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HC900 Hybrid Controller Installation and User

1. o Figure 46 Analog Input Wiring Slidewire Position Proportion Block Revision 16 HC900 Hybrid Controller Installation and User Guide 86 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 16 point High Level Analog Input Wiring Figure 47 Be sure to set the module DIP switches for voltage or current mode See page 77 V Source Y ra Az V Input IN 3 ma IN 4 KO IN 6 IN 5 i IN 6 IN 7 om IN 8 K 14 IN 7 bog 4 20 mA Input VOCS Cs Pt IN 15 IN 18 o IN 15 j IN 18 32 NC lon NC 34 i OOOOODOOOOOOOOOOOD in Figure 47 16 point High Level Analog Input Wiring 4 channel Analog Output Module Wiring An example of Analog Output Module wiring is shown in Figure 48 Specifications for this module and for other modules are given in the Specifications section of this manual Isolation The four outputs are isolated from each other Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section WARNING A 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 16 HC900 Hybrid Controller Installation and User Guid
2. Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 79 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 41 shows wiring examples of each of the analog input types An example of wiring for eight TC inputs is given in Figure 43 Specifications for this module and for other modules are given in the Specifications section of this manual H ATTENTION 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 16 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 10 034 0 029 0 069 0 018 0 018 0 023 0 020 12 0 081 0 091 10 054 0 046 0 109 0 028 0 029 0 037 0 031 14 0 064 0 146 10 087 0 074 0 175 0 045 0 047 0 058 0 049 16 0 051 0 230 10 137 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 10 357 0 298 0 707 0 185 0 190 0 235 0 200 24 0 0201 1
3. mn Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 226 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 212 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Contact Digital Input Action Connect field wiring 16 Point DC Digital Input Step Action 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired cable to 16 point DC DI module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long e Install 16 point DC DI module label into the module connector cover e 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 71 2 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP Revision 16 HC900 Hybrid
4. Approvals CE Conformity This product is in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC 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 PDA Certificate of Manufacturing Assessment No 06 BA766694 X General Purpose Safety Compliant with EN61010 1 UL UL 61010C 1 CSA C22 2 No 1010 1 Hazardous Classified Location Safety FM Class I Div 2 Groups A B C D CSA Class I Div 2 Groups A B C D Class 1 Zone 2 IIC Module Temperature Classifications Module Type T Module Type a bi Rating Rating Redundant CPU Rack T6 Scanner 2 Port T6 Redundant PS Ext Rack T6 Analog Input 8 chan T6 8 Slot Redundant PS Ext Rack T6 Analog Input 16 chan T6 12 Slot Redundant PS Ext Rack T6 Analog Output 4 chan T4 4 VO Slot Rack T6 Analog Output 8 chan 8 VO Slot Rack T6 Digital Input Contact type 16 chan T5 12 VO Slot Rack T6 Digital Input 24 Vdc 16 chan T4 Power Supply P01 T4 Digital Input 120
5. See page 35 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 62 Rack Installation Assemble Controller Rack Step Procedure Comments References 3 WARNING Ay Ensure that AC power to the rack is disconnected Carefully place the Controller Modules in the rack adjacent to the Power Supplies Fasten them in place with captured screws at top and bottom ATTENTION The CPU battery 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 187 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 63 Rack Installation Assemble I O Expansion Racks Assemble I O Expansion Racks I O Expansion Rack assembly information is given in Table 12 Table 12 Assemble I O Expansion Racks Step Procedure Comments References 1 Insert power supply into left most slot in the I O rack See Table 10 steps 1 and 2 for wiring details If using redu
6. rrrrnvrnnnvnnnnvnnnnvnnnnrnnnvrnnnvvnnnvnnnnvnnnrrvnnnnnnsrnnneennne 137 Operating Characteristics sa 140 Introduction t E E E RE E NN 140 ONE EN EE a EN ee 140 Power Down Power Up manrnennvnnenvnnnnrnnnnrnennrnennrnrnnnnennenennnnenrnnennnnenensennnssnnnsennnssnenssnerssnessennsssnsssnesssnesenne 140 Controller Modes ci 25e2 vee cvudeevteeh soee eden esses ee sedi dete N A E 144 File Download Upload Functions ccceceeceeeeeeeeeeeeeeeeeaeeeeaeeeaaeeeaaeeeeaeeeaaeeeaaeeeeaeeesaeeeaaeseaaeseaaeenaeeseaeeesas 149 Redundant Operating Characteristics ccceeesseceeeeeeeseeceeeeeeeeeeeaeeeeeeeesseeeeeeeeeeeaes 151 OVENEM ger 151 Star Up reser re ke Pu hore Tee set 151 Modes of operation Figure 82 rnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnrnnnnurnnnurnnnrnnnnrnnnnennnnrnnennnnnrnennsnenen 151 Steady State Operations seii enpa E E teres senna tebes sates teres sans deras sesam nest echt 152 FANNO aa a T ere 154 File Download Upload Functions rsrrrnvrnronrnennrnennrnrnvnnrn annen A A N 155 Diagnostics and Tonbeshodimeavurvpvvertand ee alernedee sende 157 OE LE EE EE ee 157 External Indications of Diagnostic Information ceeceeeeeeeeeeeneeeeeeeeeeaeeeaaecesaeeeeaeenaaeseaaeeeaaeenaeeeeaaeenaeeesas 157 Controller CPU indicators cececceeeceeeeeeeeeceeeeeeeeaeeeeeeesaneeeaeeeseeeesaeecsaeeesaeeesaeeeseeeesaeeeseeeseaeeseeeeseeeeseeeeeeees 158 SCANNEMINGICAOr Sins net ae ests ea
7. Revision 16 HC900 Hybrid Controller Installation and User Guide 18 10 09 Components and Architecture Hardware Components Power Status Module C70R The Power Status Module PSM Figure 11 sits between redundant power supplies o page 16 It is a status module for both power supplies and indicates which are in use 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 with in 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 16 HC900 Hybrid Controller Installation and User Guide 19 10 09 Components and Architecture Hardware Components Controller Module Figure 12 C30 C50 C70 C7OR Controllers share the same features with exceptions noted CPU model number C30 C50 C70 C7OR Lithium battery beneath cover which is readily accessible for field replacement 1 2 3 Mode switch Pgm Run Pgm Not present on C70R see RSM 4 Two serial ports S1 and S2 each configurable as RS 232 or RS 48 modem or Modbus devices RS 485 interfaces to PC Germ 5 LED status indicators for communications functions 6 Connection to I O port of Scanner Module 2 C50 C70 C70R only 7 Second Ethernet Host Connection to PC GX applications or peer
8. CAUTION If the battery is removed from the Controller Module when AC power is not applied the content of SDRAM will be lost Before beginning this procedure upload and SAVE 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 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 Extract the battery 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 16 10 09 HC900 Hybrid Controller Installation and User Guide 186 Specifications General Specifications Specifications General Specifications
9. Figure 50 16 channel Analog Output Wiring Diagram Revision 16 HC900 Hybrid Controller Installation and User Guide 89 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 within each group An example of Digital Input Module wiring is shown in Figure 51 Specifications for this module and for other modules are given in the Specifications section of this 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 52 A WARNING A 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 90 10 09 I O Module Installation and Wiring I O Terminal Block
10. ag ET position jumper cut in half E D AD T for a Relay Output IZ 18 Module e 20 20 Refer to terminal block wiring diagrams for specific information 4 For each configured and 120 240 labeled I O Module break Vac OUT off the key tabs in the pattern that identifies each module type For a diagram of each key tab pattern use the I O Modules and or the diagram shown next page Example Tabs Removed for AC Output Module Revision 16 HC900 Hybrid Controller Installation and User Guide 74 10 09 I O Module Installation and Wiring I O Module Installation Procedures 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 5 s 5 b z 3 S p 3 g g 5 g S I 380 z S S 3 3 A 8 a zA 3 2 F Nm ow oO NO lt e lt Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 75 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 5 If installing High
11. 1 Mount the Rack in the enclosure as follows 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 Drill and tap for 10 or M4 screws Start the mounting screws Supplied by the user in the drilled holes Hang the Rack on the screws at the top Mark the locations for the bottom screws See CAUTION at right Drill and tap for 10 or M4 screws 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 57 Rack Installation Mount Racks Step Procedure Comments References Reference Center for Drilled Holes at Top of Rack As y f 2 slot racka f racks pe 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
12. Abstract This document provides descriptions and procedures for the installation operation and maintenance of the HC900 Hybrid 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 Hybrid Controller Technical Overview Specification 51 52 03 31 HC900 Module Specification 51 52 03 41 HC900 Controlware Specification 51 52 03 42 Hybrid Control Designer Specification 51 52 03 43 HC900 Hybrid Controller Operator Interface User Guide 51 52 25 108 HC900 Hybrid Control Designer User Guide 51 52 25 110 HC900 Hybrid Control Utilities User Guide 51 52 25 126 HC900 Hybrid Controller Function Block Reference Guide 51 52 25 109 HC900 Hybrid 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 Hybrid Controller 51 52 25 148 Station Designer Software manual 51 52 25 149 Contacts World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL Corporate http www honeywell com Honeywell Process Solutions http hpsweb honeywell com Technical tips http hpsweb honeywell com Cultures en US Products Instrumentation hybrid hc900 TechnicalTips documents htm Telephone Contact us by telephone at the numbers listed below
13. 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 Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 187 Specifications General Specifications 12 I O slot chassis with redundant power support Redundant CPU rack C30 C50 C70 C70R 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 ex
14. INDEX SENSE SENSE OUTFUT1 CUTPUT2 OUTPUT3 OUTPUT4 a OSSA DOD ODS DOO ENCODE ENCODE DU P 5 to 24Vdc Figure 69 Quadrature Single Ended External Power Wiring Altention For Input1 Input 2 and Index reverse polarity to Encoder 200mV sa N 1 to A 6 0V 2 Differential 4 Grs N 3 PNY 8 N3 NI N4 1 200mV 8 ka ge ph o NDEX 60v 7 an 10 INDEX Differential _ a be SENSE mn Internal jumper Ei N 12 SENSE ks 1 O id OUTPUTI LAR dal 14 OUTPUT2 m 15 OUTPUT3 18 OUTPUTA4 EE AN COM abe OR ENCODE S rz Ka 18 ENCODE EG Se gt Attention 24 For Inputt Input 2 and Index reverse polarity to Gre Figure 70 Quadrature Differential HC900 Power Wiring Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder At IN 1 Single ended a IN 1 BH IN 2 B 2 IN 2 IN 3 IN2 IN 4 IN 4 INDEX INDEX SENSE Internal jumper y SENSE OUTPUT1 OUTPUT2 CUTPUT3 OUTPUT4 com ENCODE ENCODE Encoder power az Figure 71 Quadrature Single Ended HC900 Power Wiring Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 111 Communications Installation Overview Overview This section contains descriptions procedures and recommendations for ins
15. Maximum per module 8 0A Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 101 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 61 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 fuse with UL CSA approval for 250 VAC A WARNING A 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 102 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Output Out 7 H Out 7 NO Out 8 H Out 6 NO Legend External Disconnect User Suppliod Safety Device Figure 60 AC Output Module Wiring Diagram Out 1 H Out 1 NO Out 2 H Out 2 NO Out 3 H Out 3 NO Out 4
16. Model Selection Guide Model Selection Guide Description Racks 4 I O Slot Rack 8 I O Slot Rack 12 I O Slot Rack 8 Slot Rack Red Power 12 Slot Rack Red Power Redundant CPU Rack Controllers Controller C50 CPU Config SW amp Docs Controller C50 CPU Controller C30 CPU Config SW amp Docs Controller C30 CPU Controller C70 CPU Config SW amp Docs Controller C70 CPU Model number 900R04 0001 900R08 0101 900R12 0101 900RO8R 0101 900R12R 0101 900RRO 0001 900C51 00XX 00 900C52 00XX 00 900C31 00XX 00 900C32 00XX 00 900C71 00XX 00 900C72 00XX 00 Controller C70R CPU Config SW amp Docs Controller C70R CPU Redundancy switch module I O Scanner 2 Port 1 per I O rack I O Scanner for remote rack Redundant Power Status Module Power Supplies 120 240VAC 60W 120 240VAC 28W 24VDC I O Modules 900C71R 0000 XX 900C72R 0000 XX 900RSM 0001 900C73R 0000 XX 900C53 00XX 00 900PSM 0001 900P01 0001 900P02 0001 900P24 0001 Analog Input 8 channel 900A01 0102 High Level Analog Input 16 channel Analog Output 0 to 20mA 4 channel Analog Output 0 to 20mA 8 channel Analog Output 0 to 20mA 16 channel Digital Input Contact type 16 channel Digital Input 24VDC 16 channel Digital Input 24VDC 32 channel Digital Input 120 240 VAG 16 channel Digital Output Relays 8 channel Digital Output 24VDC 16 channel 900A16
17. Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 800 822 7673 Service Revision 16 HC900 Hybrid Controller Installation and User Guide iii 10 09 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 WARNING not avoided could result in death or serious injury This CAUTION symbol may be present on Control Product instrumentation 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 GAUTION 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 VAN handling electrostatic sensitive devices CAUTION HOT SURFACE This symbol warns the user of potential h
18. Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 95 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Contact Input Module Wiring The Contact Input Module has sixteen inputs in one group An example of Contact Input wiring is shown in Figure 56 Specifications for the Contact Input Module and other modules are given in the Specifications section of this manual Internally Powered Input Channels The Contact Input Module provides voltage to the field contacts A 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 A 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 96 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Contact Input cg AA O IN 1 IN2 IN3 IN4 INS IN6 IN7 AAI Jr av OOS VOSS odo COM COM COM COM COM COM COM COM Figure 56 Contact Input Wiring Diagram DC Output Module Wiring The DC Output Module provi
19. mn Jumper open i Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 226 for RTP internal schematic 4 Connect field wiring LOADS ARE 0 to 750 ohm a1 zla alo alc 6 2 3 2 o 2 SIX OSOPMOODOGDHDDOGHGODOHOD VU 7 Wy NTV YY 0 2 3 Revision 16 HC900 Hybrid Controller Installation and User Guide 211 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Contact Digital Input Action ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired cable to 16 point Contact DI module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point contact DI module 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 71 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP Mg Jumper open
20. Always observe the wiring cabling guidelines on page 45 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 118 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software A Direct Serial RS 232 Connection Com1 Com 8 v RS 232 7 Null Modem cable RS 232 Configuration port PC Attention Always observe the wiring cabling guidelines on page 45 Step Procedure 1 Prepare a null modem cable Refer to RS 232 Direct Link to PC Configuration Tool page 120 for specific instructions on the null modem cable 2 Connect one end of the null modem cable to the HC900 controller s RS 232 configuration port 3 Connect the other end to an available serial port COM1 through COM8 on your PC Refer to RS 232 Direct Link to PC Configuration Tool page 120 for specific instructions on the null modem cable 4 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 5 From the Utilities Worksheet Utilities tab in the main window in the HC Designer software set up the 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 fa
21. C30 C50 C70 C70R Controller Design Modular design with metal rack enclosure power supply controller CPU 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 1w o switch using to 4 with recommended Honeywell switches Ethemet direct cable Up part no 50008930 001 to 5 with recommended 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 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 I O Capacity Combined Analog and Digital Analog Inputs Analog Outputs 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
22. FAX 359 2 40 20 990 Czech Republic Honeywell spol s r o Phone 420 242 442 232 FAX 420 242 442 131 Denmark Honeywell A S Phone 45 39 55 55 55 FAX 45 39 55 55 58 Finland Honeywell OY Phone 358 0 20752 2753 FAX 358 0 20752 2751 France Honeywell SA Phone 33 0 1 60198075 FAX 33 0 1 60198201 Germany Honeywell AG Phone 49 69 8064 299 FAX 49 69 806497336 Hungary Honeywell Kft Phone 36 1 451 4300 FAX 36 1 451 4343 Italy Honeywell S p A Phone 390292146307 FAX 39 0292146377 The Netherlands Honeywell B V Phone 31 0 20 5656200 FAX 31 0 20 5656210 Norway Honeywell A S Phone 45 39 55 55 55 Poland Honeywell Sp zo o Phone 48 22 6060900 FAX 48 22 6060901 Portugal Honeywell Portugal Lda Phone 351 21 424 5000 FAX 351 21 424 50 99 Romania Honeywell Bucharest Phone 40 0 21 2316437 FAX 40 0 21 2316439 Russian Federation RF ZAO Honeywell Phone 7 095 796 98 00 FAX 7 495 797 99 64 Slovak Republic Honeywell s r o Phone 421 2 58247 410 FAX 421 2 58247 415 Spain Honeywell S A Phone 34 0 91313 61 00 FAX 34 0 91313 61 30 Sweden Honeywell AB Phone 46 8 775 55 00 FAX 46 8 775 56 00 Switzerland Honeywell AG Phone 41 18552448 FAX 41 1 855 24 45 Turkey Honeywell Turkey A S Phone 90 216 578 71 00 FAX 90 216 575 66 35 Ukraine Honeywell Tel 380 44 201 44 74
23. 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 232 RS 485 unterminated RS 485 terminated RS 485 with external last link in network bias unterminated CAS TSN ToN FI vw am am 0 MM am ZEON Z CHIN Z CAN ZA IN Honeywell SW1 ap ER le NW ESS BEAT W i SW2 FO m FI m J Z CON Figure 23 Serial Ports DIP Switch default settings Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 34 Components and Architecture Serial Ports RS 232 and RS 485 Simultaneous port configurations Figure 24 Figure 25 and Table 4 show the ways the CPU s two serial ports can be configured simultaneously The referenced figures show the C30 but any controller can be used Port S2 left side is RS 485 by default port S1 right side is RS 232 by default Be sure to make RS 485 connections to both CPU A and CPU B of redundant controllers having C70R CPUs Do not make RS 232 connections to both CPU A and CPU B of redundant controllers Table 4 Simultaneous serial port configurations See RS 232 Port Configured as RS 485 Port configured as Figure 24 1 ELN device ELN device Figure 24 2 Controller is Modbus Slave ELN device Figure 24 3 ELN device Controller is M
24. Inputs 1 to 8 EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN to 9 24VRTN to 11 External 24VDC supply Revision 16 HC900 Hybrid Controller Installation and User Guide 223 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP A Cable wire positions and colors for cable assembly drawing applies to 8 AO Twisted Pair Number of Cable A HC900 Module TB Position RTP A J1 Plug Connector Color Black Red Black White Black Green Black Blue Black Yellow Black Brown Black Orange Red White Red 0 Green 10 Red 0 Blue HC900 Terminal Block ADANADAOAARWNM ww sw SW SPST 181 akobi bake a CON40 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 224 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Output Step Action 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 91 e Remove appropriate key tabs from terminal board to allow mating with t
25. e Latch to rail See page 241 e 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 e Note Inputs 9 and 10 are wired between both RTPs 3 Set verify jumper positions on each RTP as shown EE Jumper open Ez 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 73 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 See page 238 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 227 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input Action Connect field wiring Refer to the appropriate figure for your type of analog input 900000000 RTP A for 24 426 646 inputs 1 to 10 RTP B for inputs 9 to 16 DOSVSOSVSONHOSYVS Notice that Inputs 9 and 10 are connected across RTP A and RTP B Figure 99 Voltage input connections RTP A for inputs 1 to 10 RTP B for inputs 11 to 16
26. otherwise use default Refer to the HC900 Hybrid Control Designer 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 134 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software D Network Access to one or more controllers Ethernet 10Base T LAN 165 125 163 25 165 125 163 26 Attention Always observe the wiring cabling guidelines on page 45 Step Procedure Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled Be sure the NIG 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 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 n
27. 10 100Base T Ethernet devices in an Ethernet network Devices Switch or include other HC900 Controllers HMIs and can Router also include routers brouters servers and other devices in wider networks 7 Ethernet CAT5 Connects I O expansion racks C50 C70 CPU only Third party suppliers or shielded cable to controllers and or to 10 100baseT Ethernet Honeywell switches 10 or 20 3 04 or 6 08m Fiber Optics Controller to remote rack distance up to 750m Cable 2460 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 Cross over cable is used for Controller Honeywell to PC connection straight through for Controller to e connection 20 6 08m 9 RS 485 cable Belden 9271 or equivalent up to 2000 601m Third party suppliers 10 RS 232 cable Null modem cable up to 50 15 24m PC modem Third party suppliers or cable if used with Modems Honeywell Revision 16 HC900 Hybrid Controller Installation and User Guide 12 10 09 Components and Architecture Redundant components Redundant components AMES AME MEER Figure 5 Redundant Configuration with multiple I O racks CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Sca
28. 16 HC900 Hybrid Controller Installation and User Guide 10 09 Rack Installation Assemble Controller Rack Step Procedure Comments References 2 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 Note 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 ATTENTION Do not connect PE Ground Green Wire directly to terminal on Power Supply sl 0 Brown Black Eure USA L2 N Blue Eure 14 AWG 2 1 mm Copper 75 C White USA Grou
29. 16 HC900 Hybrid Controller Installation and User Guide 163 10 09 Diagnostics and Troubleshooting Scanner indicators Scanner indicators SCANNER 1 PORT SCANNER 2 PORT Figure 85 LED Indicators on Scanners 1 port left 2 port right See Table 29 Table 29 LED Indications on Scanner Module Blinking Green Figure 80 LED LED State Color Description item 1 Scanner Status Off No power Solid Red Failed Blinking Red Diagnostic Code refer to Table 30 Scanner LED Diagnostics Solid Green Startup Mode Scan Mode 10Base T port 2 XMT upper LED 3 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 164 10 09 Diagnostics and Troubleshooting Scanner indicators Figure 80 LED LED State Color Description item NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by software 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 30 Scanner LED Diagnostics Number Possible Cause Sca
30. 2 that has a See the See Rack remote VO conditions on their warn pins off and their status LED indicating a diagnostic associated rack s Diagnostics exist output pins to the failsafe value and follow the scanner 2 diagnostic Rack Diagnostics dialog box e Communications 2 Associated blocks set their IO section to solve the problem Overview display between the CPU statuses to either Channel No for details anda Scanner 2is Comm if the module cannot be regarding the failing communicated to or a message diagnostic Scanner 2is indicating the bad channel unable to condition communicate toa 3 Associated rack monitor block s module or a wrong module fail pin is tumed on module is installed 4 Associated rack monitor block s e A module in the VO RACK OK pin is turned off rack is reporting a 5 ASYS and FSYS blocks HW OK diagnostic pins are turned off e C70R and Scanner 2 firmware versions are incompatible e Scanner 2 I O rack or power supply is defective e C70R module is defective e Abad channel has been detected on one of the modules 6 High temperature 1 Associated Al blocks that are condition in a Scanner configured as T Cs set their fail pin 2 rack has been on their warn pin off and their detected 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
31. 200 500 C JIS 200 500 C 78 JIS100 328 932 F JIS 328 932 F 79 JIS100 200 260 C JIS 0 100C 72 JIS100 328 500 F JIS 32 212F 73 Cu10 20 250 C Cu10 20 250 C 84 Cu10 4 482 F Cu10 4 482 F 85 YS1405 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 020 99 MV 0 10 mV 010 88 MV 0 50 mV 0 50 92 MV 0 100 mV 0100 95 MV 10 10 mV 10 10 89 Revision 16 HC900 Hybrid Controller Installation and User Guide 194 10 09 Specifications HC900 Analog Input Ranges vs UMC800 Analog Input ranges Type Range Range High EU Reference Corresponding Low UMC800 Input type and range MV 50 50 mV 50 50 93 MV 100 100 mV 100 100 96 MV 500 500 mV 500 500 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 195 10 09 Specifications System Sizing and Availability Summary System Sizing and Availability Summary Table 43 System Size and Availability Summary Specification C30 C50 C70 C70R Combi
32. 23 EEC as amended by 93 68 EEC on the harmonization of the laws of the Member States relating to the safety of equipment designed for use within certain voltage limits The models covered by this Declaration are listed in and evidence of conformity is provided by Technical Files 51452404 and 51452405 The following standards are referenced in the file EN 55011 1991 Limits and Methods of measurement of electromagnetic disturbances of ISM radio frequency equipment EN 61326 1998 Electrical equipment for measurement control and laboratory use EMC requirements EN 61010 1 1993 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements Manufacturer Honeywell Automation India Ltd 55 amp 56 Hadapsar Ind Estate PUNE 411 013 India A ed Honeywell International Inc EE mm 512 Virginia Drive Edward A Child Fort Washington PA 19034 Principle Engineer Regulatory Compliance amp Approvals Engineering Issue Date 25 July 20 08 HC900 51452401 E doc Revision 16 HC900 Hybrid Controller Installation and User Guide 236 10 09 Appendix Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail Honeywell HON 08 ATEX 0001X Revision A Manufacturer s ATEX Declaration of Conformity 3G ExnAlic CE This Declaration applies to the following apparatus HC900 Modular Control System Low Power Modules per attached list The apparatus
33. 240 Vac 8 chan T3C Ta 60 deg C T4 Ta 40 deg C Power Supply P02 T4 Digital Input Vdc 32 chan T5 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 C70R CPU T5 Digital Output 120 240 Vac chan T4 Redundancy Switch Module RSM T6 Digital Output Vdc 32 chan T6 Scanner 1 Port T6 Pulse Frequency Quadrature 4 chan T5 Environmental Conditions Ambient Reference Rated Extreme Transportation amp Storage Temperature F 77 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 0g amplitude 2 5 mm amplitude 2 5 mm peak to peak 14 Hz to 250 Hz acceleration 1 g peak to peak 14 Hz to 250 Hz acceleration 1 g Applies up to 40C Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 192 Specifications HC900 Analog Input Ranges vs UMC800 Analog Input ranges HC900 Analog Input Ranges vs UMC800 Analog Input ranges Users of UMC800 Controllers from Honeywell will find the analog range selections of the HC900 Controller differ slightly from those available in
34. 490 0 878 0 7526 1 78 0 464 0 478 0 594 0 560 26 0 0159 12 381 11 405 1 204 2 836 0 740 0 760 0 945 0 803 30 0 0100 5 984 3 551 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 in Figure 40 Figure 41 and Figure 42 oe oe npu For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 Tryp I amp 2 This same current source Igrp I amp 2 is also used for an RTD input at channel two terminals 4 and 5 RTD 3 Wire Input Figure 40 and Figure 44 show examples of RTD input wiring 2 wire and 3 wire RTDs Four wire RTD inputs are not available Figure 40 RTD Inputs Revision 16 HC900 Hybrid Controller Installation and User Guide 80 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 Ixrp 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 ar
35. 87 Terminal Board Connections for Al Calibration Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 175 Overview Analog Output Calibration 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 88 The specifications of the meter must be consistent with calibration requirements See page 90 for terminal connections for 8 and 16 channel AO AFTE Milliameter Pree Vannnnnnnnnnnnnnn OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 88 Terminal board Connections for AO Calibration Revision 16 HC900 Hybrid Controller Installation and User Guide 176 10 09 Removal and Replacement Procedures Overview Removal and Replacement Procedures Overview This section contains procedures for removing and replacing the active components of an HC900 Hybrid 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 inves
36. 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 connect 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 179 Removal and Replacement Procedures Safety Considerations PLAN AHEAD 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 All control action stops 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 Control to all I O expansion racks is lost If power is available to the expansion racks outputs go to configured Failsafe values C70R module e Does not impact the other C70R CPU module which will continue to control the process e Contains start up diagnostics after replacem
37. An HC900 Redundant Controller configuration with multiple I O racks is illustrated in Figure 5 This illustration includes key numbers that identify components that are described in Table 2 CAUTION Communications lockout is possible in high network 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 16 HC900 Hybrid Controller Installation and User Guide 10 10 09 Components and Architecture Components TT E Figure 4 Configuration with Multiple Controllers CAUTION The HC900 expansion T 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 T O link Switch Failure to comply will cause communication failures on the T O link causing I O modules to go in and out of their failsafe settings Revision 16 HC900 Hybrid Controller Installation and User Guide 11 10 09 Components and Architecture Components Table 1 Descriptions of Major Components Figure 4 Key No Component Description Source Name 1 Controller Includ
38. 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 NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by software Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 172 Analog Calibration Overview 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 RS 485 Port and or a PC on the RS 232 Port and or the Ethernet 10Base T Port using Hybrid Control 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 Operator Interface HC Designer or HC Utilities to select actions and enter custom calibration data values calibration into the I O module This section contains information and instructions for connecting calibration devices 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
39. Controller Installation and User Guide 213 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Input Action Set verify jumper positions as shown for the 16 point digital input module 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 73 for more details ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 226 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 9980988988 I Install jumper wires DC Supply Revision 16 HC900 Hybrid Controller Installation and User Guide 214 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point AC Digital Input Step Action 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired
40. Diagnostics If the reserve s Overview dialog status LED is box indicating the If the reserve s failure see status LED is MEMORY in the indicating the Reserve CPU failure see Diagnostics Memory display Diagnostics in the Reserve Diagnostics Overview dialog box Revision 16 HC900 Hybrid Controller Installation and User Guide 159 10 09 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 4 Battery voltage is low e ASYS and FSYS blocks Replace battery LOWBTRY pins are turned on e ASYS and FSYS blocks HW OK pins are turned 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 turned 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 HCUtilties 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 lo ASYS and FSYS
41. 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 C70R T O for redundant controllers is the same as I O Expansion Network page 25 with the following exceptions notes e In Figure 18 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 I O ports are 100 Base T instead of 10Base T 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 commu
42. Input Step Action Note You must set switches 1 8 for RTD Input 2 Input 3 Input 4 Figure 96 Three wire RTD input connections Input 5 Input 7 Note You must set switches 1 8 for Ohms A OO0000000000800000000 ote Install jumper wires 3 23 6 26 22 OGOGOPGEGPEG 13 33 16 36 17 37 20 40 Input 1 Input 2 Input 3 Input 4 Input 6 Input 8 Figure 97 Two wire RTD or ohm input connections Revision 16 HC900 Hybrid Controller Installation and User Guide 203 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Note You must set switches 1 8 for Ohms Input 2 Input 3 Input 4 Input 6 Input 8 Figure 98 Slidewire feedback connections for actuators Analog Input accuracy specification Range Al Module Accuracy RTP Cable Accuracy Al Module RTP TT 1000 1000 Plat RTD RTD 0 1 of 20 1 of Range e 0 04 0 04 Range 0 357 C 0 357 C 0 14 of 20 14 of Range JIS RTD 0 1 of Range 0 12 Range 0 824 C 0 22 of Range 10Q Cu RTD 0 1 of Range 0 57 Range 1 540 C 0 67 of Range 2000 OHMS 0 1 of Range 0 07 Range 0 1409 0 17 of Range 0 10mV LINEAR 0 1 of Range 0 04 Range 0 004mV 0 14 of Range Revision 16 HC900 Hybrid Controller Installation and User Guide 204 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input RTP
43. Internal schematic HC900 Terminal Block J1 TBI 1 6 r O O A SW 1 2 250 Ohm au 4 a SW 2 2 250 Ohm 5 10 le SW 3 2 250 Ohm 7 19 o 8 18 au 9 17 O o SW 4 2 250 Ohm 16 a a 11 15 O O SW 5 2 250 Ohm H r KE S a iC E Ea 14 12 O O GE A SW 6 2 250 Ohm i i AEE I 6 OW SW 7 2 250 Ohm 17 2 19 4 W 8 2 250 Oh ss SW 8 2 250 Ohm ONO O O E ONO O O O O O SW SW SW SW SW SW SW SW 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 O Revision 16 HC900 Hybrid Controller Installation and User Guide 205 10 09 Appendix Installation of Remote Termination Panels RTPs Relay Output 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 75 e Connect desired cable to relay output module at controller Choose from 900RTC HO10 Remote Terminal High Voltage Cable assembly 1 0 meters long 900RTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC 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 shie
44. LNG S IN 9a g OG ga gal 9 20 ga Q 8 NO 00S v IN amp 8 9as 09S amp 90 a S ZINI S S ZNI s OOS 6 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 RTP B connect the following terminals 1 22 2 23 5 24 6 25 13 26 14 27 17 28 18 29 Figure 100 Current connections with 2 wire transmitter Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 228 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Output Step Action 1 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect terminal block end of desired cable assembly to 32 point Digital Output module at controller Choose from 900RTC 3210 Remote Terminal Cable assembly 1 0 meters long 900RTC 3225 Remote Terminal Cable assembly 2 5 meters long e Install 32 point DC DO label into the module connector cover e Connect both shield drain wires to the grounding bars at the base
45. 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 SER _ 7 O NEZ Ww EG EI Obs MA We Na J 3 6 If installing 8 or 16 channel Analog Output module set its DIP switch as follows Switch is located at edge of module marked 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 76 10 09 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 7 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 SW1 y Tv ON orr INDEX SF Settings using Input 1 as example Single ended factory setting og N1 DIFF gm LIN Za N IN1 SINGLE Or Ni 1 and 2 SINGLES QNI 3 and 4 DIFF OFF Differential SINGLE ER Ni 1 and 2 SR an 3 and 4 DIFF ON Revision 16 HC900 Hybrid Controller Installat
46. O Module Installation and Wiring Terminal Block to Field Signal Wiring The shield for each input should be grounded at the grounding bar optiqnalkatikgcjop or botena rack as indicated in Figure 38 For low frequency noise rejection I O wdiaeR ifef g should Be 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 should be used between the shield and the grounding bar on the DC isolation rack High Frequency Capacitor Noise Rejection Shield wire Figure 37 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 38 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 gjvot up or down allowing ready access to the module and is the preferred method for a limited numbe D For a larger number of wires or for i y wires of a heavier gauge it is advisable ber to route some wires throu
47. 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 Hybrid Control 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 127 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Best Data 56SX Data Fax External 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 ter
48. Replace the expansion rack s scanner module 9 Ensure that the Scanner 2 and 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 6 The modules installed do not No action is taken Verify that the correct modules agree with those required by the are installed for the configuration configuration 6 The Scanner cannot communicate No action is taken For each module with a red to a module or the module is blinking LED follow the actions experiencing a diagnostic described in the I O Module condition Diagnostic Indication page 172 6 An Al module s CJ temperature No action is taken 1 Improve ventilation to rack reading is indicating a thermal 2 Replace Al module problem The scanner determines i this problem not the Al module therefore the module s status LED will not indicate this diagnostic Possible reasons for this diagnostic are 1 One of the two CJs on the module is indicating a temperature reading greater than 70 degrees C 2 Both cold junction sensors are failing to convert 3 The CJs are converting properly but their differential is greater than 10 degrees C Revision 16 HC900 Hybrid Controller Installation and User Guide 167 10 09 Diagnostics and Troubleshooting Scanner indicators Number Possible Cause Scanner Action User Action of Strobes 6
49. The scanner determined that a No action is taken Refer to the Bad I O Channel module has a bad channel In this condition the module s status LED will not indicate the failure because the Scanner determines the condition not the module itself Diagnostics on page 173 to determine the nature of the problem and possible user actions One of the power supplies failed No action is taken Replace the power supply Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 168 Diagnostics and Troubleshooting I O Module Indicators I O Module Indicators Figure 86 I O Module LED indicators Table 31 LED Indications on I O Module Blinking Green Figure 86 item LED LED State Color Description 1 Module Status Off No power Solid Red Hardware failure Blinking Red Diagnostic Code refer to Table 32 I O Module LED Diagnostics Blinking Yellow At least one output is Forced Solid green Cold start with passing diagnostics Normal scanning Channel LEDs one per input or output Green On Off For Inputs indicates On or Off status 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 16 10 09 HC900 Hybrid Controller Installation and User Guide 169 Diagnostics and Troubleshooting I O Module Indicators I O Module Diagnostic Indi
50. Via Software Command from Modbus TCP amp Serial Modbus RTU Hosts e Via Software Command from OI 1042 amp OI 559 Operator Interfaces 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 149 Revision 16 HC900 Hybrid Controller Installation and User Guide 154 10 09 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 hardware 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 operatin
51. 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 bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 71 Revision 16 HC900 Hybrid Controller Installation and User Guide 218 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point AC Digital Output Step Action 2 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP 3 Set verify jumper positions as shown EEE Jumper open z 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 73 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 226 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 219 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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
52. blocks HW OK CPU Diagnostics Diagnostics in pel it was powered pins are tumed off display i frr own Note If the reserve s battery fails If the reserve s Ber dialog when it is powered down The lead status LED is 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 Diagnostics indicating the display failure see Real Time Clock Diagnostics in the Reserve Diagnostics Overview dialog box 5 One of the following Same actions as described above 1 Use HCDesigner HCUtilities or Ol RTC conditions to program the real time clock occurred RTC e RTCwas 2 If problem persists replace the CPU previously module programmed but when it was last read its date and time were deemed invalid e An attempt was made to program the RTC but it was unsuccessful e The RTC is unable to be read Usually indicating a serious hardware failure Revision 16 HC900 Hybrid Controller Installation and User Guide 160 10 09 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 6 One of the following 1 Associated blocks set their fail pins Locate the Scanner
53. 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 operator interface Hybrid Control Designer 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 database 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
54. conditions for failover Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 152 Redundant Operating Characteristics Failover Lead Controller Reserve Controller SYNC SYNC Control SYNC Control SYNC Execute Control Strategy Execute Control Strategy Write Outputs Diagnostic Check Diagnostic Check Communications Figure 83 Lead Controller synchronization Failover Automatic Failover Triggered on any of the following conditions of the Lead Controller Loss of communications with I O Rack s Processor exception conditions 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 During the transition from the Lead to the Reserve analog and digital output status is maintained at the T O racks Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 153 Redundant Operating Characteristics File Download Upload Functions 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 key e Via Software Command from HC Designer amp HC Utilities PC Software e
55. fused in the module but adding a fuse here protects the wiring Revision 16 HC900 Hybrid Controller Installation and User Guide 220 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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 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 RTP Internal schematic Applies to 4 AO 16 DI 16 DO 8 DO RTP J2 J3 J4 J5 sw HC900 07 o Terminal Z y y i Block dJi C1 C1 C1 C1 SW SPST TB1 1 6 4 2 7 f u 3 8 4 9 pp ee 5 10 fd 6 20 a ey ee 4 m 10 1 47 1 T 1 ET 20 ac Ze CON40 Revision 16 HC900 Hybrid Controller Installation and User Guide 221 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output Action ATTENTION RTP and cables are intended for permanent installation within t
56. have gold contacts are for use with 8 point AO 16 point AO 16 point AI 32 point DI and 32 point DO modules e Terminal blocks may be keyed by the installer to prevent high voltage terminal blocks from being installed on low voltage modules See Table 15 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 16 HC900 Hybrid Controller Installation and User Guide 68 10 09 I O Module Installation and Wiring Remote Termination Panel RTP 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 203 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 th
57. modules There are three RTP types See page e 8 point Analog Input 204 e Relay Output 211 e 16 point Analog Input Digital Input Digital Output Analog Output 215 HC900 Controller Cable various om lengths available Shield drain wire RTP mounted on Terminals for field f DIN rail Figure 91 Example installation not shown 2 RTP amp cable for high capacity Al DI DO Revision 16 HC900 Hybrid Controller Installation and User Guide 199 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input 8 Point Analog Input 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 91 e Remove appropriate key tabs from terminal block to allow mating with the module See page 75 e Connect desired cable to Al module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 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 71 Mount RTP to DIN rail e Latch to rail See page 241
58. of static electricity is minimized or eliminated See Environmental Conditions and Approvals on page 195 Revision 16 HC900 Hybrid Controller Installation and User Guide 42 10 09 Pre Installation Planning Heat Rise De rating 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 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 refer to Table 5 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 5 Power Applied by Module Type Module HC900 Hardware Field Power Total Power Power Watts Watts Watts Controller C30 4 2 0 0 4 2 Controller C50 4 7 0 0 4 7 Controller C70 5 9 0 0 5 9 Controller C70R 7 7 0 0 7 7 Redundancy switch module RSM 0 1 0 0 0 1 Power Status Module PSM 0 1 0 0 0 1 Scanner 1 Port 3 4 0 0 3 4 Scanner 2 Port 3 9 0 0 3 9 Analog Input Universal 0 8 0 0 0 8 Analog Input High level 1 6 0 0 1 6 Analog Out
59. of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 71 2 Mount RTPs to DIN rail e Latch to rail See page 241 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 3 Set verify jumper positions on each RTP as shown BE 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 73 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 See page 238 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 229 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Output Connect field wiring RTP A for outputs 1 to 16 x Q amp E 3 nr Se 3 Q 2 Q Q 929968 DC Supply ol 10 6 6 Ja lt lt lt f lt ol JOP JO JOP 10 2 12 Ley 12 ol ya Ja SI 13 15 I 23 2 RTP B for outputs gt Install jumper wire yy Ie amp DC Supply refers to
60. private Ethernet linked sub 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 rack Redundancy e Redundant C70R 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 Two serial ports each configurable as RS 232 or RS 485 e RS 232 port used for link to PC configuration tool up to 50 feet or 12 7 meters or modem Port configurable as Modbus RTU TCP master or slave e RS 485 port used for 2 wire link to the Operator Interface up to 2000 feet or 601meters Port configurable as Modbus RTU master or slave e Ethernet 10 100Base T connection to up to 5 PC hosts via Modbus TCP protocol Peer to Peer communication with other HC900 Controllers and the Internet C70 has 2 Ethernet ports for connection to up to 10 PC hosts It also supports Modbus TCP Initiator function over both ports e Private Ethernet 100Base T connection to I O expansion racks except C30 CPU Redundancy e Supervisory Network Ethernet 10 100 baseT to PC Applications HC Designer amp HC Utilities communicates to peer HC900 Controllers over Ethernet C70R has two Ethernet ports Le
61. pva dabbet dd aged gobi E tobi Mest sheaves 13 Hardware Components 7 f c2 ni ee a ede Ab ae cede Seite te tds S TA 15 Ethernet Devices Considerations cceccceecceeeceeeeeeeeeeeeeneeseeeeseneesenaeseeeeseeaeseaaeseaaeseeaeseaeeeeaaeseaeeeaaeeeaeeesaes 24 VO NENO e ian Sie dee Pe LNG ETNE Need east 25 Ethernet Open Connectivity N twOrk ecceeccesecceeeeeeseeeeeeeeeseneesneeeeeeeeeeceeeseaeeseeeeseaeesnaeeseaeesnaeenaeeeaes 26 Serial Ports RS 232 and RS 485 mnnrnnnnvnnnvnnnnvnnnnvnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnrnnnnnnnnnrnnnurnnnnnnnavannnrnnnurnnnrnennen 34 Pre I1nsalai r Pla Nrg a rss aS 39 OVENEN aa NT 39 AC Power Supply Selection for racks with O nrnranrnnnnvnnonvnnonvnnnnvnnnnrnnnnrnnenrnnnnrnnnnrnnnrrnsnrvnnnennenrrnnnrnsnnvennn 40 DG Power Supplyauisusnititgie det etisk nd ret added ene eten 41 Rack Orientation and Mounting ecese a E AE a E EE AR E 41 Remote Termination Panels aerer o roe Aa AA AAA EA E OAE AE R TA 43 Environment anssedsitesusdetr hegne needs phil denned enieudee die eee hae 43 Heat Rise De tating isn asset 44 Cable Wiring Distance Planning ersero urnen Na ERa EET AAN AAR AARE ANEA AE AA E 45 Electrical Considerations ci iie nie elie rele R A E E A AA neared 47 System Montor Function Boek Seat E E A E A EE ARS 54 Reksta 55 OVevlew 4400 Teater aent eee 55 VOIH m a a STE EEEE EA ONE E Ants ne 58 Assemble Controller Rack rrnrnnnnrnnnnvnnnnvnnnnrnnnnrnnnnvnnnnrnnnnvnnnnrnnnnvnnnnr
62. 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 and 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 2 Power up the modem 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 16 10 09 HC900 Hybrid Controller Installation and User Guide 124 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem configuration examples Below are procedures for setting up the following commercially available modems e 3Com US Robotics 56K Data Fax External Modem e Zo
63. sits between the CPUs Redundant CPU Power Two power supplies for the CPUs 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 V O 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 Redundant Networks for Host communications Redundant Networks for Host communications are provided on the C70R CPU Both network ports are continuously active on the Lead controller The network ports on the Reserve CPU are not available for external communications An OPC server is available from Honeywell to support redundant Ethernet communications and automatically transfer communications during a network failure Scanner 2 module has 2 ports one for each CPU connection to I O Figure 3 Single process with redundancies Revision 16 HC900 Hybrid Controller Installation and User Guide 8 10 09 Introduction Feature Summary Feature Summary Hardware e Modular rack structure components are ordered individually as needed e CPU with Ethernet communications e Easy to assemble modify and expand e Local C30 and Remote input output racks C50 C70
64. 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 For downloading procedures refer to the Operator Interface User Manual 51 52 25 108 Configuration Upload Controller configuration files setpoint profiles and recipe files can be uploaded for storage and archiving in a PC and or to a disk in the Operator Interface Using the PC the Upload function is accessed from the Hybrid Control Designer For details of uploading configuration items refer to Hybrid Control Designer and Operator Interface 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 149 Redundant Operating Characteristics Overview 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 p
65. 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 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 Deviations from the installation conditions specified in this manual may invalidate this product s conformity with Low Voltage and EMC WARNING A 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 serious 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 46 Revision 16 10 09 Pre Installation Planning Electrical Considerations Shields Grounding Bar Sasan ere pg FIA AWG 2 1 mm a ma L1 H L1 H L2 N PE Power Source Figure 31 Cabinet Wiring Single Chassis HC900 Hybrid Controller Installati
66. the switched negative side of the DC supply Note SDC are connected through the RTP cable Same for terminals 10 and 12 DC DC Note Terminals 9 and 11 230 HC900 Hybrid Controller Installation and User Guide Revision 16 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Input Step Action 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect terminal block end of desired cable assembly to 32 point Digital Input module at controller Choose from 900RTC 3210 Remote Terminal Cable assembly 1 0 meters long 900RTC 3225 Remote Terminal Cable assembly 2 5 meters long e Install 32 point DC DI label into the module connector cover e 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 71 2 Mount RTPs to DIN rail e Latch to rail See page 241 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 Set verify jumper positions on each RTP as s
67. 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 23 The functions of the Mode Switch are described in Table 24 and the procedures that the co
68. 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 21 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 31 10 09 Components and Architecture Ethernet Open Connectivity Network HC900 Controller LAN Controller monn Controller sti Legend Ethernet Fiber a ee n ft Router Cable Modem fF Figure 21 Typical installation using a Cable Modem Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 32 Components and Architecture Serial Ports RS 232 and RS 485 Serial Ports RS 232 and RS 485 Overview 291 RS 232 default RS 485 terminals Shield a RS 232 terminals 1 and S2 can be set to RS 232 or RS 485 Figure 22 Controller Serial Ports e 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 35 For RS 232 cable connect
69. 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 communication 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 Hybrid Control Designer 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 Hybrid 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 Figur
70. 0001 900B01 0101 900B08 0001 900B16 0001 900G01 0102 900G02 0102 900G32 0001 900G03 0102 900H01 0102 900H02 0102 Digital Output 24VDC 32 channel Digital Output 120 240 VAC 8 channel Pulse Frequency Quadrature 900H32 0001 900H03 0102 900K01 0001 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide Introduction Model Selection Guide Description I O Components Low VoltageTerminal Block Euro style Low VoltageTerminal Block Barrier Style High VoltageTerminal Block Euro style High Voltage Terminal Block Barrier Style High Density Terminal Block Analog Input Remote Terminal Panel RTP I O Components Relay Output Remote Terminal Panel RTP DI DO AO Remote Terminal Panel RTP Low Voltage RTP Cable 1 0M 3 28ft Low Voltage RTP Cable 2 5M 8 2ft Low Voltage RTP Cable 5 0M 16 4ft High Voltage RTP Cable 1 0M 3 28ft High Voltage RTP Cable 2 5M 8 2ft High Voltage RTP Cable 5 0M 16 4ft Model number 900TEK 0001 900TBK 0001 900TER 0001 900TBR 0001 900TCK 0001 900RTA L001 900RTR H001 900RTS 0001 900RTC L010 900RTC L025 900RTC L050 900RTC H010 900RTC H025 900RTC H050 High Density RTP Cable 1 0M 3 28ft 900RTC 3210 High Density RTP Cable 2 5M 8 2ft Filler Block Terminal Cover Shield Terminal Strip package of 2 Terminal board jumpers 10 two pos jumpers Termina
71. 0XX XX 10420Z 00XX XX 900CS10 xx and 900CS15 xx TMPCONS5 51404493 501 51404524 501 51500452 501 51404551 501 51451315 501 51404533 502 51404528 501 559 T12 T4 Inverter Board 51404597 501 559 T12 T4 Ol to Controller Connector 559 T12 T4 Cable Kit 559 T12 T4 Replacement Display Lamp 1042 Zip Drive Replacement Upgrade Kit 1042 Ol Knurled Fastner Kit 1042 Ol Maintenance Parts Kit 51404600 501 51404797 501 51404610 501 51451948 501 51452136 501 51451582 501 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 XXY Y 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 900C071R 0000 40 Scanner 2 900C73R 0000 40 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 1042 Operator Interface 10420F 0040 40 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Introduction Model Selection Guide Example of a compatible non redundant system Component Mod
72. 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 RTP A J2 J3 J4 J5 Swi WP Tr Tr m Terminal y v y v Block JH C1 C1 C1 C1 SW SPST TB1 1m 6 j 2 7 D eae 3 8 E OS 7 E SE la 7 19 8 18 T 18 17 a 17 16 Cr eg rn Fe T T rH 9O T B e E Ea 1 E al SS A 7 i A i i 4 16 H 5 oY ct lt a 9 13 10 12 Sry ee A A A A S a 11 11 T 22 y me saij Il 13 2 12 1 3 18 15 17 t14 Ea CON40 cont d Revision 16 HC900 Hybrid Controller Installation and User Guide 233 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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 HC900 Terminal CON
73. 16 Analog Output 1 configurable value step Step Execution On Time Event 1 Event2 or via Advance Next Step Any step Sequences Number of 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 189 Specifications General Specifications Communications C30 C50 C70 C70R Network Communications Ports Number of Ethernet 1 1 2 2 10 100Base T connections Ethernet 10 100Base T RJ 45 connection 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 Hybrid Control Designer configuration software Supports redundant Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Init
74. 16 10 09 HC900 Hybrid Controller Installation and User Guide 120 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software RS 232 Remote Connection to PC Configuration Tool 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 72 and shown in Table 20 A second Null Modem cable is used between the PC and the internal or external modem at the other end as shown in Figure 72 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 Hybrid Control Designer 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 Telephon Modem Cable Pod _ Telephone Cable Figure 72 RS 232 Remote Access via Modems Revision 16 HC900 Hybrid Controller Installation and User Guide 121 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software B Modem Connection Modem RS 232 Configuration port ar Internal Modem assigned to a COM port Attention Always observe the wiring cabling guidelines on page 4
75. 3 Wire Pen tae Input asset ING H hammmmmmm innemen IN7 PE leo 7 amp 8 i dn l RTD 2 Wire i Input i Jumper IN 1 D i T 4 len 1 amp 2 Pe 2 mas IN 3 r rir IN 4 a n 8 av Ln5 amp 6 S ie vs n Nr L 7 amp 8 me amp eink S a P g Figure 42 Examples of RTD Input Wiring Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 82 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Thermocouple Inputs Shield Ground F typical Figure 43 Analog Input Wiring Eight TCs Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 83 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Thermistor Inputs IN8 Shield Ground typical Figure 44 Analog Input Wiring Eight Resistance Inputs Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 84 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Temperature Device Inputs ODOOADOGIE Shield Ground typical Figure 45 Analog Input Wiring Eight RTDs Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 85 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Slidewires s g mi O Q
76. 30 820 mA 0 mA 0 Controller C50 930 mA 0 mA 0 Controller C70 1150mA OmA I 0 Controller C70R 1500 mA OmA 1 0 Scanner 1 Port 670 mA 0 mA 0 Scanner 2 Port 770 mA 0 mA 0 Power Status Module PSM 22 mA 0 mA 0 Analog Input 8 pts 40 mA 25 mA Analog Input 16 pts 75 mA 50 mA Analog Output 4 pts 40 mA 200 mA Analog Output 8 pts 225 mA 350 mA Analog Output 16 pts 350 mA 700 mA AC Digital Input 16 pts 130 mA 0 mA 0 DC Digital Input 16 pts 130 mA 0 mA 0 Contact Input 16 pts 130 mA 40 mA DC Digital Input 32 pts 215 mA 0 mA 0 AC Digital Output 8 pts 220 mA 0 mA 0 DC Digital Output 16 pts 340 mA 0 mA 0 DC Digital Output 32 pts 235 mA 0 mA 0 Relay Output 8 pts 110 mA 100 mA 1 Pulse Frequency Quadrature 110 mA 250 mA Limit 10 Analog Output modules per I O rack Total mA 5V Total mA 24V Limit 4 PFQ modules per I O rack 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 Sum results of 4 and 5 5 Divi
77. 31 C30 C50 controller rack assembly 59 F C70R controller rack assembly 62 Cabinet Wiring 46 47 Field Signal Wiring 69 Cable length 44 Filler Block 79 cable segment 25 Flash 140 Cable Type 114 Form A relays 105 Cables Form C relays 105 how to make shielded CATSE 45 Fuses 102 captured screws 67 Fusing 105 CE Conformity 50 Cold Start 140 G COM 1 23 Communications Installation 113 ground voltage potential 70 Contact Input Module Wiring 96 grounding bar 70 Controller access grounding bars 58 how to access via serial port when port settings are Grounding lug 18 unknown 146 Controller Modes 143 Controller Module 20 H Controller Module Diagnostics 158 HC900 Hybrid Controller 6 Controller Name 28 Heat Rise De rating 43 Controller Rack 15 HMI 29 custom graphics 30 Hub 26 Hybrid Control Designer 23 Revision 16 HC900 Hybrid Controller Installation and User Guide 239 10 09 INDEX T O channel numbers 68 1 O Expansion Network C50 CPU only 25 I O Expansion Network C70R 26 I O expansion port 21 22 T O Expansion Rack 16 T O expansion rack assembly 64 T O implementation 26 T O Installation Procedures 73 I O Module Diagnostics 170 I O Module Installation 1 50 56 67 T O numbering assignments 26 T O rack address 65 I O slot 67 I O Wiring 80 T O wiring shields 70 Input Output Modules 22 Installation Tools 54 Intellution 30 IP address 28 El 115 E2 115 Irto 81 isolation capac
78. 3ms for up to 500 fast fast logic blocks fast logic blocks fast logic blocks logic blocks 67ms for up to 315 53ms for up to 500 53ms for up to 660 67ms for up to 780 fast logic blocks 67ms for up to 1040 fast logic blocks 107ms for up to 1380 fast logic blocks 133ms for up to 1700 fast logic blocks 267ms for up to 3300 fast logic blocks fast logic blocks 107ms for up to 1040 fast logic blocks 133ms for up to 1300 fast logic blocks 267ms for up to 2500 fast logic blocks fast logic blocks 107ms for up to 400 fast logic blocks fast logic blocks 67ms for up to 780 fast logic blocks 107ms for up to 1040 fast logic blocks 133ms for up to 1300 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 188 Specifications General Specifications C30 C50 C70 C70R 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 Features C30 C50 C70 C70R Maximum user 400 2000 5000 configurable Function Blocks Maximum Control Loo
79. 40 Revision 16 HC900 Hybrid Controller Installation and User Guide 234 10 09 Appendix Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail Latch Unlatch RTP to rail Step Action 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 Insert other side of DIN rail at B and push B over the rail to snap into place 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 235 10 09 Appendix Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail Honeywell 51452401 Revision E DECLARATION OF CONFORMITY C We declare that the following product HC900 Hybrid Controller Models 900A01 900A16 900B01 900B08 900B16 900G01 900G02 900G03 900G32 900H01 900H02 900H03 900H32 900K01 900RSM 900PSM 900C31 900032 900C51 900C52 900C53 900C71 900C72 900C71R 900C72R 900C73R 900P01 900P02 900P24 900RTA 900RTR 900RTC 900R04 900R08 900R12 900RRO 900RO8R 900R12R 900RPE is in conformity with the protection requirements of Council Directives 89 336 EEC as amended by 92 31 EEC and 93 68 EEC on the harmonization of the laws of the Member States relating to Electromagnetic Compatibility and 73
80. 44 Fiber Optics Equipment Recommendations rrvvrvvnverenrvvevrnnvrnervrrnveverrrneevsrnsrneevsrnseneevrrnseneevssvesvessssner 200 Revision 16 HC900 Hybrid Controller Installation and User Guide viii 10 09 Figures Figure 1 Small HC900 Controller Configuration srnvrvranrnvrvrrvnevrnvrrnvereverrneevernrrneevarvervesvasvennaveasvesnevsesvevrasesvene 6 Figure 2 Expanded HC900 Controller Configuration C50 C70 CPU only evenrrnvrvenrrnvnveverenevvrrnernevnrrverravservene 7 Figure 3 Single process with redundancies rsvrvervrrnvrvervrrnenvrrvrrnrevsrnsrverrrnsrneevarnerveveasververeasvesvesessvevsasvernevssssevsenn 8 Figure 4 Configuration with Multiple Controllers osoorvavrrnvrvenvrrnrnvrnerrnevvrrnervevnarnervernavnesnevsesvevnevsevsevsrneeneevssner 11 Figure 5 Redundant Configuration with multiple I O racks eenenvornrrvrrnovrnvnrrvevravnrrvennevsnrnevsrereveevererersevsrereneevssnee 13 Figure 6 Controller Rack Components rrnnonnnnernervrrnvrvevvrrnerververnernernarvesneveasvevnevsesvevsavsenvevsssrensevssnsensevssneenasvrsner 15 Figure 7 Redundant Controller Rack Components snrnvavrrvrrnvavennvrnrvvrrnvrnevvarnenvervarvenveveasvesvavsesvesnavsesvevssneeneevssner 15 Figure 8 I O Expansion Rack Components evrnvrvrrnorvrrvrrvenvernrrnevrarvervevsenvevsrereneevsrnsrnevasnennevsesvevsserevsevssnsenesvrsner 16 Feire 9 Rack Options s sec cecctscecsetetanes satires apen idet e
81. 5 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 PG 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 Hybrid Control Designer 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 Select the number to call Ea Phone Number 215 822 3001 Add to List Name Remove from List Cancel HC300 Furnace 1 Comments Plant3Locaton FrcnmN Phone Number List HC900 Furnace 2 9 610 726 4530 Plant 3 Location HC900 Furnace 1 215 822 3001 Plant 3 Location 4 On t
82. 6 HC900 Hybrid Controller Installation and User Guide 17 10 09 Components and Architecture Hardware Components Power Supply The PO1 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 processor rack power P24 power supply provides SVDC and 24VDC to satisfy the power requirements of a single controller with I O a Remote I O rack or a Redundant C70R CPU The 60 watt capacity requires minimal de rating of the available HC900 I O modules A tool secured door covers the voltage connections An internal non replaceable fuse limits supply current under certain fault conditions WARNING SHOCK HAZARD MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT 24V 5V GND Each power supply includes an internal 5 0 amp fuse that is not field replaceable An external fuse may be added by the user See page 61 Items shown with key numbers 1 Voltage test points PO1model only 2 AC Input terminal block 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
83. AO Calibration sorrrnerrnvrrnrnvernvrnervrrnervarnervevrarsevravseneevsrvseneressner 178 Figure 89 Extended Distance Example 1 renrrnvrnrnnrrnvrrrrvrrvrnverenevnnvrrnvevererrnvevererrveevsrnsrneevsrvsevervrsvesnervasvesnesessner 200 Figure 90 Extended Distance Example 42 esnrnvrnrnnrrnnrvrrvnrnveverenernevsrnvevarerrneevsrerrneevsrvsrneevsrnsenervrsvennarvasvesnesvssner 201 Figure 91 Example installation not shown 2 RTP amp cable for high capacity AI DI DO esovenvvrrvevrvsvrseense 204 Figure 92 Analog input terminals seeooonorrrorrrvrovervnevrvvrrnenvsrnrrnernrrnennervervesrarsesvevsenvevravssneevssnsenesvasnsenesvasvesnesessner 206 Figure 93 Two wire transmitter connections with common 24 VDC supply srrvernrevrrnornrrnrnnnrnrrnrvnevvarver versene 206 Figure 94 Milliamp input connections with 250 ohm shunt resistance cece sseese ee cseeeeeseceeeesesseeeeeseeseees 207 Figure 95 Volt millivolt input connections esrarnrrravrrnverrrvernrevernernernarnevrarsennevreneevsrnsrneevssvernavessvennarvasvesnesessnee 207 Figure 96 Three wire RTD input connections esrrvrrnvrvernvrvrevernvrvrevern erverv srneevarnerneevavereneevssvennesvasvesnesvasvesnesessner 208 Figure 97 Two wire RTD or ohm input connections snrnvrvarvernonvrvnrrvennarnnrvevravnenvevravsenvevererenrevsensevasvrsvesnasnssner 208 Figure 98 Slidewire feedback connections for actuators sernernarnrrnrvnrvnn
84. AV VIN fy N 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 lV 1 Remove reinsert module values 2 Replace module 8 HARDWARE General Hardware Failure y Replace module Al convertor notworking 9 HW SW Key The software residing on the y V v IN y Replace module module does not match the module type This diagnostic should only resultin the factory 11 Shift Register The loopback test of the shift y NNN Vv v Replace module register failed Revision 16 HC900 Hybrid Controller Installation and User Guide 170 10 09 Diagnostics and Troubleshooting I O Module Indicators 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 33 is a list of conditions that can cause a bad channel diagnostic Table 33 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 Check terminal block is failing burnout checks connections Replace sour
85. AX 52 55 5570 2985 Puerto Rico Honeywell Inc Phone 809 792 7075 FAX 809 792 0053 Trinidad Honeywell Inc Phone 868 624 3964 FAX 868 624 3969 Venezuela Honeywell CA Phone 58 2 238 0211 FAX 58 2 238 3391 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 243 Honeywell Honeywell Process Solutions Honeywell 51 52 25 107 Rev 16 512 Virginia Drive October 2009 Fort Washington PA 19034 2009 Honeywell International Inc http hpsweb honeywell com
86. CAUTION Incorrect execution sequences can contribute to delays in processing outputs and or improper or unexpected operation 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 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 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 Lead Controller automatically synchronizes the Reserve with run time data during each function block execution cycle 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 Figure 83 The Lead and Reserve controllers exchange system status to determine
87. China PRC Xi an Honeywell China Ltd Xi an Phone 86 29 8833 7490 Fax 86 29 8833 7489 China PRC Shenzhen Honeywell China Inc Phone 86 755 2518 1226 Fax 86 755 2518 1221 Indonesia PT Honeywell Indonesia Phone 62 21 535 8833 FAX 62 21 5367 1008 India Automation India Ltd Honeywell Ltd Phone 91 6603 9400 Fax 91 6603 9600 Japan Honeywell Inc Phone 81 3 6730 7197 Fax 81 3 6730 7228 Malaysia Honeywell Engineering Sdn Bhd Phone 603 7958 4788 Fax 603 7958 8922 New Zealand Honeywell Limited Phone 64 9 623 5050 Fax 64 9 623 5060 Toll Free 0800 202 088 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 Thailand Honeywell Systems Thailand Ltd Phone 662 693 3099 FAX 662 693 3089 Taiwan R O C Honeywell Taiwan Ltd Phone 886 2 2245 1000 FAX 886 2 2245 3243 SE Asia Countries see Honeywell Pte Ltd Singapore for Philippines Pakistan Cambodia Guam Laos Myanmar Vietnam East Timor SE Asia Countries see Honeywell Automation India Ltd for Bangladesh Nepal Sri Lanka EUROPE Austria Honeywell Austria GmbH Phone 43 316 400123 FAX 43 316 40017 Belgium Honeywell SA NV Phone 32 0 2728 24 07 FAX 32 0 2728 22 45 Bulgaria Honeywell EOOD Phone 359 2 40 20 900
88. Controller s I O 100Base T CAT5 cable with RJ 45 port to Scanner 1 s I O port connectors I O Single I O rack Shielded Ethernet C70R CPU A s I O port to 100Base T CAT5 cable with RJ 45 Scanner 2 s I O A port connectors C70R CPU B s I O port to Scanner 2 s I O B port Revision 16 HC900 Hybrid Controller Installation and User Guide 115 10 09 Communications Installation Wiring and cabling Controller Link Type Cable Type To Device Port Port Controller to Connector Type I O 2 or more I O Shielded Ethernet C70R CPU A s I O port to 100Base T racks CAT5 cable with RJ 45 approved switch From this connectors switch to each Scanner 2 s I O A port One 1 additional switch may be used for a total of 2 switches between CPU A and the I O racks C70R CPU B s I O port to approved switch From this switch to each Scanner 2 s I O B port One 1 additional switch may be used for a total of 2 switches between CPU B and the I O racks Revision 16 HC900 Hybrid Controller Installation and User Guide 116 10 09 Communications Installation Connecting the Operator Interface to the Controller Connecting the Operator Interface to the Controller Using parts in Table 19 connect the Operator Interface to the RS 485 port on the controller See page 34 for port location Typically the cable that interconnects this port to the Operator Interface must be made during installation because it will probably be
89. DC digital output modules sinking type d 32 point digital output DC voltage sourcing type 8 point relay output module four form C type and four form A type relays 8 point Universal Analog Input module 4 channel Pulse Frequency Quadrature I O module 00000000 00000000 Figure 16 I O Module Terminal Blocks 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 22 Components and Architecture Hardware Components Personal Computer A Personal Computer is required for creating the control and data acquisition strategy configuration file that runs in the controller using the Hybrid Control 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 A PC can be connected to the controller via the RS 232 Port on the Controller module and can also be networked to the controller via the Ethernet 10 100Base T Open Connectivity Network p
90. Fax 380 44 201 44 75 United Kingdom Honeywell Control Systems Ltd Phone 44 0 1344 655251 FAX 44 0 1344 655554 MIDDLE EAST Abu Dhabi U AE Middle East Headquarters Honeywell Middle East Ltd Phone 971 2 4041246 FAX 971 2 4432536 Sultanate of Oman Honeywell amp Co Oman LLC Phone 968 24 701153 Ext 33 FAX 968 24 787351 Saudia Arabia Honeywell Turki Arabia Ltd Jubail Office Phone 966 3 341 0140 Fax 966 3 341 0216 Honeywell ATCO Dammam Office Phone 0096638304584 Fax 0096638338059 Kuwait Honeywell Kuwait KSC Phone 965 242 1327 to 30 Fax 965 242 8315 And Phone 965 326 2934 1821 Fax 965 326 1714 AFRICA Mediterranean amp African Distributors Honeywell SpA Phone 39 02 250 10 604 FAX 39 02 250 10 659 South Africa Republic of and sub saharan Honeywell Southern Africa Honeywell S A Pty Ltd Phone 27 11 6958000 FAX 27 118051504 NORTH AMERICA Canada Honeywell LTD Phone 1 800 737 3360 FAX 1 800 565 4130 USA Honeywell Process Solutions Phone 1 800 343 0228 FAX 1 717 771 8251 Email sc cp appssales honeywell com LATIN AMERICA Argentina Honeywell S A I C Phone 54 11 4383 3637 FAX 54 11 4325 6470 Brazil Honeywell do Brasil amp Cia Phone 55 11 7266 1900 FAX 55 11 7266 1905 Chile Honeywell Chile S A Phone 56 2 233 0688 FAX 56 2 231 6679 Mexico Honeywell S A de C V Phone 52 55 5259 1966 F
91. For the Networking Example shown connect one end of the Ethernet 10Base T cable to the PC s network port Connect the other end of the Ethernet 10Base T cable to the Ethernet switch Connect an Ethernet 10Base T cable to each HC900 controller s Open Ethernet RJ 45 port top RJ 45 port Connect the other end of each Ethernet 10Base T cable to the Ethernet switch 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 downloading edits to a configuration while in RUN mode Otherwise you may inadvertently download a configuration to the wrong controller Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 135 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Setting Up the Controller Network Parameters See the Hybrid Control Designer 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 ma
92. H Out 4 NO Out 5 H Out 5 NO Out 6 H Out 6 NO OQut 7 H Out 7 NO Oul 8 H Out 8 NO Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 103 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Output 6 ne annnnnnn cannes PT TT annan punmuunt nnnnnnng RENENEEEEENENEN HEKKEKEKNERNE KEEKNEKEKENEEEENENEEEN KEKKNNEKEENENENEEEENEENEEEEEEEEEEEEEEE EnEn as sa g aunnsg sem emmee eed om Oo med 6 7 O mon AL lt 68 16 ON Figure 61 AC Output Module Jumper Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 104 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 62 Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure Fuses appropriate for load and for wire used Ni are provided by user a o Fuses appropriate for load and for wire used are provided by user Figure 62 Schematic Example Relay Output and External Wiring Contact Ratin
93. HC900 controllers C70 C70R Run Pgm 0S1 only 8 First Ethernet Host Connection to PC applications or peer HC900 controllers 9 LED status diagnostic indicator for serial port S2 p left 10 LED status diagnostic indicator for serial port S1 nar right 11 LED status diagnostic indicator for controller Sa module Redundant controller rack contains two C7ORs see page 15 Left CPU is designated CPU A right CPU 7 is CPU B either CPU can be Lead Figure 12 Controller Module D oe na 7 Run Pgm s i gt Pgi Run 4 to PC external Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 20 Components and Architecture Hardware Components Redundancy Switch Module C70R only The Redundancy Switch Module RSM is shown in Figure 13 It sits between C70R controllers on rack Left Controller is designated RSM CPU A right Controller is CPU B Features include CPU A CPU B Lead 1 Lead Reserve controller status indicators lt gt Reserve 2 Keyed switch for manual changes to controller modes or to facilitate a Manual Fail Over Figure 13 Redundancy Switch Module Scanner 1 Module C50 C70 only The Scanner 1 Module is shown in Figure 14 It sits in the I O rack and provides the O between the controller and remote I O Features at the front of the module include SCANNER Q 1 PORT En 1 LED status indicator for scanner functi
94. Honeywell HC900 Hybrid Controller Installation and User Guide Doc No 51 52 25 107 Revision 16 Date October 2009 Honeywell Process Solutions About This Document Warranty Remedy Notices and Trademarks Copyright 2009 by Honeywell Revision 16 October 2009 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 512 Virginia Drive Fort Washington PA 19034 Honeywell is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners Revision 16 HC900 Hybrid Controller Installation and User Guide ii 10 09 About This Document
95. Input Digital Input Digital Output Analog Output 16 Point Analog Output Connect field wiring LOADS ARE 0 to 750 ohm RTP A for Outputs 1 to 8 9 and 10 RTP B for Outputs 11 to 16 9 and 10 009A Install 24V wires as shown 22 to 10 22 to 12 24VRTN to 9 External 24VDC supply 24VRTN to 11 16 Point Analog Input 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect terminal block end of desired cable assembly to 16 point Analog Input module at controller Choose from 900RTC 3210 Remote Terminal Cable assembly 1 0 meters long 900RTC 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 the shield grounding section page 71 Revision 16 HC900 Hybrid Controller Installation and User Guide 226 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input Step Action 2 Mount RTPs to DIN rail
96. Module Wiring Diagram esoevornorvorvrrnervrvvrrnervernrrnernernrsnervernrrnervevsrsvesvavsesvennevsesvevssvsenasvrsner 95 Figure 55 AC Input Module Jumper isseneviranieienrrsposnsrebenetkanerbeababdresktnrnekveserinbk save spabuhenton EE saben sesbenpesoberneests 96 Figure 56 Contact Input Wiring Diagram ssorvornornrrnorvevvrrnernervrrnervernarvesversasnesvevsrsveveaveasvesnevsesvevnevsevsevssnsenesvrsner 98 Figure 57 DC Output Module Wiring Diagram esvoevornovvrvrrenernevrnvnerveverevevvevsresevsevsrveevsevsrneevasvrsvenvasvrsvesnesessner 100 Fr ur 58 DE Output Jumpers eos tend iv heralds Rae AU EN Rae ees 101 Figure 59 32 point DC Output Module Wiring seenrrvrvrrnvnvrvvrrnvrvernvrnevnrrnesnervevvevrarvevravsrnvevssvsenesvasvennesvasvesvesessner 102 Figure 60 AC Output Module Wiring Diagram ssorvoovorvorvorvrrerevrevsrnervarvrrneevsrereneevsrvsrneevsrvsevervrsvernervrsvesvesessner 104 Figure 61 AC Output Module Jumper visere eeii reris aer E E E E EE EEEE KA EEE ATAA E 105 Figure 62 Schematic Example Relay Output and External Wiring serrovrrnorvrnvrrnvevrrvrrnreverereervrrnervernsrververser 106 Figure 63 Relay Output Module Wiring Diagram eerrrvorvrvrrnvevererenrevernenvervrrnenvarserversarverravserverrevseneevsrvesvesessner 107 Figure 64 Relay Output Module JUMpeT S ni en n i ai e atiis 108 Figure 65 Pulse Counting Wiring errovrrvnovrnvrrnvevrnvrrnvevereveveeveren
97. Out 6 No Eg a m CO nedre Qu No rane kp a f Out Ne D Out 7 No weemememmsmne Fo 3 Out 8 No Out No S Out 8 Com Outs Com 8 Outs Ne Out Ne S FormaC External Kagee N Te User Eapplied Safety Devices Figure 63 Relay Output Module Wiring Diagram Revision 16 HC900 Hybrid Controller Installation and User Guide 106 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Relay Output Module y One half 10 position jumper To Relay Loads via wine external disconnect switches fuses QAAAIOODE BEPHEBEE Figure 64 Relay Output Module Jumpers Pulse Frequency Quadrature Module Wiring Figure 65 through Figure 71 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 A and B pulses can be applied to only Channels I 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 78 Revision 16 HC900 Hybrid Controller Installation an
98. PLAN AHEAD 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 battery 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 battery in place and with the CPU in the initialized state the current draw on the battery is approximately 800 microamps 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 800 microamp level the battery will retain sufficient energy to maintain the content of SDRAM for 50 weekends approximately 100 days 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 184 10 09 Removal and Replacement Procedures Safety Conside
99. PU 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 The total number of switches is limited to 2 in series between a CPU and its scanners Revision 16 HC900 Hybrid Controller Installation and User Guide 25 10 09 Components and Architecture Ethernet Open Connectivity Network Configuration 3 shows the C50 C70 CPU with 3 I O expansion racks Since there are at least 2 I O expansion racks a switch is required When an Ethernet switch is used to connect to expansion I O a cable goes between the 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 T 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 jumpers or DIP switches 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
100. ROGRAM 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 OFFLINE RUN Function Block execution starts immediately Any calibration process that was in progress is immediately aborted and the results are discarded Revision 16 HC900 Hybrid Controller Installation and User Guide 147 10 09 Operating Characteristics File Download Upload Functions File Download Upload Functions The following is a general description of file transfers between the controller and computer devices external to the controller A 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 81 PC Configuration Tool 01 1042 Operator Interface Host device w PC Con
101. Rack components 15 MODE switch 146 default gateway 31 Mode Transitions 146 determine component compatibility 4 Model number 2 Ethernet connections 130 compatibility 4 example of single process 8 Model selection guide 2 failover 153 Revision 16 HC900 Hybrid Controller Installation and User Guide 240 10 09 INDEX features hardware 9 1 0 network 26 I O wiring 45 modes of operation 150 network 27 network connections 131 networks 130 operating characteristics 1 140 150 peer to peer 28 Power Status Module 19 power supplies wiring of 49 power supply installation 64 rack dimensions 41 serial port configuration 35 start up 150 steady state operations 151 Relay Output Module Wiring 105 107 Removal and Insertion Under Power 72 Removal and Replacement Procedures 177 Replacing an I O Module 182 Replacing the Controller Module 180 Replacing the Power Supply 178 Replacing the Scanner Module 181 Reserve Power Supply 16 17 RIUP 72 177 182 Router 28 31 RS 232 119 120 RS 232 Modem 23 RS 232 Port 20 RS 485 Port 20 RTD Input Wiring 82 RTD Inputs 80 RTU 29 RUN Mode 143 SCADA 30 Scanner 2 Module 16 17 22 Scanner Diagnostics 165 Scanner Module C50 21 scanner rack assembly 64 Serial port accessing See Controller access Serial ports 33 RS485 RS232 33 S1 S2 33 service provider 31 shielded twisted pair 50 Signal Grounding 70 Simple Mail Transport Pro
102. S 241 Declaration of Conformity sumar eskadre tags bieeteysedeensas 242 ATEX CernificaiON sao seose tnea e a Seiser EOE ade 243 MAE vere SN 245 Revision 16 HC900 Hybrid Controller Installation and User Guide vii 10 09 Tables Table 1 Descriptions of Major Components Figure 4 rerrrnvrvrnvrrnrevrrnrrnevvrrnernernrvnervevservevsavsenvevsavsenvevsrvseneevssner 12 Table 2 Descriptions of Major Redundancy Components Figure 5 ernrnrrnrvrarnerrnvrrnvrvererrnrevsrvernevnrrversavsrsversene 14 Table 3 Serial port DIP Switch setting Sassersson es ena eeaeee e Sa ea eaa E cuss itavisen 35 Table 4 Simultaneous serial port configurations sesnrnvrvrevrrnveverrrnrvvrrnernervarnervevservevravservevravseneevsrneevsevsrneenasvssner 36 Table 5 Power Applied by Module Type enrnvrnnnvrnvnnnnnvrnvvrvanvrrnenvarververvarvernevsrsvevsavseneevarereneevssvennevsensevssneenesvssner 44 Table 6 Guidelines for Grouping Wires rnvrvenvrnnvevrnvrennevernenververnernernarvevneveasvevneveesvevraveesvevsavsenvevssneevsevssnsenasvrsnee 51 T abl 7 Installation Toolssaussnnmksst AER EEEE 55 Table 8 Site and Equipment Preparation ssornrnvrvrnenrvrrvrnvvrvernrrvevrarnennevsenveverereneevsrnsrneveavnevnevsenvevssnsevsevssnsenesvssner 56 Tabl 9 Mo untR cks nardskugvansngsadetm an auikru stakket erre 58 Table 10 Assemble C30 C50 C70 Controller Rack soennnvvrnvevrnnvrnrrvrrnennevnrrnevnevservevravserneveavsen
103. Table 14 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s Potentially lethal voltages on Disconnect all signals at terminal A WARNING Terminal Boards associated with blocks from sources of power before I O Modules removing the terminal block from Hazardous Voltages the I O module A CAUTION Each signal at each of the Either terminals for an I O module has a gt specific function Any or all of the Using trained personnel and Loss of control or View of 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 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 16 HC900 Hybrid Controller Installation and User Guide 72 10 09 I O Module Installation and Wiring I O Module Installation Procedures I O Module Installation Procedures Table 15 Connect Input Output Wiring 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 bottom hold the label in place Step Procedure Comments Ref
104. Wiring Diagrams DC Input Legend External y 7 Disconnect pue t Com 1 IN 1 8 Com 2 In 9 16 User Supplied Safety Devices Figure 51 DC Input Module Wiring Diagram Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 91 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Jumper either 10 12 a or 9 11 dad Connect any of 9 to 12 4 to DC Figure 52 DC Input Module Jumper Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 92 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 32 point DC Input Module Wiring The 32 point DC Digital Input module Figure 53 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 Van l GJOPIOPPJP OOO AEN 8 o O a a a a op D a 5 A a S 5 a bd amp GEOJO Legend dcemal s Disconnect s aan User Supplied Safety Devices Figure 53 32 point DC Input Module Wiring AC Input Module Wiring The AC Input Module has sixteen inputs An example of AC I
105. ad C70R CPU supports up to 10 concurrent sockets It also supports Modbus TCP Initiator function over both ports e I O Network Direct connection to each C70R CPU e Device Network RS 232 or RS 485 Serial Interface Modbus RTU Two serial ports available Each port can be set as Modbus Master or Slave Host Serial Interface for Honeywell or third party operator interface For more information For complete feature summary and specifications see Specifications on page 190 Revision 16 HC900 Hybrid Controller Installation and User Guide 9 10 09 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 Hybrid 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 1
106. address 8 Download the configuration 9 Set the Real Time Clock 10 If all status indications are green power may be restored to the I O modules per the application s procedures Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 180 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing the Scanner Module Removing and replacing the Scanner Module from an I O expansion rack C50 C70 C70R 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 37 Scanner Module Replacement Step Action 1 If a process is currently in operation then e Either ensure that powering down the expansion rack 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 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 Sca
107. al 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 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 145 Operating Characteristics Controller Modes Controller Mode Transitions Mode changes are controlled primarily by positioning of the MODE switch Figure 80 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 descri
108. allation and User Guide 137 10 09 Communications Installation Connecting the HC900 Controller to Modbus device s If the RS485 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 76 120 ohm Termination Locate on physical last device on network Modbus Slave Devices HC900 Controllers B amp B electronics or equivalent 4850PDR 120 ohm Termination I i i t VDC GND Figure 76 RS 485 Modbus slave wiring with isolation Revision 16 HC900 Hybrid Controller Installation and User Guide 138 10 09 Communications Installation Connecting the HC900 Controller to Modbus device s For XYR 5000 base stations if the RS485 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 77 shows recommended installation procedure for using an external isolator and additional port bias 120 ohm Termination Locate on physical last device on network gt r ar woes XYR5000 3 HC900 Controllers Base Stations sua ERX B amp B electronics or equivalent 120 ohm Terminati A850PDR 120 ohm Termination VDC GND Figure 77 XYR 5000 RS 485 Modbus connectio
109. and controlled shutdown L 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 2 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 terminal block from the module 3 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 4 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 5 Replace the terminal block on the module 6 If the rack was powered down for the procedure restore power to the rack 7 Re connect signals to field devices Revision 16 HC900 Hybrid Controller Installation and User Guide 183 10 09 Removal and Replacement Procedures Safety Considerations
110. ation India Ltd 55 amp 56 Hadapsar Ind Estate Pune 411 013 india Honeywell international Inc AE JA hake 512 Virginia Drive Edward A Child Fort Washington PA 19034 USA Regulatory Compliance amp Approvals Engineering Issue Date 12 May 2007 ATEX_CERT_HC900 toe Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 237 Appendix Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail Revision 16 HC900 Hybrid Controller Installation and User Guide 238 10 09 INDEX INDEX AC Input Module Wiring 93 AC Input terminal block 18 AC Output Module Wiring 101 Access See Controller access Alarm Groups 31 Alarm Event messages 31 Analog Calibration 173 Analog Input Calibration 174 Analog Output Calibration 176 Analog Output Module Wiring 87 Appendix Installation of Remote Termination Panels RTPs 199 ASCII 29 backplane 60 67 barrier style 68 Barrier style 22 Battery Installation 61 63 184 Battery Installation Replacement 61 63 Battery Replacement 186 D DC Input Module Wiring 90 DC Output Module Wiring 97 Diagnostics and Troubleshooting 155 Distance planning 44 Download Upload 148 DSL 31 E Mail 26 E Mail Communications 31 Emergency Stop switches 51 enclosure 46 equipment enclosures 42 Ethernet Devices 24 113 Ethernet Open Connectivity Network 24 26 Euro style 22 68 C Event Groups
111. 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 I 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Introduction Functional Description Redundancy Vista or 3 Party Software Ethernet Ethernet Switch m mm mm am mm mm ME ME m FUP mm mm mn mm mm mm AE JE m mm AE I I a O Redundant CPUs Redundancy is provided by two C70R CPUs operating in a controller rack this rack has no I O Each CPU has its own 100 base T Ethernet physical communication link with one or more racks of I O A Redundancy switch module RSM
112. bed in Table 24 The effects on controller operation for each mode transition are described in Table 25 Run Run Pgm Fail Pgm id Over Run Pgm Pg Run Run Pgm Figure 80 Mode Switches Controller left RSM right Table 24 Mode Switch Functions Mode Name Mode Selections at Switch Function Operator Interface RUN None locked in RUN In this position the Controller is locked in the RUN mode of Locked operation Run mode configuration changes are disabled and mode can not be changed at any operator interface RUN PROG PROGRAM In this position the mode can be changed at any operator interface using screen selections PROGRAM RUN or RUN OFFLINE OFFLINE PROG None locked in Program In this position the Controller is locked in the PROGRAM Locked mode of operation Mode can not 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 Hybrid Control Designer s Utilities to view any setting of any controller port such as network IP address and change if needed Refer to Hybrid Control Designer documentation for details Placing the Run Program switch in RUN or RUN PROG mode returns S1 to its configured protocol and settings Failover N A Transfers all primary tasks to the Reserve Controller establishing this contro
113. ber 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 Parameters Double Register Format Selectable per device Speed 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 200 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 191 Specifications General Specifications
114. cable to 16 point AC DI module at controller Choose from 900RTC HO10 Remote Terminal High Voltage Cable assembly 1 0 meters long 900RTC HO25 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC HO050 Remote Terminal High Voltage Cable assembly 5 0 meters long e Install 16 point AC DI module label into module connector cover e 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 71 2 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP 3 Set verify jumper positions as shown EE Jumper open a 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 73 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 226 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 215 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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 cable
115. cation 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 32 outlines the potential module diagnostics Table 32 I O Module LED Diagnostics Number of Failure Descripion Al AO DI DO PFQ User Action os Contact AC DC Relay AC DC 1 FAIL SAFE The moduleis in the failsafe state V NNN V IV IN 11 Ifexpansion I O rack go to step 2 because it is not receiving message If no expansion I O rack go to requests from the CPU or Scanner step 3 ata rate that satisfies the configured 2 Check the Scanner status LED failsafe timeout see p 166 If it s flashing 6 times proceed with step 3 If it s flashing some other red status code refer to Table 30 to solve that problem first If its 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 Failediits checksum VW 1 Remove reinsert module 2 Replace module RAM NN S N NN 4 ROM v B N ND 2
116. cation 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 the following command string AT E1 Q0 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 50 amp KO S0 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp WO 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 Hybrid Control 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 129 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Connecting C70R Redundant Ethernet to a PC with HC Designer or other applicat
117. ce element Replace module Under range The signal at the terminals is less than Check the signal level being 10 below the range of the sensor applied to the terminals Replace module Over range The signal at the terminals is more than Check the signal level being 10 over the range of the sensor applied to the terminals Replace module Failing to convert When attempting to take a reading the Check the signal level being ADC fails This could result if the incoming applied to the terminals signal is either too large or small It also could result if the ADC circuit is failing lf Replace module the problem is the ADC circuit most likely other channels will have the same failure AO Bad Channel The board indicates that the channel is Check terminal connections failing to output the correct value Replace module DO Bad Channel The number of configured channels in the Reconfigure the DO function DO function block exceeds the number of block hardware channels on the DO card Replace DO card with correct number of channels Revision 16 HC900 Hybrid Controller Installation and User Guide 171 10 09 Diagnostics and Troubleshooting Ethernet Switch indicators Ethernet Switch indicators Table 34 LED Indications on Ethernet Switch LED LED State Color Description 10Base T port XMT upper LED LINK lower LED Green On Off Green On Off On while a message is being sent from the Main
118. d User Guide 107 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Figure 65 Pulse Counting Wiring ENCODE IN 2 IN 3 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUT3 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUT2 OUTPUTS COM ENCODE ENCODE Figure 66 Pulse Output Wiring Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 108 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams IN 1 m IN 2 IN IN 3 IN 3 Frequency Inputs 5 24V INDEX SENSE SENSE SENSE SPOT OUTPUT1 OUTPUT2 OUTPUT2 OUTPUTS OL OUTPUT4 com COM ENCODE pote ENCODE Eve Figure 67 Frequency Wiring Attention Encoder For Input1 Input 2 and Index reverse polarity to IN 1 IN 2 IN 3 IN 3 IN 4 200mV to NT 60V 7 INDEX Differential Z 4 IDEX PP enn Internal jumper es OUTPUT1 OUTPUT2 OUTPUT3 OUTPUT4 COM ENCODE ENCODE 1 DODOSOSHODOOGOSS 4 P Encoder power P OO DOOD 5Vdc to 24Vdc Figure 68 Quadrature Differential External Power Wiring Revision 16 HC900 Hybrid Controller Installation and User Guide 109 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder 5to24Vdec a IN 1 Single ended A IN 1 B IN 2 IN 2 IN 3 IN 3 IN 4 IN 4 INDEX
119. de 158 10 09 Diagnostics and Troubleshooting Controller CPU indicators 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 on ASYS and 1 Use the Ol HCDesigner or in the configuration FSYS blocks turn on HCUtilities to configure one of the and no men e All Modbus slave and Modbus serial ports S1 or S2 as a master por 18 COMMUTER AR read blocks freeze their output 2 Use the Ol HCDesigner or odbus master pins to the last value HCUtiities to download a e Al slave blocks have their BAD confguration that has no slave COMM pin on ons e Allslave 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 3 One of the following At the time of the exception the To clear the diagnostic force a cold Ifthe lead s status If the lead s status microprocessor microprocessor resets If its 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 flan as CPU in the Lead CPU Diagnostics s 5 CPU Diagnostics in the Lead time
120. de results of 6 by 1000 6 Is the result of 7 less than 28 Yes No If the answer to 8 is Yes use power supply 900P02 0001 If the answer to 8 is No use power supply 900P01 0001 Revision 16 HC900 Hybrid Controller Installation and User Guide 39 10 09 Pre Installation Planning DC Power Supply DC Power Supply The P24 DC power supply is for use with 24V input power applications The wattage rating is the same as the POL 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 Pi AA AO NA NO OEP Rear mounting T 12 Slot kinn i plate Chassis Rack Rac j height height componens 6 90 54 For 32 DI DO amp 175 137 16 Al Reference Center for Drilled Holes e fa stot at Top of Rack facks onl hi h ne AD lt 6 04 153 158 153 Figure 26 Rack Dimensions C30 and C50 Revision 16 HC900 H
121. des 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 Specifications for this module and for other modules are given in the Specifications section of this manual Examples of DC Output wiring are shown in Figure 57 DC Output Module Wiring Diagram Over Current Protection Electronic high current and high temperature limiting provides overload protection resets after cycling power Conventional external fuses may be used if desired 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 97 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 58 V Terminals The V1 terminal 9 and V2 terminal 11 are the positive power supply input to po
122. dewire 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 50 Pre Installation Planning Electrical Considerations 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 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
123. e 19 Typically a Router is used for interconnection to another network LAN WAN or other Remote 0001 PC Host i PC Host PC Host PC Host LAN i i 44 1 2 WAN 1 1 E LI amp Networking Devices e g Hubs Switches etc PC Host PC Host 2 45 H i Configuration File Configuration File Function Blocks Function Blocks PDE Read PDE Read PDE Write PDE Write PDE Control PDE Control A HC900 Controller LAN Figure 19 Modular Network Structure Revision 16 HC900 Hybrid Controller Installation and User Guide 28 10 09 Components and Architecture Ethernet Open Connectivity Network Connection to PC Hosts Connection to PC hosts for example PCs that include HMI supervisory software and or Hybrid Control Designer 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 The 5 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 five PC hosts 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 has five sockets software and memory resources each of
124. e 87 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams OUT 4 OUT 4 Figure 48 4 channel Analog Output Wiring Diagram 8 and 16 channel Analog Output Module Wiring Examples of high level Analog Output Module wiring are shown in Figure 49 and Figure 50 Specifications for this module and for other modules are given in the Specifications section of this manual Before installing be sure to determine power requirements See page 40 and 77 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 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING A 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 16 HC900 Hybrid Controller Installation and User Guide 88 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 1 Li Li Li LI Li Li Li O E 3 ra 1 Q OQ EGG O O O 0 O O 0 0 O O 00 Q 0 OG 7 JO OPPP GEMP EE AN amp QOO m 24VDC 1 O 3 ran RJ C d ir OUT1 IO QOOKMOMOLGID EVV OOOOOOOOOOODOOOOO0 YC NEO
125. e Connect cable to RTP 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 Wickmann part 3740080041 UL CSA approved Volt millivolt Transmitter Milliamp SW9 is the red power switch for 24 volt supply Module RIUP is not affected by using the RTP See page 210 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 200 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input 4 Action Connect field wiring Refer to Figure 92 through Figure 98 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 i 1 1 1 1 Ko 00 BG OG 60000 Niz Se ee i 3 135 mi Se ais EE a eee Si BIZ 2 226 aA CSAS ZZ NAG Pee a OA ey EE i 1 Xi Xi XK XX XX N Il elie 1 KZZ S52 2122 S332 2 552 2 S152
126. e Ethernet Open Connectivity Network which links an HC900 Hybrid 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 24 Components and Architecture I O Network I O Network I O Expansion Network C50 C70 CPU only LL LEU Examples of HC900 Controller I O expansion configurations are shown in Figure 18 Figure 18 HC900 Controller Configurations In Figure 18 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 200 Configuration 1 is the C50 C70 CPU with I O but no I O expansion racks Configuration 2 shows the C50 C70 CPU with 1 I O expansion rack The Ethernet cable connects directly between the 10Base T connectors on the C50 C
127. e Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network v Device Name Honeywell HC900 Controller v Address 192 168 1 254 v Statistics Protocol Modbus R TCP Speed bps N A gt PC Port Setup for Controller Access Network COMI Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Be also sure 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 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 typically used 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 119 Attention IP addresses for E1 and E2 must be on different subnets 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
128. e 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 terminal block Wiring Rules and Recommendations In general stranded copper wire should be used for non thermocouple electrical connections Twisted pair wiring with shielded cable 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 13 Table 13 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 47 Also all wires must be securely terminated using appropriate wiring practices Signal Grounding Figure 37 Revision 16 HC900 Hybrid Controller Installation and User Guide 69 10 09 I
129. e configured in Hybrid Control Designer as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in Figure 44 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING A 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 RTD 3 Wire a ae Input a H i RTD FI 6 i ri E Fog fem IN 1 IN 14 z eo N1 N1 Thermocouple Se Mo 1 amp 2 leo 1 amp 2 Input IN2 IN2 a H IN2 N2 s r IN 3 IN 3 ETEN NS IN 3 mm j 3 amp 4 lero 3 amp 4 Ohms rv a BBE a IN 4 IN 4 Input sanper C aa N4 IN 5 IN 5 IN5 N5 leo 5 amp 6 leo 5 amp 6 le IN 6 IN 6 mV V mV or v I pen IN6 Pos z 1 N7 Input Source EN H nT INT sum IN7 ha leo 7 amp 8 lem 7 amp 8 z IN 8 IN 8 m j N8 N8 4 20 MA i Input mum Figure 41 Universal Analog Input Wiring Diagram Revision 16 HC900 Hybrid Controller Installation and User Guide 81 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Ce er g RTD 3 Wire ETENA H Input F i Qi i E ka H H hmmm IN 1 i Vans eee RTD 3 Wire mm km 1 amp 2 Input ane IIN ul dogma IN2 z i 2 N3 ler 3 amp 4 IN 4 IN 5 lin 5 amp 6 RTD
130. e 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 C30 and C50 CPU 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 Hybrid Control Designer 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 This will typically be the LAN side IP address of the routers used to connect the controller
131. e 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 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 38 provides some general guidelines for establishing appropriate procedures at a given installation Table 38 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s CAUTION Loss of control or view of a running process can cause damage to equipment and or to process product 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 Either Using trained personnel and appropriate control mechanisms transfer to manual control of each signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the remova
132. ed 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 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 e available from Honeywell Plantscape Vista Software which operates under Windows 2000 XP Pro 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 PlantScape 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 available in release 400 which includes a standard template for creating batch reports SpecView32 SpecView Corporation OPC Server works
133. ee 17 Figure 10 Power Supply rena e arsen one eee estere 18 Figure 11 Power Status Module PSM ccsscssssssssssceeceeeeceeesaeesaceseeececeeecaecsaeeseceseseeseceeecaeesaeseaeeaeceaeeeeeeneeaees 19 Fretre12 Controller Modul vunnet repenra rera aretas eee SS Skt rusten NT Eai EEE 20 Figure 13 Redundancy Switch Module iee a er a r E E IE R EA E R A 21 Figure 14 Sc nner I Modtlles csccccschscecses ss cesesseshese sass tenesecesesavsene fossvonzenstovesnessasucdcevasbeusabvanaeeseonanaesodsbesten snd Sava 21 Figure 15 Scanner 2 Mod le s senro loses seatatespeecesasks RAE E ated soe RA N aS 22 Figure 16 I O Module Terminal Blocks oonrorvrnvnvrrnorvrrvrrvevrrnrrvevvarnerneverevevsrrenvevsrerenervasnennevsesvevnevseneevssneenesvrsnee 22 Figure 17 RS 232 Modem Devices rnorranvrvrnvrrevevenvrrnernrrnervevsrsnevravsrneevsnersnesvrsnennevessvevssvrennevssneenasvasneensevssnesnasvrsner 23 Figure 18 HC900 Controller Configurations rnvrnrrvrrvrevrvnvrnrevernernernrrnenneverrnenerservevraveesvevravsenvevssneensevssneeneevssner 25 Figure 19 Modular Network Structure rsoasnrnvrnrovrrnvrvevvrrnernervrrnernernarnevveveasnevnevsesvevsavsesnevsasenvevssnsevsevssneenasvrsner 29 Figure 20 M dbus TCP Brain sss sess psp e a a a ae dies ters inatestel E aeaa i E EE 29 Figure 21 Typical installation using a Cable Modem eenvovrrnorvenvrrnrevrrnernervrrnernevnrsvenvevsrvvevravsenvevravsenvevssneenes
134. ee 171 Table 32 VO Module LED Diagnostics r ar a rr a Tea en E AEE E EK E E e o aara a Eai 172 Table 33 Bad I O Channel Did gnostiese reren e eE EE est AEEA ees 173 Table 34 LED Indications on Ethernet Switch seeenerennerrrrrnnnrrenrennnenenennrvresnrenrneneseneensnensersesnsennssnnnsnenereensssrsenee 174 Table 35 Power Supply Replacement all except C7OR nnornornennonnevnrrnevravvervevravverrevsrnvevsrereneevsrnseneevsrvesnesvssner 181 Table 36 Controller Module Replacement vrrnvrnvnnrnnvrvrnvrrnnevevernnnevsrnvenervrrneenervrrnenvaresrververvsevesnarvesvevrarvennevseneer 183 Table 37 Scanner Module Replacement sonvrrnnnnorvrrvrvrrrvnvrvvrrnvevernvrnervarnennernervevrarvevvevsenvevssvsenesvasvsenesvasvesnesessner 184 Table 38 RIUP Potential Hazards and Recommended Actions senrnvrvanvrrvvrvrnvrrvevvrrnrrneevernreneevrrnsenervssvernesnssner 185 T ble 39 1 0 Module Replacement usensurerte led 186 Table 40 Installing Backup Battery CPU not initialized eerrnorrorvrrnvovervrrnrevrvvrrnnevsrnernervrrnernervrrnsenervrrvesvernsene 188 Table 41 Replacing a Backup Battery CPU Powered sresnrnvrvvnvrrnvrvrrnrrnvevarnerneevevereneevsrververereververnsrvervesvssner 189 Table 42 HC900 PV Input Types and Ranges nori annia Ea E AE E E R 196 Table 43 System Size and Availability Summary esvovrrvrrvorvrrnvrvrrvrrnvrvererrvvrvsrnrrveevsrvseneevsevsevesvrsvernarvrsvesvesessner 199 Table
135. el Number XXXXXXX XXYY ZZ HC900 CPU 900C51R 0040 00 Scanner 1 900C53R 0040 00 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 1042 Operator Interface 10420F 0040 40 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide Introduction Functional Description Functional Description All Controllers The Honeywell HC900 Hybrid 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 Hybrid 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 me a Figure 1 Small HC900 Controller Configuration Revision 16 HC900 Hybrid Controller Installation and User Guide 6 10 09 Introduction Functional Description 00000000 Controller Rack with 8 slot O Expansion I O Figure 2 Expanded HC900 Controller Configuration 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
136. ematic HC900 Terminal Block Ji TB a o oo N OA FF WO PD o ON DO oa A WO PD N N o o i A A EN ol o o gt pre o gt a I I o Oo i i mn oO mn oO Revision 16 HC900 Hybrid Controller Installation and User Guide 208 10 09 Appendix Installation of Remote Termination Panels RTPs Relay Output RTP Cable wire positions and colors applies to 8 point Al and Relay Output 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 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 209 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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 215 e 16 point Contact Digital Input 217 e 16 point DC Digital Input 218 e 16 point AC Digital Input 220 e 16 point DC Digital Output 221 e 8 poi
137. ement 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 authorized 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 177 10 09 Removal and Replacement Procedures Safety Considerations PLAN AHEAD 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 Hybrid 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 ampere
138. ent to verify proper operation e If there is a Lead Controller the configuration database is automatically copied from the Lead to the newly replaced C70R CPU module Before replacement If possible upload and SAVE a copy of the configuration or ensure that a previously SAVEd copy of the current configuration is available If possible bring the process to a safe and orderly shutdown Table 36 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 3 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 4 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 5 Re install communications cables 6 Using the user supplied switch re connect site AC power to the rack 7 If using the Ethernet port for configuration use the Hybrid Control Designer software to set the proper network
139. er connecting the thermocouple extension wire to the terminals you must wait for the terminal temperature to stabilize 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 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 TC mVolts Volts inputs 1 microvolt resolution Ohms RTD inputs 01 ohm resolution 4 20mA inputs 4 microamp resolution Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 174 Analog Calibration Overview RTD Input See note Resistor Decade Box Thermocouple T C extension wire Input See note Compensated Calibrator T C extension wire Ohms g 0000000 Input pe See note EV Sannas gannnnnnnnne MV or mV or vir v Millivolt Volt Source san Input Source ara See note fide 4 20 mA E Xmtr Input Milliamp Batea Source gunnndunnsg 24 Vdc or use Or Copper wire T C extension wire Thermocouple Input pi i ao o n See note TIC extension wire Note The following Al types are not available for High Level Analog Input modules RTD Thermocouple Ohms mV Figure
140. erence 1 Using Rack Slot 120 240 VAC g ge Channel data from a p tier yds ORANGE WHITE TEXT Hybrid Control Designer Select Labol apps with ct 24 VDC s report fill in the tagnames Color Bar ji Maal OREEN WHITE TEXT on the Label for each s F N senn d configured I O Module Tagnames 4 Psp GREEN WHITE TEXT Module slot position 5 should take heat de rating 6 120 240 wo RED WHITE TEXT into account See Heat 7 Rise De rating page 44 ri pr eer DARK BLUE WHITE TEXT Be sure to use the appropriate label for each a 3 RED WHITE TEXT module type WHITE DARK GREY TEXT YELLOW DARK GREY TEXT 2 Place the appropriate label CAUTION DE ENERGIZE MODULE FIELD POWER BEFORE SERVICING Term Na IN1 Ni 2 InTDI 2 3 IN2 4 IN2Q 5 IN2 6 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 73 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 3 Optional Install jumper Ac hipit combs into designated ACO Alta Barrier style Terminal gb BEOU ee Cure Blocks to reduce the wiring required to supply power 2 2 Two position jumper for 2 6 the DC Input Module ic and or on the DC Output j Q G O O Module Ea O E ZN O Q Ten position jumper for the AC Output Module S OE 173 Five position jumper 10
141. eristics Steady State Operations Module RSM Figure 82 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 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 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 Lead Controller issues polls to I O Racks for inputs Both Lead and Reserve read I O responses from I O Racks Lead and Reserve both execute function blocks in the control strategy Only the Lead Controller writes physical outputs to the I O Racks Lead Controller responds to communication messages from host devices on the Supervisory Network and RS 232 RS 485 interfaces Lead Controller handles comm
142. es Rack Power Supply Controller Module Honeywell Local Rack and I O modules 2 I O Expansion Optional Includes Rack Power Supply Scanner Honeywell Rack Module and I O modules C50 C70 CPU only 3 Operator Optional link to RS 485 port on a Controller Honeywell Interface Module provides operating and utilities displays Includes buttons and optional AT keyboard interface 4 PC Optional PC laptop or desktop connects to PC is from third party Configuration RS 232 port on any one Controller module supplier Configuration Tool Includes Honeywell Hybrid Control Designer software is from configuration software Honeywell 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 Interface other networks including Internet is available from Typically includes HMI operating software Honeywell PlantScape or SpecView32 or May also include Hybrid Control Designer from third party configuration tool and utility software supplier 6 Ethernet Enables connection of the private Ethernet Honeywell 100Base T 100Base T port on a Controller Module to the Switch Scanner modules on 2 3 or 4 I O Expansion racks C50 C70 CPU only If a single I O expansion rack is connected directly to a Controller Module the Switch is not required 6a Ethernet Enables inter connection of several 10 100Base T Third party suppliers
143. etwork before they have been given unique IP addresses will cause problems On the PG use the Utilities Worksheet in the HC Designer software to set up the serial RS 232 connection to the controller at the desired baud rate see Direct Serial RS 232 Connection above This will require a null modem cable 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 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 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 Hybrid Control Designer software
144. evnevsrneevarvreneevavvrenenvarnsrneevssnsenesvrsnsenesvasvesvasessner 109 Figure 66 P lse Output WirN gss a aa E T RA E R A A shee S 109 Figur 67 Frequency W ming eves aE EE ER E R EE 110 Figure 68 Quadrature Differential External Power Wiring rsvrvrrvnrnvrvrnvnevravrrnvrvrevsrnveverereneevsrereneevsrvernernssner 110 Figure 69 Quadrature Single Ended External Power Wiring serrernrrnrvvavnrnvevravnervevrenvevsrereneevsrereneevsrvsenesvssner 111 Figure 70 Quadrature Differential HC900 Power Wiring esrrnrarnevennrvrnenrerrernrenrnenenenereresrnssresnrennssneneneenseersesne 111 Figure 71 Quadrature Single Ended HC900 Power Wiring srsvrvrrvrrnvrvervrrnravsrnerveevsrvernervrrnervarvrrvervarssrversarser 112 Figure 72 RS 232 Remote Access via Modems enrnvrrnovvrrnevrrerrvnvrrneevarnervervrrvernevsrevevsrerenervrrnesvervssnevrasvevnevsenser 121 Figure 73 Redundant Networks see Table 21 errrnnnnnnnronnenrrrrnenrennnenenennrennererrrenseensenneenreennssresnrenssenenenessresnsesne 130 Figure 74 Two redundant systems with PC supervision sesernvrnvavrrnvrvevvernennevnrrvesnerservevererevsevsrereneevsrvesnesvssner 133 Figure 75 RS 485 Modbus slave Wiring esravrrnvovravrrnvevrrevevreverenevrevsrnvevarvrrneevsrvreneevarnsrneevsrnsevesvrsnseneevasvesnesessner 137 Figure 76 RS 485 Modbus slave wiring with isolation sservornrrvrvrrerevvrvrrvverrevrrnvevrevsrnvevsrereneevsrvsenervrr
145. figuration Tool Configuration Download Upload Figure 81 Pathways for Upload Download Transactions Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 148 Operating Characteristics File Download Upload Functions Configuration Download Configuration files include the items indicated in Table 26 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 26 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 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
146. fulfills the requirements for Group II Category 3 equipment in accordance with Directive 94 9 EC The design incorporates requirements of IEC 60079 15 2005 and is documented within Honeywell Technical File 51453806 The apparatus is incapabie of producing arcs sparks or hot surfaces which may cause ignition and is designed to be installed and used in accordance with IEC 60079 14 2002 The marking of the apparatus shall include the following x II 3 G Ex nA IIC T Ta lt 60 C Doc No HON 08 ATEX 0001X Manufacture of the apparatus is controlled by an ISO 9001 approved system The apparatus satisfies the EMC requirements of IEC 61326 related to measurement control and laboratory equipment and satisfies the requirements of IEC 61010 1 for operator safety See attached list of modules for individual Temperature Classifications Conditions for the installation of the apparatus in Zone 2 hazardous areas 1 The HC900 must be mounted in an enclosure that provides a degree of protection not less than IP54 per EN60529 2 External transient protection is required at the power supply terminals and shall not exceed 140 of the rated power supply voltage 3 Modules are not to be inserted or removed unless the area is known to be non hazardous 4 All necessary precautions are to be taken to avoid the danger of ignition due to electrostatic charge build up during installation use and maintenance Manufacturing Location Honeywell Autom
147. g group connecting wires into bundles see Table 6 and route the individual bundles through separate conduits or metal trays Use shielded twisted pair cables for all Analog I O Process Variable RTD Thermocouple dc 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 67 Use suppression devices for additional noise protection You may want to add suppression devices at the external source Appropriate suppression devices are commercially available 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 6 Guidelines for Grouping Wires Wire Group Wire Functions High voltage e AC Line power wiring 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 Sli
148. g 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 Jumper Comb A ten position jumper comb available for the AC Output Module can be cut in half and used as shown in Figure 64 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common Revision 16 HC900 Hybrid Controller Installation and User Guide 105 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams A WARNING A 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 Relay Output Form C Out 1 No Out 1 COM DNO N C Out Ne Out 2 No Form C OVO LOAD 3 Form C 0u 2 COM mem Our2 CO OQut 2 No Form A L1 L2 N Out 3 No Out 3 Nor o ol Outs COM e Form ud No mm For No Form A Out 4 COM Out 5 No Oras Form ee Form A
149. g 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 158 Scanner indicators 166 I O Module Indicators 171 Ethernet Switch indicators 174 e Screen items on The Operator Interface connected to the RS 485 port See Operator Interface manual 51 52 25 108 APC with Hybrid Control Designer Hybrid Control Utilities connected to the controller module via the RS 232 port or the Ethernet 10Base T Open Connectivity port See the Diagnostics section in the application s help Revision 16 HC900 Hybrid Controller Installation and User Guide 155 10 09 Diagnostics and Troubleshooting Controller CPU indicators Controller CPU indicators Figure 84 LED Indicators on Controller CPUs See Table 27 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 156 Diagnostics and Troubleshooting Contr
150. ge 37 Figure 24 amp 3 Plug controller is equivalent instructions Figure 25 8 8 9 connector slave Revision 16 HC900 Hybrid Controller Installation and User Guide 114 10 09 Communications Installation Wiring and cabling Controller Port Connector Type RS 485 3 Plug connector E1 10 100 Base T RJ45 E2 10 100 Base T RJ45 E1 10 100Base T RJ45 E2 10 100Base T RJ 45 Link Type Controller to Modbus slave network controller is master Host Peer and Internet Devices Host Peer and Internet Devices Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Hybrid Control Designer configuration software Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Hybrid Control Cable Type Belden 9271 or equivalent Shielded CAT5 cable up to 100 meters Shielded CAT5 cable up to 100 meters To Device Port Refer to device s port instructions RJ45 connector on Host Peer or Internet Device RJ45 connector on Host Peer or Internet Device Details Page 37 Figure 25 7 10 Default IP address is 192 168 1 254 Default IP address is 192 168 2 254 Default IP address is 192 168 1 254 Default IP address is 192 168 2 254 Designer configuration software I O Single I O rack Shielded Ethernet C50 C70
151. gh the top of 5 o GET the terminal block and some through Era the bottom as indicated in Figure 38 Ser In this case it is necessary to adjust I I HE ET EM og wire length so as to ensure adequate OG alee p flexibility of the twisted wires and to L T a Sjo provide clearance sufficient to remove A the I O module SS lob Figure 38 Wire Shield Grounding Revision 16 HC900 Hybrid Controller Installation and User Guide 70 10 09 I O Module Installation and Wiring Terminal Block to Field Signal Wiring 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 39 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 39 Terminal Block Jumper Installation Revision 16 HC900 Hybrid Controller Ins
152. he PC 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 un Q S Loop Back Statistics Dial Xircom CardBus Ethernet 100 Modem 56 Modem Interface Protocol Honeywell Inc ELN Speed bps N A Port e Gae e i PC Port Setup 7 Network COM1 Revision 16 HC900 Hybrid Controller Installation and User Guide 122 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem requirements Most commercially available modems can be used with the HC900 Controller The modem must have the following capabilities e RS 232 interface e Auto answer e 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 e Hardware handshaking can be disabled e Software handshaking can be disabled e Data Terminal Ready DTR input can be disabled e Result codes can be suppressed e Echo can be disabled e Must be equipped with non volatile memory NVRAM so that settings that are configured using command strings can be retained during a power outage e 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 con
153. he module See page 75 e Connect terminal block end of desired cable assembly to 16 point Analog Output module at controller Choose from 900RTC 3210 Remote Terminal Cable assembly 1 0 meters long 900RTC 3225 Remote Terminal Cable assembly 2 5 meters long 900RTC 3250 Remote Terminal Cable assembly 5 0 meters long e Install 16 point Analog Output label into the module connector cover e 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 71 2 Mount RTPs to DIN rail e Latch to rail See page 241 e 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 e Note Inputs 9 and 10 are wired between both RTPs 3 Set verify jumper positions on each RTP as shown EE Jumper open live as 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 73 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 229 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 225 10 09 Appendix Installation of Remote Termination Panels RTPs Analog
154. heir own enclosure Mount RTP cable assembly to HC900 Controller Figure 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 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 900RTC 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 71 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP 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 73 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 229 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 222 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output Action Connect field wiring LOADS ARE 0 to 750 ohm RTP A for
155. hen press the ENTER key The modem should respond with OK Revision 16 HC900 Hybrid Controller Installation and User Guide 125 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Step 8 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 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 W0 The Modem will not respond Action 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 Y0 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 Hybrid Control Designer software Set up Hybrid Control Designer software to dial the HC900 Controller Verify that communications is established with the remote HC900 C
156. hown EE Jumper open a 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 73 See page 238 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 231 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Input Connect field wiring RTP A for inputs 1 to 16 RTP B for input 17 to 32 DC Supply Note SDC refers to switched positive side of the DC supply Note Terminals 9 and 11 DC are connected through the RTP cable Same for terminals 10 and 12 DC Revision 16 HC900 Hybrid Controller Installation and User Guide 232 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 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
157. iator non redundant Peer to Peer and Hybrid Control Designer configuration software Up to 5 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 Ports Ports per controller Baud rates Modem Two user selectable between RS 232 and 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 Hybrid Control Designer software or Ol For remote connection to Hybrid Control Designer software requires external modem at controller 1200 baud to 57 6KB RS 485 Ports Ports per controller Cable type 1042 559 Distance from controller 1042 559 Power to Ol Unit addresses Two user selectable between RS 485 and RS 232 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 RS 232 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 tfor2 1200 2400 4800 9600 19200 38400 57600 115200 Selectable byte order RS 232 RS 485 Modbus Slave Operation Number of ports per controller Masters pe
158. il 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 16 HC900 Hybrid Controller Installation and User Guide 136 10 09 Communications Installation Connecting the HC900 Controller to Modbus device s Connecting the HC900 Controller to Modbus device s S1 RS 232 default RS 232 terminals 1 and S2 can be set to RS 232 or RS 485 RS 485 Modbus connections Use HC Designer software to configure the controller s RS 485 port as a master or slave In Figure 75 through Figure 77 the controller s S1 right side port has been configured for RS 485 by setting its DIP switches page 35 Install resistor as shown for terminated devices except HC900 For terminating HC900 do not install resistor Instead set internal DIP switches for termination page 35 When using the HC900 XYR5000 transmitter function blocks and RS485 serial communications ports connect Base Stations to the HC900 controller as shown in Figure 75 HC900 Controller Modbus Modbus Modbus Slave 1 Slave 2 Slave 3 120 ohm Termination Figure 75 RS 485 Modbus slave wiring Revision 16 HC900 Hybrid Controller Inst
159. in Figure 79 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 78 Revision 16 HC900 Hybrid Controller Installation and User Guide 141 10 09 Operating Characteristics Power Down Power Up 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 an operator interface e When initiated by the user after download with Cold Start selected or any transition from PROGAM Mode to RUN Mode COLD TART Build empty database invalid database Mode Switch position Operate in RUN Mode Operate in PROGRAM w initialized process values Mode w all outputs off Figure 79 Cold Start Operation Revision 16 HC900 Hybrid Controller Installation and User Guide 142 10 09 Operating Characteristics Controller Modes 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
160. 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 pin is tumed 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 turned on 7 ASYS and FSYS blocks HW OK pins are turned off 6 Scanner 2 has a CPU 1 Associated rack monitor block s See CPU or See CPU or or Memory diagnostic RACK OK pin is turned off MEMORY in the Memory in Rack 2 ASYS and FSYS blocks HW associated rack s Diagnostics OK pins are tumed off Rack Diagnostics dialog box Overview display Revision 16 HC900 Hybrid Controller Installation and User Guide 161 10 09 Diagnostics and Troubleshooting Controller CPU indicators slave the data link layer is reporting that at least 75 of the last characters their read pins frozen to the last value read e Slave blocks associated with use the slave status screens to determine which slaves are experiencing the problem For those slaves check Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 7 A Scanner 2 rack has 1 Associated rack monitor block s Locate the Scanner 2 that indicates a See POWER See Power a bad power supply RACK OK pin is turned off bad
161. ing Diagrams DC Output Jumper 9 11 for one V Supply to both s groups of outputs Jumper 10 12 for one Common abe Ground for all outputs Figure 58 DC Output Jumpers Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 100 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 32 point DC Output Wiring The DC digital Output module provides 32 externally powered outputs in 2 groups of 16 Figure 59 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 A green LED on the module provides indication of an ON state for each output Requires Low Voltage Euro style 36 terminal terminal block AC Output Module Wiring e v OOO anaga ADNO 10 5 to 32 Vdej EO EIGD GGGGGGGOVGGOOOODOP Figure 59 32 point DC 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 60 Specifications for this module and for other modules are given in the Specifications section of this manual Output Loading Voltage 85 to 240 Vac Maximum per output 2 0A resistive load
162. ion and User Guide 10 09 77 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 8 Insert a wire tie into the top and or bottom end of the terminal block Form a bend in each wire to provide strain relief and secure the wire bundle with the tie Euro Terminal Block Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 78 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 9 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 the tie 10 Install I O modules in racks Be sure to follow placement guidelines under Heat Rise De rating page 44 Q SIS SOOM aig elelelelsjelelg 11 Install I O module install a Filler Block cover Part number 900TNF 0001 12 In each slot location not occupied by an I O module install a Filler Block cover Part number 900TNF 0001 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
163. ions Only use Shielded CAT 5 cable for network connections See Figure 73 and Table 21 Figure 73 Redundant Networks see Table 21 Attention Always observe the wiring cabling guidelines on page 45 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 130 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Table 21 Redundant Network connections in Figure 73 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 3a 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 3b to Ethernet port 3a Ethernet switch for CPU A E1 port 3b Ethernet switch 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 CPU A S2 port RS 485 to Operator Interface port 9 Connect CPU B S2 port RS 485 to Operator Interface port 10 Connect CPU A S1 port to PC RS 232 port Table 22 Redundant netwo
164. ions see page 120 For RS 485 connections see page 137 e 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 Honeywell Operator Interface 1040 559 Must be on RS 485 port S2 Will not work on port S1 even if set to RS 485 Will not work on RS 232 port with 232 485 converter Honeywell HC Designer PC software Third party PC HMI software Third party Operator Interface e Controller can 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 RS 232 and RS 485 both as master ports For multiple slaves on RS 232 port a 232 to 485 converter is required e Modbus master ports default to slave ports ELN protocol when CPUs are in Program mode e Baud rates to 57 600 Revision 16 HC900 Hybrid Controller Installation and User Guide 33 10 09 Components and Architecture Serial Ports RS 232 and RS 485 Setting serial ports S1 and S2 to RS 232 or RS 485 SI serial port default setting is RS 232 S2 serial port default setting is RS 485 terminated Functionality is determined by DIP switch setting on SW1 for S1 and SW2 for S2 See Figure 23 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
165. 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 Do 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 166 10 09 Diagnostics and Troubleshooting Scanner indicators Number Possible Cause Scanner Action User Action of Strobes 5 C70R only The communications C70R only This problem may cause on C7OR only har the reserve is failing for the demand failover attempts to be unsuccessful 1 Verify that the CPU A cable is ONANING GASONS connected to the A port and 1 There is a problem with the the CPU B cable is connected connection between the to the B port on the Scanner scanner and the reserve 2 2 The scanner port used to 2 Ifa switch is used check that communicate to the reserve all cables are properly has a hardware failure 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 5 Cycle power to the Scanner 2 6 Cycle power to the switch 7 Cycle power to the reserve 8
166. 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 78 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 16 HC900 Hybrid Controller Installation and User Guide 140 10 09 Operating Characteristics Power Down Power Up Diagnostics RAM Firmware Strobe 1 at Status LED Disable all Communications Diagnostics Database Mode Switch position Operate in RUN Mode using process values stored prior to power down Operate in PROGRAM Mode w all outputs off Figure 78 Warm Start Operation Cold Start A Cold Start clears the data in battery backed RAM turns all outputs off transfers the configuration file from flash memory to RAM and reinitializes all dynamic data The Cold Start procedure is flowcharted
167. itor 70 IT networking professional 24 J jumper 74 Jumper Comb 90 94 98 102 105 Jumper Combs 71 jumpers 26 Kepware 30 key tabs 74 Label 73 labels 68 LAN 28 LED Indications on Ethernet Hub 172 LED Indications on I O Module 169 LED Indications on Main CPU 157 LED Indications on Scanner Module 164 LED Indicators 156 164 lithium battery 20 Local Area Network 28 Modem 122 123 124 125 Module Placement 67 Module Wiring 80 mounting racks 57 Null Modem Cable 120 OFFLINE Mode 144 OHMs Inputs 81 OPC 30 OPC server client software 30 Open Modbus TCP protocol 30 Operating Characteristics 140 Operating Modes 140 operator interface connect to controller 117 Parallel processing 9 PC hosts 29 PC Hosts 29 PC Modem Cable 121 PDE 28 Peer Data Exchange 28 Peer to peer communication 28 Personal Computer 23 PlantScape Vista Software 30 Power DOWN 140 Power Down Power Up 140 Power Status Module 16 17 Power Supply 18 59 60 62 Power transitions 140 Power UP 140 PROGRAM Mode 143 PV Input Types and Ranges 193 196 198 R rack address for I O 65 Rack Dimensions 40 rack installation 54 rack mounting 57 Rack Options 17 RAM 140 Redundancy Switch Module RSM 8 15 21 Redundant 2 systems w PC supervision 133 M C7OR controller module 20 components 13 Master Control Relay 51 controller rack 15 Modbus mapping structure 29 Controller
168. ize 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 IN THE 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 sr 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 3 The lead and until a good switch reading is seated properly If the key does not soe j a t acquired pull out turn it slightly to the proper aee eis If after the power is cycled to both position until it 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 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 Revision 16 HC900 Hybrid Controller Installation and User Gui
169. k associated with each Wiring I O module Communications 113 Guidelines for installing RS 232 RS 485 and Ethernet cabling and associated Installation components Operating 140 Characteristics of the HC900 Hybrid Controller as they relate to configuration of a Characteristics control strategy and to operation of an installed and running system Redundant 151 Characteristics of redundant operation Operating Characteristics Diagnostics and 157 Mechanisms that detect and react to faults in the operation of HC900 Hybrid Troubleshooting Controller hardware and or software components Analog Calibration 175 Hardware configuration required for calibrating Al and AO modules from the configuration software Removal and 179 Guidelines for replacing system components includes Cautions and Warnings as Replacement applicable Procedures Specifications 190 Details of HC900 Hybrid Controller design and functioning Appendix 203 The Remote Termination Panel RTP provides an easy way to connect the Installation of Remote Termination Panels RTPs 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 1 Introduction
170. k 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 Me Device Name Honeywell HC900 Controller v Address 192 168 1 254 Statistics Protocol Modbus R TCP Speed bps N A PC Port Setup for Controller Access Network COM Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Be also sure 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 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 typically used 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 119 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
171. l board jumpers 10 ten pos jumpers Manuals Full Document set on CD Full document set hard copy Engish Software HC Designer Config Software CD 900RTC 3225 900TNF 0001 900TSS 0001 900J02 0001 900J10 0001 900ME1 00XX XX 900ME2 00XX XX 900W01 00XX XX HC Utilities Software Documentation CD 900W02 00XX XX Kits amp Accessories Redundant Power Rack Extension Kit Spare I O Label Kit Replacement Battery Kit Ethernet Cable 10 feet Ethernet Cable 20 feet Ethernet Cross over Cabe 20 feet Null Modem Cable Null Modem Cable used with 900C70R 250 ohm Shunt Resistor Kit 8 pkg Ethernet Switching Hub 8 Ports 24 VDC Power Supply 900RPE 0001 51452262 501 51500638 501 51451432 010 51451432 020 51451996 020 51404755 501 50004820 501 51205995 501 50008930 001 51452041 501 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Introduction Model Selection Guide Description Operator Interface 559 T12 Type 12 559 T4 Type 4 1042 with Floppy Drive 1042 with ZIP Drive 900 Control Station TREND Manager Software Ol Accessories amp Kits 559 T12 Membrane Keypad 559 T12 Mounting Kit 559 T12 Operator Interface Cover Type 4X 559 T12 Bezel amp Case Assembly Ol Accessories amp Kits 559 T4 Panel Gasket 559 T4 Keyboard Connector Kit 559 T12 T4 LCD Color Display with Backlight Model number 559T12 00XX XX 559T04 00XX XX 10420F 0
172. l or insertion procedure WARNING Human contact with high voltage sources will result in death or serious injury Potentially lethal voltages on Terminal Blocks Disconnect all signals at terminal blocks from sources of power before removing the terminal block from the I O module Ensure that the Protective Earth PE ground is properly connected and properly functioning Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 182 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Table 39 I O Module Replacement Step Action 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
173. ld 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 71 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP Fuses 6 3A Time Lag Wickmann part 3741630041 UL CSA approved for 250V Module Removal Insertion Under Power RIUP is supported by turning off all eight switches to allow removal of the module from the rack without causing an arc Please see page 73 for more details See page 213 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 206 10 09 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output Action 4 Connect field wiring O SI 2 2 IS Q Q Q Q lt lt x lt x lt O O O O Ti m vy WD o foe Q O a at jal 8 8 8 O O OOOO 80006008 08 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 207 10 09 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output RTP Internal sch
174. ller as the new Lead Does not affect controller mode Turn key to Failover and hold it there until both Reserve lights are on then release key Revision 16 HC900 Hybrid Controller Installation and User Guide 146 10 09 Operating Characteristics Controller Modes Table 25 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 causes 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 P
175. 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 each rack in your system Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 58 Rack Installation Assemble Controller Rack Assemble Controller Rack C30 C50 C70 Controller Rack assembly information is given in Table 10 C70R Controller Rack assembly information is given in Table 11 Table 10 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 2 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
176. message frame is embedded into a TCP IP datagram as indicated in Figure 20 Transaction Protocol Length Modbus Identifier Identifier Field Frame Address Function Data Checksum Code Figure 20 Modbus TCP Framing The HC900 Controller uses either Modbus TCP or Modbus RTU not ASCII The 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 29 10 09 Components and Architecture Ethernet Open Connectivity Network 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 controller in release 4 0 and higher are not automatically includ
177. minal window key in in the following command string AT El 00 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 50 amp Y0 SO 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 wo 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 Hybrid Control 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 128 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software 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 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 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 communi
178. n and or poor system performance Factors to consider in your pre installation planning include C70R CPUs require the 900P02 Power Status Module I O Rack can use AC Power Supply 900P01 900P02 see page 40 or 24DC Power Supply 900P24 see page 41 Limit of 10 Analog Output modules per rack Limit of 4 PFQ Power Supply rack space if using redundant I O power see page 42 Rack orientation and mounting see page 41 Remote Terminal Panels see page 43 Environmental conditions see page 43 Heat rise de rating see page 44 Cabling wiring distance planning see page 45 Electrical considerations controller grounding CE conformity grouping wires master control relay for emergency shutdown see page 47 System monitor function blocks see page 54 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 38 Pre Installation Planning AC Power Supply Selection for racks with I O AC Power Supply Selection for racks with I O To determine which I O rack AC power supply to use P01 or P02 calculate power requirements below H ATTENTION Using inadequate power supply will cause the controller to cycle power on and off A B Cc D E Max Max Enter Current Current Calculate 5V current Calculate 24V current Module type Quantity 5V 24V D A B E A C Controller C
179. nd onl PE Ground anden Yellow Green 14 AWG 2 1 mm Copper 75 C Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 60 Rack Installation Assemble Controller Rack Step Procedure Comments References 3 WARNING Ay Ensure that AC power to the rack is disconnected Set controller module s communication ports to desired settings page 35 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 ATTENTION Do not install the battery at this time Installing the battery 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 187 I O will be installed later See Page 67 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 61 Rack Installation Assemble Controller Rack Table 11 Assemble C70R Controller Rack Step Procedure Comments References Carefully place the Power Supplies in the leftmost and rightmost slots in the Rack ensuring that the connector at the back seats properly See Table 10 steps 1 and 2 for power supply wiring details Set controller communication ports
180. ndant power your I O rack will contain a second smaller compartment see 1 in figure below 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 side of the smaller compartment see 1 in figure above See Table 10 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 10 steps 1 and 2 for details Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 64 Rack Installation Assemble I O Expansion Racks Step Procedure Comments References 3 Set scanner address for the I O rack using the Scanner Module DIP switches on SW3 shown at right For C50 C70 use address 1 4 For C70R use address 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 w Honeywell EN 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
181. necessary to run the cable through conduit On C70R connect cable from each CPU s RS 485 port to the Operator Interface See Operator Interface manual 5 1 52 25 108 for connection details Table 19 Parts needed to make RS 485 Cable Part Quantity Description 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 Ferrite cable clamps Supplied with the operator interface Nylon cable ties 047260 089037 1 10 terminal connector Supplied with the operator interface Phoenix 1840379 or 1 Connector 3 pin Supplied with the equivalent for C30 C50 controller CPU module Phoenix 1803581 for C70R Revision 16 HC900 Hybrid Controller Installation and User Guide 117 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software To establish communications between the HC900 controller and the Hybrid Control HC Designer configuration software use any of the following methods e A Direct Serial RS 232 connection See page 119 e B Modem connection See page 122 e C Direct Ethernet connection See page 133 e D Networked Ethernet connection See page 135 These methods are described below Attention
182. nector be sure to use a DB 25 to DB 9 modem cable The Null Modem cable used to directly connect a PC running Hybrid Control Designer software to the controller 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 123 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem configuration Before connecting a modem to the controller s RS 232 port marked CONFIGURATION the modem must be configured with the following settings Baud Rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller Parity None 1 stop bit 8 data bits No handshaking Ignore DTR Suppress result codes Suppress echo Auto answer 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
183. ned 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 375 000 375 000 375 000 375 000 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 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 Suppo
184. nevrarnennevsesvevravsenvevssnesnesvrsner 85 Figure 45 Analog Input Wiring Eight RTDS soeeorenrnorvrrvorvervrrvernernerversrevervevrenvevsrerenervssnernevsrsvevnevseveevsrnsenesvssner 86 Figure 46 Analog Input Wiring Slidewire Position Proportion Block rernrrvevrrnrnvevvrrnrvvrrnernevnrrvevrrerennevsenee 87 Figure 47 16 point High Level Analog Input Wiring esrovrrnvrvrrvrrnrevrnerrneevsrnernevnrrnervevsarvesnevsesvevravsenvevssnssnesvssner 88 Figure 48 4 channel Analog Output Wiring Diagram s eeorenrnoovennernrrvrrnernervrrnernernrrvervevrrsnesvevsesvevvevsesvevssvsenesvssner 89 Figure 49 8 channel Analog Output Wiring Diagram eeorvnrnoovernerneevrrnernervrrnernernrsverversrvvesvevservennevsesvevssveenesvrsner 90 Figure 50 16 channel Analog Output Wiring Diagram s serrvoovenvvrnorvrrnernevvrrnervevserverravsesvevravsenvevsnvsevvevssvvenasvrsner 90 Figure 51 DC Input Module Wiring Diagram esoevorvornovvrrnorvervrrnernernrrverveversvervevsrenerveveasnesvevsesvevnevsesvevssvesnasvrsner 92 Figure 52 DC Input Module Jumper ornnrnnnvnrnvnvenvrnnenvrrvenvevvannenveverevevravseneevssnseneevarvenneveasvevsavsenvevssneevsevssnesnaevrsner 93 Figure 53 32 point DC Input Module Wiring ernorvrrvvrvevvrrnnrvervrrnervernrrvernerearnevnerservernevrasnevnevsesvevnevsensevssneenesvrsner 94 Revision 16 HC900 Hybrid Controller Installation and User Guide ix 10 09 Figure 54 AC Input
185. nication e Connection to other PC hosts e Inter connection to other networks such as for sending Alarm Event messages via e mail GAUTION Communications lockout is possible in high network traffic conditions Revision 16 HC900 Hybrid Controller Installation and User Guide 26 10 09 Components and Architecture Ethernet Open Connectivity Network 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 Redundant Networks Honeywell 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 Hybrid Control Designer configuration software Redundant ports may be used in simplex mode non redundant Revision 16 HC900 Hybrid Controller Installation and User Guide 27 10 09 Components and Architecture Ethernet Open Connectivity Network 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 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
186. nnector Attention Always observe the wiring cabling guidelines on page 45 Step Procedure 1 Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled 2 Connect an Ethernet 10Base T crossover cable to the HC900 controllers Open Ethernet RJ 45 port top RJ 45 port 3 Connect the other end of the Ethernet 10Base T crossover cable to the PC s network port 4 On the PG use the Utilities Worksheet in the HC 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 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 133 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Step Procedure 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 Loopbac
187. nner Action User Action of Strobes 1 RAM or ROM failed diagnostics on Executes an infinite loop that toggles the LED 1 Cycle power power up Communications and module scanning are disabled Module outputs are in the power off s Replace scanner state DO outputs are off and AO outputs 3 Replace rack are at zero milliamps 4 Check grounding 5 Ensure system is properly isolated from noise Revision 16 HC900 Hybrid Controller Installation and User Guide 165 10 09 Diagnostics and Troubleshooting Scanner indicators 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 CPU were Aer relle en module eee 2 C7OR only Verify that the Possible causes include are TI ld ae Acar cen aA La ea CPU A cable is connected to was never established to the Scanner then the A port and the CPU B Scanner address switches are the module outputs are in the power off state ER cable is connected to the B not correctly set port on the Scanner 2 2 Ke port 3 If a switch is used check that all cables are properly Scamner 2 VOpor connected to the switch 3 Ifa switch is used there may p
188. nner 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 the new Scanner Module in the rack and secure it in place with the captured screws at top and bottom of the module 7 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 181 10 09 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing an I O Module A 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 th
189. nners 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 13 10 09 Components and Architecture Redundant components Table 2 Descriptions of Major Redundancy Components Figure 5 Key No Component Description Source Name 1 Controller Includes Rack 2 Power Supplies 2 C70R Honeywell Local Rack Controllers 1 Redundancy Switch Module RSM 2 I O Expansion Includes 1 Scanner 2 module 1 Power Supply Honeywell Rack and 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 Operator Optional link to RS 485 port on a Controller Honeywell Interface Module provides operating and utilities displays Includes buttons and optional AT keyboard interface 4 PC Optional PC laptop or desktop connects to PC is from third party Configuration RS 232 port on any one Controller module supplier Configuration Tool Includes Honeywell Hybrid Control Designer software is from configuration software Honeywell 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMIs o
190. nnnnrnnenrnnnnrnnennnnenrnnnuvnnernnenrnnennnnnuvenee 60 Assemble 1 0 Expansion Racks ct0nc02 ainda aina a dei 65 Revision 16 HC900 Hybrid Controller Installation and User Guide v 10 09 I O Module Installation and Wiring sornnvrrnnnnnnonnnrrnnnnnnnnnnvrrrnnnrnnnnvrenennrnrnnnrrennnnennnnnnnnnn 67 OVEIVIOW rat at le ka dann 67 Module Placement in RACKS niati rne raan aea Gaia ania Ga aaan AR AEEA aaa aa eaaa aani 67 Remote Termination Panel RTP heii a E 70 Terminal Block to Field Signal Wiring ecceecceeeeceeeeceeeeeeeeeeeeseeeeeeeeeeeeseaeeesaeeesaeeseaeeeseeeseeeseeeeneeeeeeee 70 Removal and Insertion Under Power RIUP rrrnvrnnnvrnnnvvnnnvvnnnvnnnnvnnnnvnnnnvnnnnvenennnnsnvennnvnsnnvennnrennnnnnsnnesnnnne 73 I O Module Installation Procedures masrvranvvnnnvnnnnvnnnnvvnnnvvnnnvnnnnvnnnnvnnenvnnnnnnnnnvenenvnnenvesnnvnsnnnnsennnssnnnssnnsssnnne 74 I O Terminal Block Wiring Diagrams rvnnnvvnnnnvnnnvvvnnvrnnnvnnnnvnnnnvnnsnvvnnnvnnnnvnnsnvenenvenervnnsnvesernensrnnsrrnnssnnsennnne 81 COMMUMEAHONS Installaatio suassessssrsersm ARGO Bab ane aks eae EAS 113 OE TE Eee 113 Wiringand Cablinga akse sa eee teg 113 Connecting the Operator Interface to the Controller arrnannvnnnnvnnnvrnnnrrnnnrrnnnvrnnnvrnnnvnnnnrnnnnrenenrnnsrnnernnnn 117 Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software rrnrnnrnnnnvnnnrnnnn 118 Connecting the HC900 Controller to Modbus device s
191. nput Module wiring is shown in Figure 54 Specifications for this module and for other modules are given in the Specifications section of this manual Revision 16 HC900 Hybrid Controller Installation and User Guide 93 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 style terminal blocks only for connecting digital common wiring at terminals 9 and 11 or terminals 10 and 12 See Figure 55 A WARNING A 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 Com 1 IN 1 8 C 1 niaL MG Go Com 2 In 9 16 In 9 16 DOOOADO Ok Legend External N Disconnect M User Supplied Safety Devices Figure 54 AC Input Module Wiring Diagram Revision 16 HC900 Hybrid Controller Installation and User Guide 94 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Input Jumper either 10 12 et or 9 11 to L2 N Figure 55 AC Input Module Jumper
192. ns with isolator RS 232 Modbus Connections Connect to the RX TX and ground pins of the controller s 3 pin RS 232 port See page 35 for RS 232 DIP switch settings Table 20 page 120 identifies the pins For connections on other device refer to its product manual For multiple devices on RS 232 use an approved RS 232 to RS 485 converter Use HC Designer software to configure the controller s RS 232 port as a master or slave Revision 16 HC900 Hybrid Controller Installation and User Guide 139 10 09 Operating Characteristics Introduction 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 151 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 continue 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
193. nt AC Digital Output 223 e 8 point Analog Output 227 Dual DI DO AO RTPs and cables are used with the following modules See page e 16 point Analog Output 230 e 16 point Analog Input 231 e 32 Point DC Digital Output 234 e 32 Point DC Digital Input 236 4 Point Analog Output Step 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 91 e Remove appropriate key tabs from terminal block to allow mating with the module See page 75 e Connect desired cable to AO module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal 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 71 2 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP Revision 16 HC900 Hybrid Controller Installation and User Guide 210 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 4 Point Analog Output Step Action 3 Set verify jumper positions as shown for use with an analog output module
194. ntroller Installation and User Guide 14 10 09 Components and Architecture Hardware Components 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 Figure 6 As indicated in this figure the Controller Rack includes 1 Rack available in 4 8 or 12 slot versions o pr r 2 Power Supply 3 Controller Module 4 Grounding bars for I O wiring optional 5 Input Output modules 6 I O Terminal Blocks v 89 OG I OQ 62 OQ 88 Q 38 Q Figure 6 Controller Rack Components HC900 Redundant Controller Rack A HC900 Redundant Controller is shown in Figure 7 1 Rack 2 Redundancy Switch Module RSM Interface between Lead Reserve controllers 3 Lead Reserve controllers Two C70R CPUs designated CPU A left CPU B right 4 Two Power Supplies Figure 7 Redundant Controller Rack Components Revision 16 HC900 Hybrid Controller Installation and User Guide 15 10 09 Components and Architecture Hardware Components I O Expansion Rack I 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 remo
195. ntroller communication ports Refer to Table 18 and the figure in Step 2 above Port availability depends on Controller model Table 18 Links to Controller Communication Ports Controller Link Type Cable Type To Device Port Port Controller to Connector Type RS 232 Desktop or RS 232 Null Modem Serial port of PC w Null For Wiring details of Null 3 plug Laptop PC cable up to 50 Modem cable Modem cable see Table connector Or 20 RS 232 PC modem or cable up tenon Modem Refer to RS 232 Remote Connection to PC Configuration Tool on page 121 RS 232 Modbus master RS 232 Null Modem Refer to device s port Page 37 Figure 24 amp 3 plug controller is cable up to 50 instructions Figure 25 2 7 9 connector single slave Or RS 232 PC modem cable up to 50 RS 232 to RS 485 converter RS 232 Modbus master RS 232 to RS 485 Refer to device s port Page 37 Figure 25 6 3 plug controller is one converter instructions connector of multiple slaves RS 232 Modbus slave RS 232 to RS 485 Refer to device s port Page 37 Figure 24 amp 3 plug network converter instructions Figure 25 4 5 8 connector controller is master RS 485 Operator Belden 9271 or Terminal connector of Page 37 Figure 24 amp 3 Plug interface equivalent operator interface Refer Figure 25 1 2 4 5 6 connector to Table 19 11 Connect from each CPU A and B to the Ol RS 485 Modbus master Belden 9271 or Refer to device s port Pa
196. ntroller performs in transitions between modes are described in Table 25 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 See the Hybrid Control Designer User Guide for precautions restrictions and procedures Revision 16 HC900 Hybrid Controller Installation and User Guide 143 10 09 Operating Characteristics Controller Modes OFFLINE Mode The OFFLINE Mode can be entered only from the RUN Mode and is intended primarily for performing AI calibration A A CAUTION Because 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 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 instruc
197. o 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 NiCroSil NiSil 0 1472 F N 321472 F 23 R 18 1704 C R 20 1760C 28 R 0 3100 F R 43200F 29 S 18 1704 C S 01600 C 30 Revision 16 HC900 Hybrid Controller Installation and User Guide 193 10 09 Specifications HC900 Analog Input Ranges vs UMC800 Analog Input ranges Type Range Range High EU Reference Corresponding Low UMC800 Input type and range S 0 3100 F S 322912F 31 T 184 371 C T 200 400 C 40 T 300 700 F T 328 752 F 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 44208 F 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 322516 F 119 Platinel 0 750 C PLTNL 70750 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 50 150 C 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 Cc Pt1000 50 400 C 120 Pt1000 40 500 F Pt1000 50 752 F 121 JIS100
198. o allow removal of the module from the rack without causing an arc See page 73 ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 226 for RTP internal schematic Revision 16 HC900 Hybrid Controller Installation and User Guide 217 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output Step Action 4 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 wire DC Supply Note DC Outputs provide electronic overload protection in the module but adding a fuse see picture protects the wiring 8 Point AC Digital Output Step Action 1 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired cable to 8 point AC DO module at controller Choose from 900RTC HO10 Remote Terminal High Voltage Cable assembly 1 0 meters long 900RTC HO25 Remote Terminal High
199. ocks are described in the HC900 Function Block Reference Guide 51 52 25 109 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 53 Rack Installation Overview 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 Tools Required The primary tools required during installation are listed in Table 7 Table 7 Installation Tools Item Description Comments Common tools 1 e Wire strippers For Power Supply and for I O Wiring 2 e Crimper For Terminal Lugs on Power Supply wiring and on I O wiring shields Screwdrivers 3 e Small flat tip For Euro style Terminal Blocks 4 e Small medium flat tip or Phillips For Barrier style Terminal blocks also for captured screws in Terminal Blocks 5 e Large long blade For use as I O Module extractor Other 6 e Electric drill with drill bits for 10 or M4 For rack mounting screws and with drill bit extender 7 e Vacuum cleaner brush For use during and after drilling operations 8 e Pen ball point or felt tip for entering data on For entering data on labels for I O modules labels for I O modules 9 e Multi Meter Volt Ohms Amps For safety checks and for equipment test 10 e Soldering pencil o
200. odbus Slave Figure 24 4 Controller is Modbus master to multiple ELN device slaves Figure 24 5 Controller is Modbus Master to single slave ELN device Figure 24 6 Controller is one of multiple Modbus slaves ELN device Figure 25 7 Controller is Modbus slave Controller is Modbus master to multiple slaves Figure 25 8 Controller is Modbus master to multiple Controller is Modbus slave slaves Figure 25 9 Controller is Modbus slave Controller is Modbus slave Figure 25 10 ELN device Controller is Modbus master to multiple slaves Figure 25 11 Controller is Modbus slave via modem ELN device Such as Honeywell HCDesigner configuration software running on a PC or Honeywell 1040 559 Operator Interface Requires RS 232 RS 485 converter Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 35 Components and Architecture Serial Ports RS 232 and RS 485 1 ELN and ELN 2 Modbus Slave and ELN 3 party HMI Modbus Master Modbus Slave protocol ELN protocol 3 ELN and Modbus Slave 4 Modbus Master and ELN ELN protocol ELN protocol 2000 Ft RS 23240 RS485 corwerter ELN protocol Modbus Master protocol Modbus Slave protocol 2000 Ft 3 party HMI Modbus Master ELN protocol 2000 Ft 5 Modbus Master and ELN 6 Modbus Slave and ELN 3 Party HMI Modbus Master Modbus RS 485 Slave RS 485 R5232 0 R5485 corwerter Modb
201. of the terminal blocks are universal that is any type of I O module can be used with either the Barrier 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 74 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 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
202. oller CPU indicators Table 27 LED Indications on Controller CPUs CPU Figure LED LED State Color Description model 79 item All 1 Controller Status Off No power models Solid Red Failed Blinking Yellow Failed Blinking Red Diagnostic Code refer to Table 28 Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode All RS 232 RS 485 models S1 port 2 XMT RCV Yellow Green Yellow when transmitting green when receiving All RS 232 RS 485 models S2 port 3 XMT RCV Yellow Green Yellow when transmitting green when receiving All E1 port models 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 C70R g 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 ee 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 16 HC900 Hybrid Controller Installation and User Guide 157 10 09 Diagnostics and Troubleshooting Controller CPU indicators Controller Status LED Diagnostic indicators When the Controller Status LED Figure 84 on page 158 item 1 is flashing red consult Table 28 WARNING AN Hazardous voltages exist in the e
203. om 56K Dualmode External Modem page 127 e Best Data 56SX Data Fax External Modem page 128 e SixNet VT MODEM Industrial External Modem page 129 3Com US Robotics 56K Data Fax External Modem Step Action 1 Ensure that the switches are set to the factory settings Switch 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 Y0 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 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 T
204. on and User Guide 47 Pre Installation Planning Electrical Considerations Grounding Barm gr tt14 AWG 2 1 mm FA L1 H Li ane Q Field a Wiring usunn i Shields 3 o o o F L1 H ein 0 oja L1 H L2 N PE Power Source Figure 32 Cabinet Wiring Multiple Chassis Revision 16 HC900 Hybrid Controller Installation and User Guide 48 10 09 Pre Installation Planning Electrical Considerations L1 H L2 N PE PE L2 N L1 H Power Source Power Source For PO1 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 Figure 33 Redundant power supplies each with external fuse and switch Revision 16 HC900 Hybrid Controller Installation and User Guide 49 10 09 Pre Installation Planning Electrical Considerations 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 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 Separate external wirin
205. ons 2 One private Ethernet 10Base 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 16 HC900 Hybrid Controller Installation and User Guide 21 10 09 Components and Architecture Hardware Components Scanner 2 Port Module C70R only SCANNER 2 PORT Input Output Modules The Scanner 2 Port Module is shown in Figure 15 The dual ports provide redundancy through the 2 CPUs Features at the front of the module include 1 2 I O module types LED status diagnostic indicator for scanner functions I O port A Private Ethernet 10Base T Port Connects directly to T O port on CPU A or indirectly through a switch I O port B Private Ethernet 10Base T Port Connects directly to T O port on CPU B or indirectly through a switch LED status diagnostic indicators for communications functions 16 point high level analog input module each point is configurable for V or mA Point to point isolation 4 point isolated analog output module Supports from 0 to 20mA each 8 or 16 point analog output module Supports from 0 to 20mA each Isolated in groups of 4 channels 16 point digital input modules Contact closure type DC voltage and AC voltage types 32 point digital input module DC voltage 8 point AC or 16 point
206. ontroller Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 126 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software 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 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 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 S0 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
207. ort Redundant controllers PC communicates with Lead Controller only NOTE For specific PC requirements and for specific software requirements refer to the Hybrid Control Designer Users Manual RS 232 Modem Devices The PC configuration tool connects from the RS 232 serial port of the Controller Module to a serial port on the PC Figure 17 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 Redundant controllers PC communicates with Lead controller only PC Configuration Tool Controller 5 PC Modem Cable Telephone Cable 5 P Telephone Cable al Figure 17 RS 232 Modem Devices Revision 16 HC900 Hybrid Controller Installation and User Guide 23 10 09 Components and Architecture Ethernet Devices Considerations Ethernet Devices Considerations Ethernet device requirements vary with specific applications Regarding intended use however 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 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 Components of th
208. ot 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 LD Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to protective earth at the 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 electrical 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 16 HC900 Hybrid Controller Installation and User Guide iv 10 09 Contents Symbo DEMONS eei kanna heaiears Ars dashes Amann dna an es iv Naliko lelei game E cme creep oe eerie ee 1 PUrPose rL ang TFT 1 Model Selection Guide una casi a Ven cee ates dived cde na ct eed dd aad diego dda cde evaded dias 2 Furetional Descriptohiraaau utradert eee Meme ate ied uel teats 6 Feature SUMMAN seer ceil cee zelcc cane E a eee ee FLERE 9 Components nd Architecture Lurer eksegeser Aase 10 OVEeNeN rn ee aS aent 10 COMpPONENIS Aisin dia hoe eee enti dia ties eteriske rase 10 Redundant Components mva dead edda
209. oth terminal block screws before applying field power to the module e Do not apply energized live field wiring to an input output module that 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 67 10 09 I O Module Installation and Wiring Module Placement in Racks Terminal Block Styles The terminal block is available in the barrier style shown at right Not shown a Euro style with 36 connections is also a 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 36 Terminal Block Styles The 20 pin inline connectors at the back
210. otherwise use default Refer to the HC900 Hybrid Control Designer 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 Lead CPU If using a single network connection during initial setup verify connection is made with the Lead CPU Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 132 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Two redundant systems with PC supervision OPC Server to PC Software EE TT 10 100 baseT Peer to Peer pm Data Exchange Controller Rack Ethernet Controller Up to Rack 100m 100 baseT Ethernet Switch Dy I O Rack Il EAU Po I O Rack I O Rack Figure 74 Two redundant systems with PC supervision 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 Crossover cable Host 10Base T Ethernet port RJ 45 co
211. out When the microprocessor 14 Ensure the system is properly display 9 Diagnostics e Address error completes its reset condition it will grounded ORA become an available reserve if a If the reserve s Overview dialog e Prefetch error lead is present or become a leadif 2 Ensure the system is properly status LED is box e Dataaborterror no lead is present isolated from external noise sources indicating the If the reserve s e Software interrupt This diagnostic will cause the 3 Upgrade the firmware failure see CPU in status LED is i HWOK pins of the AYSY and FSYS 4 Replace the CPU board the Reserve CPU indicating the e Undefined blocks to be tumed off 4 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 RAMI 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 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 turned off LED is indicating LED is indicating ie at the failure see the failure see sll upgrade is stil MEMORY inthe Memory Lead CPU Diagnostics in Diagnostics the Lead display
212. ower 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 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 C70R assumes Lead Incase 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 82 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 local 1042 or 449 operator interfaces 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 16 HC900 Hybrid Controller Installation and User Guide 150 10 09 Redundant Operating Charact
213. plies each with external fuse and SWitCh essornrrnovrnvnrnvrvvnvnrnvevravsevrevsrerensevsenee 50 Figure 34 Master Control Relay Wiring Fxample snonnorornvovrrnorvrnvrrnenvarnernevrrrvevravsrneevsrnervevsesvevnevsenvevsrnesvasvssner 53 Figure 35 I O Module Installation eerorvrrnorrronrvrnvrrnvrnrrnervevvarnervevrarnernevsrnvevsrereneevarnsrnevvarvennavseneevssneevsevssneeneevesner 67 Figure 36 Termin l Block Styl suss ansees kake ed 69 Figure 37 Signal Wire Grounding rvvevrnvrrnvevernvrnnnvrrnvrnevvrrnervervrrnernerearvesneveasvevnevsesvevsaveesvevsavsenvevssneevsevssnssnesvrsner 71 Figure 38 Wire Shield Grounding sieneen R AR DERRE 71 Figure 39 Terminal Block Jumper Installation eosoerorvorrorrrnvrvervrrnrevrrerrnrevrrnervevnrrnerverearnesvavsesvevravsensevsrnvenesvrsnee 72 Figtire40 RITD Inputs eree aeaa e ates s dan gne Auden ENE EARST EPEE ESE EEA EE EiS 81 Figure 41 Universal Analog Input Wiring Diagram esoevrrvornoovernrrnervrrvrrnervrrnervervrrvervevsrsvervevsesvernevsesvevsrveenervrsner 82 Figure 42 Examples of RTD Input Wiring seroornorrrvnrnvrvervvrvervrrvervarnerververnernevservevsavseneevsvereneevssvernevsevsevssneevasvrsner 83 Figure 43 Analog Input Wiring Fight TCs seroornrorrnvovererrrevsrnsrnervrrnsrnersrsvervevservevravsesvevsavsenvevsavseveevssnesnasvrsner 84 Figure 44 Analog Input Wiring Eight Resistance Inputs xssorrorrvrnvrrnvrvrrnvrnrevarnrr
214. power supply diagnostic and SUPPLY Supply 2 ASYS and FSYS blocks HW replace the defective supply DIAGNOSTICS in Diagnostics in OK pins are tumed off the associated Rack rack s Rack Diagnostics Diagnostics dialog box Overview display 80r9 If8 flashes the S1 1 ASYS and FSYS blocks HW 1 Check baud rate serial port is reporting a OK pins are tumed off gt Check connectors diagnostic 2 If configured as a Modbus 13 Check cable polarity If 9 flashes the S2 master Li eee cabina from elean serial portisreporinga asySandFSYSblocks nereng Y diagnostic Modbus Master Fail pins are FRE 200 DAS Possible causes are turned on 5 23 to 485 converter 5 f used check its power switch jumper e if the port is e Slave and read blocks settings and polarity configured as a associated with the slaves 6 ek ined asa Modbus master Modbus or ELN experiencing the failure have Cog z the slaves experiencing the free T 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 rity i e been invalid e COMM STATUS is set to BAD pa e Ifthe portis for all slaves experiencing the number of stop bits configured as a failure e for electrical interference eae at e The slaves with the data link e grounding least 75 of the last reques
215. pr i gt i o Y E ole PIT MO PAG Io 02 B C S CO oa 0009 08909089 a Use 3 5 5 5 5 5 5 5 D ne ke OD OD ne ne ne Sw9 g S S S S amp S S switch Red 1 0 Figure 92 Analog input terminals so OOOOOOO ve Note NSO You must set switches 1 8 for OOP OG OGPEGOPOPD GPO transmitters 25 26 Input 1 a Transmitter Input 3 Input 5 Input 2 Transmitter Input 4 Transmitter Input 6 Input 7 Transmitter Transmitter Transmitter ansmitter Input 8 Transmitter Figure 93 Two wire transmitter connections with common 24 VDC supply Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 201 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Sets OOG ee Fe O OBO JO OE OM amp DOOPLOOYH mA Input 7 mA Input 8 SG mA mA Input 1 mA Input 3 mA Input 5 m Input 2 Input 4 Input 6 Figure 94 Milliamp input connections with 250 ohm shunt resistance DOOS Note You must set switches 1 8 for Volts Millivolts Oi V mV V mV Input 1 V mV Input 3 Input 2 OOOOOOOOOOOOOOO oe separei iess G V mV Em Input7 V mV Input 8 Figure 95 Volt millivolt input connections Revision 16 HC900 Hybrid Controller Installation and User Guide 202 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog
216. procedures in this section Failure to comply could result in death or serious injury H ATTENTION For calibration procedures refer to the Operator Interface manual or Hybrid Control Designer manual Revision 16 HC900 Hybrid Controller Installation and User Guide 173 10 09 Analog Calibration Overview Analog Input Calibration Analog input modules can accommodate five input types RTD Thermocouple Ohms Volt milliVolt 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 Figure 87 is an adaptation of the wiring diagram given in the installation section of this manual This 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 be compensated in each individual thermocouple calibration cold junction calibration may be skipped Aft
217. ps Quantity based on available memory System Blocks Not user configurable 100 not part of 400 2000 or 5000 for Alarm Group blocks System 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
218. put 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 16 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 Out 1 1 12 0 13 1 PFQ 6 7 0 1 6 8 Revision 16 HC900 Hybrid Controller Installation and User Guide 43 10 09 Pre Installation Planning Cable Wiring Distance Planning 240 VAC mmnnnnnnnnnnmnnr 264 Vac mmmennnnr Number of ON Points 0 5 10 15 20 25 30 35 40 45 50 55 60 Temperature C gt Figure 29 AC Input Module de Rating N a a Number of 40 per Rack Oo 5 10 15 20 25 30 35 40 45 50 535 60 Temperature C Figure 30 Power Supply de Rating 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 Controller to Operator Interface 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 exce
219. quipment 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 28 Controller Status LED Diagnostics Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol 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 because the control are disabled C70R C70R 3 Replace power supply communication communication 4 Replace rack ports are disabled ports are disabled 5 Check grounding 6 Ensure system is properly isolated from noise 2 At least one function The block s output s is are forced to If it is not desirable to have forced See SYSTEMin See System block has 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 synchron
220. r each 4 slots in each rack e Wiring terminal lugs for connecting I O shields to grounding bars e 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 2 Install or verify correct installation of enclosures for HC900 Mount Racks Controllers and ancillary equipment Table 9 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 55 10 09 Rack Installation Overview Step Procedure Reference 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 67 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 56 10 09 Rack Installation Mo unt Racks Mount Racks Rack assembly information is given in Table 9 Table 9 Mount Racks Step Procedure Comments References
221. r gun for attaching filter For attaching filter capacitors on I O wiring capacitors to I O wiring shields shields Special tools 11 e Precision meters If required for testing Analog calibration refer to Analog Calibration in this manual Revision 16 HC900 Hybrid Controller Installation and User Guide 54 10 09 Rack Installation Overview Equipment Preparation A checklist for site preparation is given in Table 8 Table 8 Site and Equipment Preparation Step Procedure Reference 1 Verify that sufficient numbers of the following items are on e Section on Pre Installation hand Planning e Racks 4 8 and 12 slot e Sections on installation e Power Supplies 1 per rack e C30 C50 C70 Controller Module or Scanner 1 port 1 per rack e Redundancy Each Controller Rack 2 Power Supplies 2 C70R 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 e I O Modules correct type for each configured slot e Terminal Blocks Barrier or Euro style 1 for each I O Module e Jumpers 2 position or 10 position for designated Terminal Blocks e Tie Wraps 1 or 2 for each Terminal Block e I O Label one per terminal block by module type e Filler Block Cover 1 for each slot not occupied by an I O Module e Blank label 1 for each Filler Block Cover e Grounding Bars for I O wiring shields 1 or 2 fo
222. r port Principal Function Block Address Range Up to two One User selectable starting address range for registers assigned to each principal block type RS 232 RS 485 Modbus Master Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus One RS232 or 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 Parameters Double Register Format Selectable per device Speed 1 second fastest load dependent Modbus Master Advanced Application Recommended for use with gateway devices Speed As fast as 500ms Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 190 Specifications General Specifications Communications C30 C50 C70 C70R Ethernet Modbus TCP Initiator Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus One Models C30 and C50 Two Models C70 and C70R RS232 or 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 num
223. rations PLAN AHEAD Battery Installation Procedures Table 40 Installing Backup Battery CPU not initialized Step Action 1 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 185 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Replacement Procedures Table 41 Replacing a Backup Battery CPU Powered Step Action 1
224. renevrevsrnvevsrnsrneevsrnsevervrrnsenervrrvesnesvssnee 131 Table 22 Redundant network connections sresrarnrnrnnvernerrrrrrenreensenneenenerervresnrsnraenesenesnnnenseseensensssnesenesereensessesnne 131 Table 23 Controller Operating Modes ssnennnvvrnvnvvnvnnnnevenvrvreverenevnevsrneevarereneevsrreneevssvennervasvesnasvrsvsenesvrsvesnesessner 146 Table 24 Mode Switch Functions eononenonornonrenrnenrneneseneenvnennnsreensennesnenenenvnesnresrsensssnesnnesnresnenssesnrennesnensneseresnsenne 147 Table 25 Controller Behavior in Mode Transition eeneenenvnnrvrrnnrennreneneneenreerrerreenseensenenenenereesresnrennesnenenessresnsesne 148 Table 26 Configuration file downloading errrvvrrvrvrnvnevravrrnvevererrnnevsrnernervrsneenervrrnernaresrvernaresevesvavvsrvesravvernessenser 150 Table 27 LED Indications on Controller CPUS rennnvernorvrrnernevnnrvernavnrrvevrarnervevrarvevrevsenversreseveevsrerenesvssvesnesessner 159 Table 28 Controller Status LED Diagnostics rsvovrrnvrvrrvrrnvevenvrrnrevsrnernervsrvernervarvevnevesvesnarvenvevravsenvevsasvevvevseneer 160 Table 29 LED Indications on Scanner Module sseenvnrnnrrrnnnrnrrenreeneennnennneneenresraenseensennnensesvnssresnrennssnensnessresnsenne 166 Table 302 Scanner LED Diagnostics kasse eae aE Re eee dett 167 Table 31 LED Indications on I O Module srenrernvnrnnrennerrrrrnenrreneennnenenennenresnrsnrnsnesenesnsnensessesnsennssnessnesereensessssn
225. rk connections Step Procedure 1 Make sure the PC has 2 Ethernet NICs Network Interface Cards installed and enabled 2 Connect Ethernet 10Base 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 HC Designer software to connect to the controller over Ethernet Every HC900 C70R controller is shipped with the default IP addresses for port E1 192 168 1 254 and port E2 192 168 2 254 Default 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 Revision 16 HC900 Hybrid Controller Installation and User Guide 131 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Step Procedure 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 th
226. roper 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 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 7 Cycle power to the switch Cycle power to the controller CPU 9 Replace the expansion rack s scanner module 10 Ensure that the Scanner and 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 grounded e Prefetch error 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 4 Replace scanner module Contact Honeywell Personnel 3 One of the exception vectors The vector
227. rt 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 16 10 09 HC900 Hybrid Controller Installation and User Guide 196 Specifications Fiber Optics Recommendations Fiber Optics Recommendations Honeywell recommends that you use the following equipment for extended distances Table 44 Fiber Optics Equipment Recommendations 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 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 Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet FO Connector SC Type Figure 89 and Figure 90 are examples of Extended Distance configurations Moxa Switch 10100 EDS 308 MM SC 10 100 HC900 Copper Main Rack Copper PP Rack 1 Fiber Cable Distance 750M 10 100 Fiber Cable i Cc Distance 750M opper Moxa Media Converter IMC 101 M SC Moxa Switch 10 100 EDS 308 MM SC Copper As a Repeater Fiber Cable Distance 750M Moxa Media Converter IMC 101 M SC Figure 89 Extended Di
228. s 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 61 Table 35 Power Supply Replacement all except C70R Step Action 1 ATTENTION This procedure does not apply to C70R 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 16 HC900 Hybrid Controller Installation and User Guide 178 10 09 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Step Action 6 Secure the lugs for
229. 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 16 HC900 Hybrid Controller Installation and User Guide 51 10 09 Pre Installation Planning Electrical Considerations L2 Power Supply in HC900 Controller Rack Power Supply in HC900 e Multiple I O Expansion Racks Power Supply in HC900 I O Expansion Rack Power Emergency Power ON Sto OFF o Or e 2 Q Q Input Modules Input Sensor p Q sleIelelelelelelele eIeISI0ISI TGIGIGJG Ee Le ele 1ele1 JOO ODOOOOT Ez Output Modules Figure 34 Master Control Relay Wiring Example Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 52 Pre Installation Planning System Monitor Function Blocks 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 These function bl
230. s are intended for permanent installation within their own enclosure ATTENTION 16 point DC Digital 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 91 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired cable to 16 point DC DO module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 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 71 Revision 16 HC900 Hybrid Controller Installation and User Guide 216 10 09 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output Step Action 2 Mount RTP to DIN rail e Latch to rail See page 241 e Connect cable to RTP 3 Set verify jumper positions as shown EE Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 t
231. ss of 100 meters and or devices other than recommended Switches will cause transmission delays that 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 repeater at the midpoint See page 200 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 44 Pre Installation Planning Cable Wiring Distance Planning 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 200 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 How to make Ethernet cables Ethernet cable shielded Cat 5 contains 4 twisted pairs of wires and a drain wire Each pair consists of a solid color wire and a color wire wi
232. stance Example 1 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Specifications Fiber Optics Recommendations Moxa Switch Moxa Switch EDS 308 MM SC 10 100 Fhc300r 110100 EDS 308 MM 5C i Copper z pp Copper Copper VO Rack 1 10 100 10 100 Copper HC900R Copper WO Rack 2 Moxa Media Moxa Media Converter 10100 10 100 Converter IMC 101 M SC Copper HC900R Copper IMC 101 M SC WO Rack 3 10 100 HC900R Copper VO Rack 4 Fiber Cable Distance 750M Fiber Cable Distance 750M 10 100 Copper Moxa Switch EDS 308 MM SC As a Repeater Moxa Switch EDS 308 MM SC As a Repeater Moxa Media Moxa Media Fiber Cable Converter 10 100 Converter Fiber Cable Distance 750M IMC 101 M SC HC900R Copper IMC 101 M SC Distance 750M WO Rack 5 Figure 90 Extended Distance Example 2 Revision 16 HC900 Hybrid Controller Installation and User Guide 198 10 09 Appendix Installation of Remote Termination Panels RTPs Overview 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
233. ster baud rates Refer to the HC900 Hybrid Control Designer 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 RV i mn Q Statistics Loop Back Protocol Honeywell Inc ELN Speed bps 38400 PC Port Setup m Network COM 6 On the PG use the Utilities Worksheet in the HC Designer software to select the Com port as the current port Revision 16 HC900 Hybrid Controller Installation and User Guide 119 10 09 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software RS 232 Direct Link to PC Configuration Tool 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 20 Table 20 Null Modem Cable Connections 9 pin D female connector 3 plug connector 9 a 5 4 8 3 7 6 a 2 1 Signal Name Pin No Connection Signal Name Plug No DCD 1 None RXD 2 Connects to TXD 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 Revision
234. tallation and User Guide 71 10 09 I O Module Installation and Wiring Removal and Insertion Under Power RIUP Removal and Insertion Under Power RIUP WARNING 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 power 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 14 provides some general guidelines for establishing appropriate procedures at a given installation
235. talling communications systems and components Communications Installation Wiring and cabling Table 17 Connect Communications Wiring and Cabling Step Procedure Comments Reference 1 Determine requirements for communications links See e Ethernet Devices Considerations on page 24 e Serial Ports RS 232 and RS 485 on page 34 e Cabling Wiring Distance Planning on page 45 2 Refer to the diagram at right and to Table 18 RS232 RS485 connectors Links to Controller top to bottom Communication Ports for en connection details TXIRX S2 RS 485 port All ports are shown To Operator Interface S1 RS 232 To PC Configuration Tool Availability depends on ras nnrmmnangess omme Jh mm nd controller model see Figure 12 p 20 E1 To PC applications Or peer HC900 controllers p Connect communications E2 To PC applications cabling or peer HC900 controllers A ree For Modbus connections To single I O Rack or hub see page 137 1 BOF Moe D Communication Ports all ports shown Revision 16 HC900 Hybrid Controller Installation and User Guide 113 10 09 Communications Installation Wiring and cabling Step Procedure Comments Reference 3 Set IP addresses and Default IP addresses subnet masks different subnets C30 C50 192 168 1 254 and Subnet Mask of 255 255 255 0 C70 C70R E1 192 168 1 254 E2 192 168 2 254 Must be on Links to co
236. te from the controller For C7OR all I O is in a rack or racks separate from the controller rack An I O expansion rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3 Scanner 1 Module C50 C70 shown or Scanner 2 Module C70R 4 Grounding bars for I O wiring optional 5 Input Output modules 6 I O Terminal Blocks 7 Power Status Module PSM req d if using Reserve Power Supply 8 Reserve Power Za optional 8 Available in 8 or 12 slot racks Figure 8 I O Expansion Rack Components Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Components and Architecture Hardware Components Rack Options 41 0 Racks are available in 4 slot 8 slot and 12 Slot versions Racks are interc interclfanges interclfangeab l the Controller rack and an I O expansion rack C50 C70 C7OR CPU only and alfithree versions shown in Figure 9 are available for either purpose i C7OR only I O rack has Scanner 2 Module 8 and 12 slot I O racks can be modified with additional slots for optional Reserve Power Supply and Power Status Module oo O n o a Note You can install redundant power on any T O rack fannnmmmm Scanner Module Slot L Power Supply Slot h mmmmmm Power Status Module req d if using Reserve Power Supply eldes Optional Reserve Power Supply Figure 9 Rack Options Revision 1
237. ted 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 always 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 replac
238. tends height to 6 9 175 3mm 6 4 162 6 for 32 DI DO and 16 Al Modules I 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 installed 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 installed external fuse Normal Scan Time 500ms Each analog input card has its own A D converter providing parallel processing Fast Scan Time 53ms for up to 250 27ms for up to 250 27ms for up to 330 5
239. th a white stripe 1 Hold the cable ends and RJ45 connectors side by side as shown 2 For straight through cable arrange wires as shown in the following table Wires go straight through no crossovers 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 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 45 Pre Installation Planning Electrical Considerations 3 For crossover cable arrange wires as shown in the following table TX and RX pairs are crossed Crossover cable assembly Cable left end 10Base T 100Base T Cable right end Left to right Signal Description Left to right Wire color pin number Wire color pin number white orange 1 TX white green 1 Orange 2 Tx Green 2 white green 3 Rx white orange 3 Blue 4 Unused Blue 4 white blue 5 Unused white blue 5 Green 6 Rx Orange 6 white brown 7 Unused white brown 7 Brown 8 Unused Brown 8 4 Crimp an RJ45 connector to each cable end To ensure reliability do not untwist the pairs any more
240. the faceplate I O will be installed later See Page 67 Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 65 I O Module Installation and Wiring Overview I O Module Installation and Wiring Overview This section contains descriptions of and procedures for installing I O Modules in controller racks all CPU models and in I O expansion racks C50 C70 C70R CPU only Module Placement in Racks Each input or output module is placed in an I O slot in a rack as shown in Figure 35 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 ga 4 x 5 Pin connector to Backplane omen 1 x 20 or 2 x 18 F Pin connector to Terminal Block A Label OQSSOQLSSSSSSBSSSSD an Figure 35 I O Module Installation WARNING A 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 b
241. the UMC800 These differences are indicated in Table 42 in the column identified Reference Corresponding UMC800 Input type and range The number to the right of the range data indicates the range number reference for the UMC800 range table When using the Hybrid Control Designer configuration software to convert UMC800 configuration files to HC900 configuration files the HC900 range to the left of the UMC800 data will be used by the conversion program There may also be UMC800 ranges that are not supported by the HC900 Controller For these ranges the conversion process will default the range data to a null not programmed range Table 42 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 322552 F 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 32 2552F 111 NiM
242. ther HC900 Controllers and supplier Interface other networks including Internet f HMI software is Typically includes HMI operating software available from i i Honeywell PlantScape May also include Hybrid Control Designer or SpecView32 or configuration tool and utility software from third party supplier 6 Ethernet Required if using 2 or more I O Expansion racks Honeywell 100Base T Provides connection of the I O Ethernet 100Base T Switch port on a Controller Module to the Scanner modules Switch not required for connection to a single I O rack 6a Ethernet Enables inter connection of several 10 100Base T Honeywell or third 10 100Base T Ethernet devices in an Ethernet network Devices party suppliers Switch or include other HC900 Controllers HMIs and can Router also include routers brouters servers and other devices in wider networks 7 Ethernet CAT5 Connects I O expansion racks to controllers and or Third party suppliers or shielded cable to 10 100baseT Ethernet switches Honeywell Fiber Optics Controller to remote rack distance up to 750m Cable 2460 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 RS 485 cable Belden 9271 or equivalent up to 2000 601m Third party suppliers 9 RS 232 cable Null modem cable up to 50 15 24m PC modem Third party suppliers or cable if used with Modems Honeywell Revision 16 HC900 Hybrid Co
243. tions may result in product damage Revision 16 HC900 Hybrid Controller Installation and User Guide 144 10 09 Operating Characteristics Controller Modes Table 23 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 Status LEDs on I O modules Other functions NOT permitted e Al calibration e AO calibration PROGRAM I O scanning Controller and expansion Racks C50 CPU only 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 loc
244. tocol 31 Site and Equipment Preparation 55 SMTP 31 sockets 29 Specifications 187 SpecView32 30 Status 140 Subnet Mask 28 System Monitor Function Blocks 53 tagnames 73 TCP IP 29 telephone links 23 terminal block 67 Terminal Block Colors 68 Terminal Block Styles 68 test points 60 The Fix 30 transmission delays 44 U UDP 28 Universal Analog Input Wiring 81 87 User Datagram Protocol 28 V Vertical Spacing of Racks 42 Voltage test points 18 WAN 28 Warm Start 140 Wire Gage 69 wire size 69 wire tie 78 79 Wiring Rules 69 XYR 5000 139 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Revision 16 HC900 Hybrid Controller Installation and User Guide 242 10 09 Sales and Service or application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below Asia Pacific Global Technical Support Field Instruments Phone 65 6580 3156 Fax 65 6445 3033 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 Beijing Honeywell China Inc Phone 86 10 8458 3280 Fax 86 10 8458 4650 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 China PRC Chengdu Honeywell China Inc Phone 86 28 6613 5078 Fax 86 28 8678 7061
245. ts ke eske ene 166 VO Module INGiCAtOrs aecenas aOR RREA NTETE E EET E AETA 171 Ethernet Switchindi atorsi Sain aA R E a bin est EA AAE caus E T neues 174 Revision 16 HC900 Hybrid Controller Installation and User Guide vi 10 09 Analog CIDR ANON ssc ate haa eee Senere 175 D E PEE E E EE AAEE EE a i a ke ool a eae ea 175 Removal and Replacement Procedures rarrrnnvnnnnnnnnnnnnvnnnnnnnnnnvnnnnenarnnnnennnnnnnnnnnnene 179 OVESEN aure EEG 179 Safety Considerations PLAN AHEAD l mnnnrnnnvvnnnvvnnnvrnnnrrnnnrrnenrnnsnrnnenvnnennenenrnnenrnennrnsnnrnsnrnnsnransennennesnennn 179 Specifications eder deres sanset teie see 190 General Speciicathons ram sspakekek elg c ia cededn apeacedcdapecded ncdgen a kind 190 HC900 Analog Input Ranges vs UMC800 Analog Input ranges srrenrrnenrrnrnrnnrnrnnrnrnrrnrnrenrnrnnrnrnnrnrnnrernn 196 System Sizing and Availability Summary eoonrnnnnvnnnnvnnnnrnnnvrnnnrrnnnnrnnnrrnnnrrnnnrnnsnrnnenrrnsnennsnrnnenrerenrnnsnresnvnnnn 199 Fiber Optics Recommendations e cresen aria a E E E ET A 200 Appendix Installation of Remote Termination Panels RTPS rrrrernvrnrnnnnnrnrnnnnrnnnnnnnn 203 ONION a a E uate ee ee Ane AE T 203 Analog Mputa N E E E eels 204 Relay OUTOU a a E Gale A AAN E AREATA ear Ge 211 Analog Input Digital Input Digital Output Analog Output rasvvrrnvvrrnvrrnnvrnnnrrrnnrrnnnrnnnrrnnnnrnnrrrnnnrrnnnrnnneenn 215 Lateh Unlateh RTP to rav un evuvsavsersmivcvmnmnnenmnnvannndnd
246. ts to a E Zero dala e _ termination resistor if at end particular slave Ted EN of ink resulted in no p ee r r s The diagnostic is cleared by response or a reply dn ond clearing the port s statistics that failed the data re NE link protocol The UART failed its See above Replace CPU module power up tests Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 162 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell OI HCDesigner HC of Red Action s Indication Utilities Indication Strobes 10 Ethernet port tests 1 E1 or E2 port diagnostic is set Replace CPU module If the lead s status If the lead s status failed during power up toe FAILED LED is indicating LED is indicating ini the failure see the failure see T e NE NETWORK Lead Port Et PORT E1 or Network Port NETWORK Diagnostics or PORT E2inthe Lead Port E2 Lead CPU Network Port Diagnostics Diagnostics in display the Lead If the reserve s Diagnostics status LED is Overview dialog indicatingthe box failure see If the reserve s NETWORK status LED is PORT E1 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
247. unications with HC900 peers Lead Controller handles communications with Modbus RTU slave devices Lead and Reserve exchange system status data to determine conditions for failover I O Scanners relay system status data between each Controller to determine conditions for failover Revision 16 10 09 HC900 Hybrid Controller Installation and User Guide 151 Redundant Operating Characteristics Steady State Operations 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 maximum scan time is 500ms for analog data types and 53ms for logic data types Execution sequence 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 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
248. us Master protocol Modbus Slave protocol Figure 24 Serial Port Configurations 1 6 ELN protocol 2000 Ft ELN protocol 2000 Ft Revision 16 HC900 Hybrid Controller Installation and User Guide 36 10 09 Components and Architecture Serial Ports RS 232 and RS 485 7 Modbus Slave and Modbus Master 8 Modbus Master and Modbus Slave Modbus 3 party HMI RS 485 Modbus Master R5232 40 R5485 corverter Modbus Slave protocol Modbus Slaves Modbus Master protocol 2000 Ft DAKUS protocol Modbus Slave aes 3 party HMI Modbus Master 9 Modbus Slave and Modbus Slave 10 ELN and Modbus Master RS 485 I ELN protocol 3 party HMI RS 485 Modbus Master Modbus Slave protocol Modbus Slaves Modbus Slave protocol 3m party HMI Modbus Master 2000 Ft Modbus Master protocol 2000 Ft 11 PC Application for Dial Out Function Modbs Slave SixNet Modem ELN S1 RS 485 iar ELN Slave or Modbus Slave protocol ELN protocol Figure 25 Serial Port Configurations 7 11 See also Refer to Communications Installation on page 113 for details on communications Revision 16 HC900 Hybrid Controller Installation and User Guide 37 10 09 Pre Installation Planning Overview Pre Installation Planning Overview Methodical pre planning of an installation will preclude false starts and errors that can cause costly hardware re configuratio
249. vesnesessner 138 Figure 77 XYR 5000 RS 485 Modbus connections with isolator rsrevrrvrrvrrnrrnrvvrrnrrnrvvrrnrrnevvrrnsenevververnernssnee 139 Figure 78 Warm Start Operation savanne andet 142 Figure 79 Cold Start Operation ciiir osi E EE EEE Eaa Eei 143 Figure 80 Mode Switches Controller left RSM right rrennronrnonnvonnovrnerrrrrrnnrenrnennseneernnersersernrenrseneneneneresnreee 147 Figure 81 Pathways for Upload Download Transactions ernrevernornrvnrrnnvnernervevrannervevsenvevsrereneevsensenesvarvesvesessner 149 Figure 82 Modes of operation On RSM ensnrrvrnnnnvenrnvevrrrvervevernvevernsrneevrsnesnervenvevravvevrevseneevssnsenesessnsenesvasvesnesessner 152 Figure 83 Lead Controller synchronization ssernovvrnnennavnrrvevravnenvevrrnennevrrevevrevsrnvevrevsenvevsrvrenesvrsvennesvasvesnesessnee 154 Figure 84 LED Indicators on Controller CPUs See Table 27 rrnnnnnnnrrnnnrrnrrnenrnennennnennernnsrrernrerrneneneneenseenserne 158 Figure 85 LED Indicators on Scanners 1 port left 2 port right See Table 29 rsnnornnnrrnnrenrrrnnrnenererrrernr 166 Figure 86 I O Module LED indicators evervrrnorvorvervrvrrrvervevrrnvevererenervarnervarsesvenarvevvevsrsvevsrsreneevssnsenesvasvesnesessner 171 Figure 87 Terminal Board Connections for AI Calibration esrrnvrvrrvrrnvrvervrrvernrrnerveverrverrevservevsrereneevsrnrenernssner 177 Figure 88 Terminal board Connections for
250. vevravsevnevsrneeneevesner 60 Table 11 Assemble C7OR Controller Rack serrnvrnrrvrrnvovrrnvrnrevennennevnrrnerveverrnennerservevravservevravseneevssneeneevsrnesnesvrsner 63 Table 12 Assemble I O Expansion Racks esnrvrrnvrvrrerrvvevernvrnrevernrrnervrrnsrnervrrnervervarververeavvesnevsenvevsavsevsevsenesnasvrsnee 65 Table 13 Minimum Recommended Wire Sizes ecceecseseesscesseceececeeceeceseceseesacesececeeeeeecseeesecseceaeeeeeeaeeneeereentes 70 Table 14 RIUP Potential Hazards and Recommended Actions cecccesessesseeseeeseeeeceeceeeeeeecaeeeaeeaeceeeeeeeeeeaees 73 Table 15 Connect Input Output Witing pr eiin eR ER RA A E R Res 74 Table 16 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F rmrnvrnrrvrrnrvvrrnervavnrnversenne 81 Table 17 Connect Communications Wiring and Cabling soervorvrnvrvrrvnrnvnvrrenerrevrrnvevrevsrnversrereneevsrnseneevrrvessernssner 113 Table 18 Links to Controller Communication Ports eonorvrrvornrvnrrnevrnvnenvrvrrenevravernnevsrnrrneevsrnsenervrsnseneevrsvesnesvssner 114 Table 19 Parts needed to make RS 485 Cable snnnnnnornnnnnrnovrrenevravrenrevernernervrrvervanvervevserversvrenervrsvernasvrsvesnesessner 117 Table 20 Null Modem Cable Connections srsvovvavnrnvrvervvrvravenenevnavsrnvevarereneevarvreneevarnsrneevasnsenesvasvennasvasvesnesessner 120 Table 21 Redundant Network connections in Figure 73 esvorvnvnrnnrvrnvnenvrvr
251. vravnrrvevrarnerrevsenvevsrereneevrrnsenervrrnesvesessnee 209 Figure 99 Voltage input connections rnrrnrvvarnnv ravner vevrrnvevrrnerneevernernernarvevsarsenvevsenvevrevssneevssvesnesvasnsenesvasvesnesessner 233 Figure 100 Current connections with 2 wire transmitter rsernrrnvrvrrvrrnvrvrnvrrnvrvrrnrrneevrrnsrneevsrnsenervrrnennervrrvesnesessnee 233 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 Purpose Introduction This publication describes the installation operation and maintenance of the Honeywell HC900 Hybrid 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 10 Functional features and physical characteristics of the system and of each major Architecture component of the HC900 Hybrid Controller Networking components and methods of interconnection Pre Installation 39 Pre planning considerations and procedural guidelines for planning an installation Planning Rack Installation 55 Procedures for installing the major components of the system controller rack I O expansion racks and communication interconnections I O Module 67 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 bloc
252. vssner 33 Figure 22 Controller Serial Ports uass asqraresrr steke 34 Figure 23 Serial Ports DIP Switch default settings servorrronrrrnvrrnvrrrnerrnrevrrnvrnevnrvnervevnarnennevsenvevravsensevsrnsenesvasnee 35 Figure 24 Serial Port Configurations 1 6 esrrerrnarvrrnvrnevvrrnnnnevvrrnervernarvesnererrvevvevsenvevsrerenvevsssreneevssneeneevssnesnesvasner 37 Figure 25 Serial Port Configurations 7 i a aE EEE ER E R A RN REA 38 Figure 26 Rack Dimensions C30 and C50 esnrennvrnenenerernnrresrnenreeneennneneenrennrssrssnssenssnnesnnnsrnnsresnrennssnesenesnsesnessrene 41 Figure 27 Rack Dimensions with reserve power SUPDPLY cscsesceecceecceeceteeeceseceseeeeececeeesaecseeeseceaeeaeeeaeeeereenees 42 Figure 28 Vertical Spacing of Racks all models srrnvrnrnnrrnvrvenvrrnrnvrrnernervrrnervevnrrnenvevservevravsenvevsrerevsevsrnesnesvssner 43 Figure 29 AC Input Module de Rating sovvovorvornorvrrnrrvevvrrnerververnervernrrnerversrrnevnevservevsavsesvevsavsenvevssvsensevsenssnasvrsnee 45 Figure 30 Power Supply de Rating e e ced nond Hans etsy Bie HA en Se eee 45 Figure 31 Cabinet Wiring Single Chassis ssenrnvovervrrnvnvrrvrrnrevernernervrrnsrnervrsnernevservevraveesnevsavsenvevssneeneevssnesnesvrsner 48 Figure 32 Cabinet Wiring Multiple Chassis eoronorrnvrrnrevrrnvrnrevernernervrrnsrvervrrnernevvarnerveveesvevsavsenvevsresensevssnsenesvrsner 49 Figure 33 Redundant power sup
253. wer 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 A 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 98 Revision 16 HC900 Hybrid Controller Installation and User Guide 10 09 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Output OUT 1 v OUT 2 OrnO OUT 1 DO KV um 2 OUT 2 D OUT 4 IG ours INO hin O OUT 4 D mg OUT 5 pz i BE da OUT 7 E EA OUT 7 Pe OUT 8 8 OUT 8 I V1 mg iya as Pp COM 1 Out 148 GO com 2 Out 1 mr V2 IG v2 rap ss lg con ons a pm OUT9 7 OUT 9 ER Q ONO ms ee re OUT 10 3 14 OUT 10 gt ourad a 15 OUT 11 lt MND o os 1 OUT 12 lo OUT 12 Ezi D KON JIN 780 roet Bari ei OUT 13 BE F O OUT 14 BB 24 Vee gt our 14 ale ONO oe oO OUT 15 19 OUT 15 HET ee EEE 20 OUT 16 EG OUT 16 Legend External r Fuse o Disconnect va N Fil L no User Supplied Safety Devices Figure 57 DC Output Module Wiring Diagram Revision 16 HC900 Hybrid Controller Installation and User Guide 99 10 09 I O Module Installation and Wiring I O Terminal Block Wir
254. which can service data requests from any networked PC on a client host server controller basis C70R has 10 sockets 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 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 Hybrid Control Designer 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 which 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
255. 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 16 HC900 Hybrid Controller Installation and User Guide 30 10 09 Components and Architecture Ethernet Open Connectivity Network 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 19 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 wanted messages and denying passage of all others The feature that gives the Router its nam
256. ybrid Controller Installation and User Guide 40 10 09 Pre Installation Planning Rack Orientation and Mounting Total Depth 1 Dett E E E RT de ee ee ee Se 1n ZN 6 0 mounting I y rs 8 Slot Controller Rack VO Ra O Rack CPUs RSM Power Supplies height height WO Racks only 5 a 25 9 mm 684 Reference Center for Drilled Holes X at Top of Rack D Figure 27 Rack Dimensions with reserve power supply Revision 16 HC900 Hybrid Controller Installation and User Guide 41 10 09 Pre Installation Planning Remote Termination Panels 6 90 175 IR Key inches mm 6 90 175 6 90 175 Figure 28 Vertical Spacing of Racks all models 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 203 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 Operator Interface 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

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