run P Figure 89 Modes of operation on RSM RUN Mode Locked In the Run mode the controller performs all control and communication tasks needed for steady state operation On line configuration edits and configuration changes are inhibited SIL application must operate in this position SIL requirements may not occur in other operational modes This RUN locked mode
256. witch or router firewall for CPU A E1 port 3b Ethernet switch or router firewall for CPU B E1 port 4a Connect CPU A I O port to Ethernet switch 5a 4b Connect CPU B I O port Ethernet switch 5b 5a Ethernet switch for CPU A s I O racks 5b Ethernet switch for CPU B s I O racks 6a Connect Ethernet switch 5a to each I O rack s I O A port 6b Connect Ethernet switch 5b to each I O rack s I O B port 7 I O Racks 8 Connect the primary Ethernet port of the 900 control Station to the Ethernet switch which is assigned to port E1 of the controller CPUs 9 Connect the Auxiliary Ethernet port of the 900 Control Station to the Ethernet switch which is assigned to port E2 of the controller CPUs 10 Connect CPU A S1 port to PC USB port through RS 485 to USB converter 50089787 001 144 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Table 21 Redundant network connections Step Procedure 1 Make sure the PC has 2 Ethernet NICs Network Interface Cards installed and enabled 2 Connect Ethernet 10 100 Base T straight or crossover cables to the HC900 controller s E1 and E2 ports 3 Connect the other end of the cables to the PC s Ethernet ports 4 On the PC use the Utilities Worksheet in the Designer software to connect to the controller over Ethernet Every HC900 C75 controller is shipped with the default IP addresses for port E1 192 168 1 254 and port E2 192 168 2 254 Def
257. work and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings 18 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Table 2 Descriptions of Major Redundancy Components Key No Component Description Source Name 1 Controller Includes Rack 2 Power Supplies 2 C75 Honeywell Local Rack Controllers 1 Redundancy Switch Module RSM 2 I O Expansion Includes 1 Scanner 2 module 1 Power Supply and Honeywell Rack up to 4 8 or 12 I O modules Optional second Power Supply and Power Status Module PSM on 8 and 12 slot I O racks 3 Control Station 900 Control Station operator interface Honeywell communicates via Ethernet or RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Serial Controller Module to a serial port on the PC software is from Interface l Honeywell RS 485 to option e For new system The PC Configuration tool USB converter is a third connects from the galvanically isolated RS 485 party device avai
258. work traffic conditions Extraneous traffic is possible when sharing bandwidth with other devices We recommend putting the controller on a private network segment Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 15 January 2014 a tet i Controller Rack with 4 slot VO E Controller Rack witn 8 slot I O Expansion I O Expansion O Q Expansion I O Q Expansion I O Figure 4 Configuration with Multiple Controllers CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings 16 HC900 Process amp Safety Controller User and Installation Manual Revision 4 0 June 2015 Table 1 Descriptions of Major Components Figure 4 Key No Component Description Source Name 1 Controller Includes Rack Power Supply Controller Module and Honeywell Local Rack I O modules 2 I O Expansion Optional Includes Rack
259. x 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet I O Capacity Combined Analog and Digital Analog Inputs Analog Outputs 384 1920 192 960 40 200 48 with heat de 240 with heat de rating rating 960 with external power source 192 with external power source Rack Size 4 I O slot chassis 8 I O slot chassis 8 I O slot chassis with redundant power support 12 I O slot chassis 5 4 137mm H x 10 5 266 7mm W x 6 0 151 7 mm D rear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 16 5 419 1mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 20 9 530 9 1mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 22 5 571 5mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm 202 Revision 4 0 June 2015 HC900 Process amp Safety Controller User and Installation Manual C30 C50 C70 C75 12 I O slot chassis with redundant power support Redundant CPU rack 5 4 137mm H x 26 9 683 3mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm N A 5 4 137mm H x 10 3 261 6mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 6 4 162 6 for 32 DI DO and 16 Al Modules 175 3mm
260. ywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 For more information EMEA Honeywell Process Solutions Phone 80012026455 or 44 0 1202645583 Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com To learn more about SmartLine Transmitters visit www honeywellprocess com Or contact your Honeywell Account Manager Process Solutions Honeywell 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell Control Systems Ltd Honeywell House Skimped Hill Lane Bracknell England RG12 1EB Shanghai City Centre 100 Jungi Road Shanghai China 20061 www honeywellprocess com 51 52 25 154 Rev 4 0 June 2015 AMERICA S Honeywell Process Solutions Phone TAC 1 800 423 9883 or 215 641 3610 Sales 1 800 343 0228 Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com Honeywell 2015 Honeywell International Inc

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