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Honeywell HC900 Process Controller Installation and User Guide

1. Specification C30 C50 C70 C75 Combined Analog and Digital I O 384 points 1920 points 1920 points 1920 points Analog Inputs 142 points 960 points 960 points 960 points Analog Outputs 40 points 200 points 200 points 200 points Block inputs Quantity based on available memory Block parameters Quantity based on available memory Block values 375 000 375 000 375 000 375 000 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 a
2. Number Possible Cause Scanner Action User Action of Strobes 3 One of the following Scanner restarts The main CPU detects that Cycling power to the scanner will microprocessor exceptions the Scanner restarted and places the clear the diagnostic occurred Scanner back into the scan mode If the problem reoccurs try the e Watchdog timer timeout following e Address error 1 Ensure the system is properly rounded e Prefetch error 2 Ensure the system is properly e Data abort error isolated from external noise e Software interrupt sources e Undefined instruction error Upgrade scanner firmware Replace scanner module Contact Honeywell Personnel 3 One of the exception vectors The vector is restored to the proper value and located in RAM became corrupted the Scanner continues to operate normally 4 Flash failed to burn properly when The boot code is the only software running Perform a code download the firmware was being upgraded This software waits for a request to burn the flash It does no scanning of modules Module outputs remain in their off state 5 C75 only The communications C75 only This problem may cause on C75 only ba the reserve is failing for the demand failover attempts to be unsuccessful 1 Verify that the CPU A cable is QHOWING TEAS ONS connected to the A port and 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 re
3. eae te SEE arya Ey ere Ey ee 20 JO 7 B 22 E N ee N D a Ease e 5 33 4 lt a M N y ord 34 5 ct ct ct ct ey 27 13 C wi 28 12 a z 7 29 11 i E 32 3 E a 31 2 E T 30 1 an en o afl a 36 15 pea L aa 35 14 rT cons J Latch U 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 244 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output DIN rail To remove using slot screwdriver to lift C up gently plastic is fragile to disengage at B Lift up and over rail then disengage at A Revision 18 HC900 Process Controller Installation and User Guide 245 02 14 Declaration of Conformity Analog Input Digital Input Digital Output Analog Output Declaration of Conformity Honeywell 51452401 Revision E DECLARATION OF CONFORMITY CE 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 900C32 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 re
4. 16 Point DC Digital Input EA 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 92 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 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DI module label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 2 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP 222 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Input 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
5. Karan O oO Moa O O Revision 18 HC900 Process Controller Installation and User Guide 02 14 217 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 218 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 219 e 16 point Contact Digital Input 221 e 16 point DC Digital Input 222 e 16 point AC Digital Input 224 e 16 point DC Digital Output 225 e 8 point AC Digital Output 228 e 8 point Analog Output 231 Dual DI DO AO RTPs and cables are used with the following modules See page e 16 point Analog Output 234 e 16 point Analog Input 235 e 32 Point DC Digital Output 238 e 32 Point DC Digital Input 240 4 Poin
6. Step Procedure Comments Reference 5 If installing High Level 16 channel Analog Input module set its SW1 and SW2 DIP switches to ON This connects an internal 250 ohm resistor A small slotted screwdriver or paperclip works well avoid using pencils gt y g Honeywell f a N f 7 f O x NE gt 0J E S25 ones o R f eS hime fee as j U Y gr pea 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 18 HC900 Process Controller Installation and User Guide 77 02 14 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 rd Honeywell a SAN TS a INPUT 1 SW2 INPUT 2 SW3 INDEX on gt Stee Settings using Input 1 as example Single ended factory setting
7. ON OFF IN1 Cas DIFF coe LIN SINGLE HY g 1 and 2 SINGLEN 3 and 4 DIFF OFF Differential ON OFF IN1 QFF 3 and 4 DIFF ON 78 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 18 02 14 HC900 Process Controller Installation and User Guide 79 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 43 Se l eleleleialey sbie 80 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Step Procedure Comments Reference 11 Install I O module install a Filler Block cover Part num
8. 4 Remove the module and check for a bent pin then reinsert the module 5 Replace the module 6 Remove other modules and replace one at a time until the problem reoccurs Most likely the last module inserted needs to be replaced 7 Replace the rack 2 EAROM EA ROM Failed its checksum Vv lV 1 Remove reinsert module 2 Replace module 3 RAM V v iv VIW ee 4 ROM vV v A ee A Ww 24V Vv iV ly 4 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 andbackup V v Replace module factory calibration 7 FIELD CAL CRC failure of field calibration Vv v 1 Remove reinsert module values 2 Replace module 8 HARDWARE General Hardware Failure V Replace module Al convertor not working 9 HW SW Key The software residing on the Vy V v v V Replace module module does not match the module type This diagnostic should only result in the factory 11 Shift Register The loopback test of the shift V V v W Vv v Replace module register failed 176 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting 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
9. Analog Output 4 pts 40 mA 200 mA I Analog Output 8 pts 225 mA 350 mA 1 Analog Output 16 pts 350 mA 700 mA 1 AC Digital Input 16 pts 130 mA 0 mA I 0 DC Digital Input 16 pts 130 mA 0 mA 1 0 AC DC Digital Input 16 pts 130 mA 0 mA 1 0 Contact Input 16 pts 130 mA 40 mA I DC Digital Input 32 pts 215 mA 0 mA I 0 AC Digital Output 8 pts 220 mA 0 mA 1 0 DC Digital Output 16 pts 340 mA 0 mA I 0 DC Digital Output 32 pts 235 mA 0 mA 1 0 Relay Output 8 pts 110 mA 100 mA I Pulse Frequency Quadrature 110 mA 250 mA I 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 ls column D total mA 5V less than 2000mA Yes No ls column E total mA 24V less than 900mA Yes No 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 Multiply Total mA 5V total by 5 1 Multiply Total mA 24V total by 24 5 Divide results of 6 by 1000 Is the result of 7 less than 28 If the answer to 8 is Yes use power supply 900P02 0001 1 2 3 4 5 6 Sum results of 4 and 5 7 8 9 10 If the answer to 8 is No use power supply 900P01 0001 Yes No 38 Revision 18 02 14 HC900 Proc
10. Signal Grounding Figure 35 j j Low Frequency Shield The shield for each input should be grounded Naise Relecticn RPA at the grounding bar optional at the top or bottom of each rack as indicated in Figure 36 For low frequency noise rejection I O wiring shields should be grounded only at the controller end For high frequency noise rejection shields should be grounded at the controller and at the field device If the ground voltage potential at the field device is different from that at the controller a DC isolation capacitor High Frequency should be used between the shield and the Noise Rejection grounding bar on the rack DC isolation Capacitor Shield wire Figure 35 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 36 To enable connection of multiple ground wires with a single screw the wires can be twisted together and secured with a wire lug To facilitate module replacement it is advisable in most cases to route all wiring through either the top or the bottom of the terminal block This allows the terminal block to pivot up or down allowing ready access to the f W module and is the preferred method 8 T T w for a limited number of wires 9 k 25 TAL P For a larger number of wires or for 2
11. User Supplied Safety Devices Figure 62 Relay Output Module Wiring Diagram 110 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Relay Output Module vm One half y 10 position i jumper Ei my O00 IO os wo ek To Relay Loads Via external disconnect 4 switches fuses 30 Vdc mansa s either OQQA AAE Figure 63 Relay Output Module Jumpers Pulse Frequency Quadrature Module Wiring Figure 64 through Figure 70 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 1 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 18 HC900 Process Controller Installation and User Guide 111 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams IN 2 IN 2 IN 3 IN 4
12. 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 the primary Ethernet port of the 900 control Station to the Ethernet switch which is assigned to port E1 of the controller CPUs 9 Connect the Auxiliary Ethernet port of the 900 Control Station to the Ethernet switch which is assigned to port E2 of the controller CPUs 10 Connect CPU A S1 port to PC USB port through RS 485 to USB converter 136 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Table 21 Redundant network connections Step Procedure 1 Make sure the PC has 2 Ethernet NICs Network Interface Cards installed and enabled 2 Connect Ethernet 10Base T straight or crossover cables to the HC900 controller s E1 and E2 ports 3 Connect
13. 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 150 HC900 Process Controller Installation and User Guide Revision 18 02 14 Operating Characteristics Controller Modes Controller Mode Transitions Mode changes are controlled primarily by positioning of the MODE switch Figure 81 on the controller module or RSM and secondarily by selection of mode names on operator interface displays That is the Mode switch takes precedence In the RUN Locked position or in the PROG Locked position selecting a mode name at the operator interface has no effect on the operational mode In the RUN PROG position the mode may be changed from any mode to any other mode The effects of the Mode switch operator interface selections are described in Table 23 The effects on controller operation for each mode transition are described in Table 24 Run Run Pgm Fail Pgm Over Run Pgm Pg Run Run Pgm Figure 81 Mode Switches Controller left RSM right Table 23 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 cannot be changed at any operat
14. 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 Automation India Ltd 55 amp 56 Hadapsar Ind Estate Pune 411 013 india Honeywell International inc By re Z AEA 512 Virginia Drive Edward A Child Fort Washington PA 19034 USA Regulatory Compliance amp Approvals Engineering Issue Date 12 May 2007 ATEX_CERT_HC900 1of2 Revision 18 02 14 HC900 Process Controller Installation and User Guide 247 INDEX Analog Input Digital Input Digital Output Analog Output AC Input Module Wiring 93 AC Input terminal block 21 AC Output Module Wiring 103 Access See Controller access Alarm Groups 33 Alarm Event messages 33 Analog Calibration 177 Analog Input Calibration 178 Analog Output Calibration 180 Analog Output Module Wiring 87 Appendix Installation of Remote Termination Panels RTPs 203 ASCII 31 backplane 59 65 barrier style 66 Barrier style 25 INDEX D DC Input Module Wiring 90 DC Output Module Wiring 99 Diagnostics and Troubleshooting 159 Distance planning 44 Download Upload 151 DSL 33 E Mail 29 E Mail Communications 33 Emergency Stop switches 50 enclosure 46 equipment enclosures 41 Ethernet Devices 27 115 Ethernet Open Connectivity Network 27 29 Euro style 25 66 Event Groups 33 Battery Installat
15. AC DC Isolated Input Module Wiring Revision 18 HC900 Process Controller Installation and User Guide 02 14 99 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 55 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 AY Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 100 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Contact Input Sy eee oh IN3 B by Wa x d o Ne e sii ts N8 E es e aS com com D COM COM i COM COM T a IN 10 O 4 i n IN 12 4 it E IN 14 5 IN 15 3 IN 16 S
16. 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 i the program s terminal window restore factory defaults by keying in the following command string AT amp F0 Then press the ENTER key 8 In the program s terminal window key in in the following command string AT El QO Then press the ENTER key The modem should give an OK response 9 Key in the following command string AT amp CO amp DO amp KO amp R1 amp SO amp YO SO 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp W0 The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem s serial cable to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC
17. If configured as a Modbus master slave the data link their read pins frozen tothe last USe the slave status screens to layer is reporting value read determine which slaves are experiencing the problem For those that atleast 75 of Slave blocks associated with slaves check the last characters the slaves experiencing the f j had P f e Power eae failure have their BAD COMM dey eaa by 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 Spee been invalid e COMM STATUS is set to BAD pary l e iftheportis for all slaves experiencing the number of stop bits configured as a failure e for electrical interference eg at e The slaves with the data link e grounding east 75 of the 2 aye last requests to a alison zero data termination resistor if at end particular slave er of link resulted in no e Theslaves experiencing the 7 The diagnostic is cleared by response or a reply failure are moved to the clearing the port s statistics that failed the data background scan rate link protocol The UART failed its See above Replace CPU module power up tests 10 Ethernet port tests 1 E1 or E2 port diagnostic is set to Replace CPU module If the lead s status If the lead s status failed during power up FAILED LED is indicating LED is indicating 2 ASYSblock s HW OK pinis the failure see the failure see tum
18. See the Designer Software User Guide for precautions restrictions and procedures 148 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 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 instructions may result in product damage Revision 18 02 14 HC900 Process Controller Installation and User Guide 149 Operating Characteristics Controller Modes Table 22 Controller Operating Modes Mode Name Functions in selected mode RUN I O scanning Controller and Expander Racks Function block execution outputs are set according to function block algorithms Monitoring of Diagnostics controller rack and I O expander racks Detection of I O Modules Other functions permitted e Downloading of config
19. TX RX 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 36 For RS 232 cable connections see page 124 For RS 485 connections see page 142 e For new systems either of two ports S1 and S2 can be configured as RS 485 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 port S1 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 e Modbus master ports default to slave ports ELN protocol when CPUs are in Program mode e Baud rates to 57 600 Revision 18 HC900 Process Controller Installation and User Guide 35 02 14 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two RS 485 ports for new systems Setting serial ports S1 and S2 to RS 232 or RS 485 For legacy systems S1serial port default setting is RS 232 S2 serial port default setting is RS 485 Each port can be
20. User selectable starting address range for registers assigned to each principal block type RS 485 Modbus Master Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed Modbus Master Advanced Application Speed One RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up to the maximum 1024 parameters per controller Up to 32 Up to 1024 max per controller Selectable per device 1 second fastest load dependent Recommended for use with gateway devices As fast as 500ms Revision 18 02 14 HC900 Process Controller Installation and User Guide 197 Specifications General Specifications Communications C30 C50 C70 C75 Ethernet Modbus TCP Initiator Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed One Models C30 and C50 Two Models C70 and C75 RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up
21. 232 PC modem cable up to 50 RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 to RS 485 converter RS 232 to RS 485 converter RS 232 to RS 485 converter Belden 9271 or equivalent To Device Port Serial port of PC w Null Modem cable For Wiring details of Null Modem cable see Table 19 or Modem Refer to RS 232 Remote Connection to PC Configuration Tool on page 125 Refer to device s port instructions Refer to device s port instructions Refer to device s port instructions Terminal connector of operator interface Refer to Table 18 Connect from each CPU A and B to the Ol Refer to device s port instructions 118 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 Designer Software configuration software Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquis
22. AT EO Q1 amp WO The Modem will not respond Power down the modem and disconnect it from the PC Set the modem switches to the following Switch Setting Position Function 1 ON DOWN Modem ignores DTR Override 2 OFF UP Verbal word results 3 OFF UP Suppresses result codes 4 ON DOWN Suppresses echo 5 OFF UP Modem answers on first ring 6 ON DOWN CD always ON Override 7 OFF UP Loads YO Y4 configuration from user defined nonvolatile memory NVRAM 8 OFF UP Disables command recognition dumb mode Connect the modem to the Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Designer Software Set up Designer Software to dial the HC900 Controller Verify that communications is established with the remote HC900 Controller Revision 18 02 14 HC900 Process Controller Installation and User Guide 131 Communications Installation Connecting the HC900 Controller to a PC with the 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 Connect power to the modem Power up the modem Run a serial communication port program such as Hyperterminal Within the communicat
23. 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 TI ji H TI a i NA y Ne VA Boek si J1 cr ct cr ch SW SPST TB1 1 6 2 7 me e A 3 8 SS Ts 4 9 5 5 10 6 20 7 19 8 18 1 X ie H 10 16 D T 45 es ET E es T T aI EC C 1 Ee a A 19 4 E v Ma A NM A 29 5 cf ct cf et 7 13 13 ee 14 12 15 11 T ee ee A a2 18 3 rd Lag C eas as 17 2 36 16 1 a Gi es 5 a a aa 11 15 aa 12 14 Lan CON40 230 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 92 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 9OORTC B825 Remote Terminal Cable assembly 2 5 meters long 900RTC B85
24. C50S C70 and C70S shown or Scanner 2 Module C75 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 Supply optional Available in 8 or 12 slot racks Figure 8 I O Expansion Rack Components Revision 18 HC900 Process Controller Installation and User Guide 19 02 14 Components and Architecture Hardware Components Rack Options Racks are available in 4 slot 8 slot and 12 Slot versions Racks are interchangeable between the Controller rack and an I O expansion rack C50 C70 C75 CPU only and all three versions shown in the following figure are available for either purpose C75 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 Note You can install redundant power on any I O rack pr 1 0 Slots 1 4 ee ey eee taeeeeeee Scanner Module Slot I La Power Supply Slot Power Status Module req d if using Reserve Power Supply p mnsssensenssuuu prnassenme 2 Optional Reserve Power Supply Figure 9 Rack Options 20 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Hardware Components Power Supply The PO1 Power Supply shown in Figure 10 provides 5 Vdc and 24 Vdc to the backpl
25. CPU or Memory in Rack Diagnostics dialog box A Scanner 2 rack has a bad power supply 1 2 Associated rack monitor block s RACK OK pin is tuned off ASYS and FSYS blocks HW OK pins are turned off Locate the Scanner 2 that indicates a bad power supply diagnostic and replace the defective supply See POWER SUPPLY DIAGNOSTICS in the associated rack s Rack Diagnostics Overview display See Power Supply Diagnostics in Rack Diagnostics dialog box 168 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indication Utilities Indication Strobes 8or9 If 8 flashes the S1 1 ASYSandFSYS blocks HW t Check baud rate serial port is reporting a OK pins are turned off 2 Check connectors diagnostic 2 If configured as a Modbus 3 Check cable polarity If 9 flashes the S2 master sevialpattis reporting al asygandFSYS blocks interna from electical diagnostic Modbus Master Fail pins are Possible causes are tumed on 5 ee T RS 485 aes B used check its power switch jumper e if hs ais e Slave and read blocks settings and aay as configured as a associated with the slaves Modbus or ELN experiencing the failure have 6
26. Figure 83 Modes of operation on RSM eceesccesseecsseecsneecssceceseecssaeeesaeesssecesaeessaeecsseecsseesseeseneeseneeeesaeensas 156 Figure 84 Lead Controller synchronization cssccsesseceseesssceceseecssceeesaeesssecesaeessseecsaeecsaeecseessneeseseeeesaeesas 158 Figure 85 LED Indicators on Controller CPUs See Table 26 0 c cccessseceseseceeeeenececesneeeeeseaeeeeseneeeesenneeenses 162 Figure 86 LED Indicators on Scanners 1 port left 2 port right See Table 28 00 eeeeeeeeeeseeeeeeeteeeeees 171 Figure 87 V O Module LED indicators ccsiccccsspitecsdedeessctedesnegesdesscesvenehestencalewsadapddeeeodsdvesdeceehassendesbscunvesbesss 175 Figure 88 Terminal Board Connections for AI Calibration ecceeeescccsseeceseeeeneeesseeeesaeeesaeessaeesseeeesaeeesaes 182 Figure 89 Terminal board Connections for AO Calibration cceeeeeseecssceceseeeeseeeeseeeesaeeesaeessaeessaeeesaeeesaes 183 Figure 90 Extended Distance Example 1 o ceceescceessessseeceseeceseeeesceessaeecsnecssaeessaeecsaeecsseesseesseesssaeeeaeessas 204 Figure 91 Extended Distance Example 2 oiccen naei araia e a a a a E a S 205 Figure 92 Example installation not shown 2 RTP amp cable for high capacity AI DI DO ccccscsceseeceeee 207 Figure 93 Analog input terminals iaeiiio eA ae EEE aE E AIE tai E TE yeteestieoesl dees 210 Figure 94 Two wire transmitter connections with common 2
27. INDEX INDEX SENSE SENSE OUTPUTT OUTPLT2 OUTPUT OUTPUT4 COM ENCODE ENCODE Figure 64 Pulse Counting Wiring IN 1 IN 1 ib an Nz Nz k IN 3 IN 3 IN3 9 ibe sit E Sai OOo INDEX INDEX 7 INDEX INDEX 7 SENSE SENSE y SENSE SENSE mme OUTPUT OUTPUT e KS OUTPUT2 OUTPUT2 O UTI 3 OUTPUTS OUTPUT2 S OUTPUT4 OUTPUTS W com ete a ENCODE ENOODE lt ENCODE ENCODE Figure 65 Pulse Output Wiring 112 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Frequency Inputs 5 24V i INDEX OUTPUTS DUTPUT4 COM ENCODE ENCODE Altention For inputi Input 2 and Index reverse polarity to Encoder 200mV to a 6 0V a Differential g B 200mV to__ H 6 0V 7 Differential Z Internal jumper OUTPUT2 OUTPUTS OUTPUTS com ENCODE ENCODE ah Encoder power S5Vde to 24Vde Figure 67 Quadrature Differential IN 2 IN 2 IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUT1 OUTPUT2 OUTPUTS OUTPUT4 COM ENCCDE ENCODE IN t IN 1 IN 2 wisis 1N 2 IN 3 IN 3 IN 4 AY D OW 1N 4 INDEX a INDEX D SENSE ze SENSE Xy S OUTPUT OUTPUT2 OUTPUTS OUTPUTS COM ENCODE ENCODE P 4 D D
28. Latch to rail See page 244 e Connect cable to RTP 2 3 Set verify jumper positions as shown m a 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 only disconnects L1 not both sides of the AC powerline See page 230 for RTP internal schematic 228 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 L1 L2 Note AC Outputs are individually fused in the module but adding a fuse here protects the wiring Revision 18 HC900 Process Controller Installation and User Guide 229 02 14 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
29. Module Refer to the wiring information on each module given in this section of this manual Figure 37 Terminal Block Jumper Installation 72 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring Removal and Insertion Under Power RIUP Removal and Insertion Under Power RIUP Ay 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 tak
30. Ohm 10 16 amp 32 11 15 T 13 o OW SW 5 2 250 Ohm 12 14 e o 14 13 13 dis 14 12 i Oo 0 w SW 6 2 250 Ohm 15 11 36 16 1 17 SW 7 2 250 Ohm 37 17 2 18 18 3 19 19 4 L 20 O W SW 8 2 250 Ohm 20 5 ie 40 es ee ee ee 0 o o 21 sw SW SW SW SW SW sw sw 8 1 7 1 61 5 1 41 3 1 2 1 1 1 ee 9 O 1 F 24 AF 25 AF3 30 NF4 31 AF 34 F 35 E 38 NAE 39 214 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 H010 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 shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described
31. Revision 18 HC900 Process Controller Installation and User Guide 121 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Connecting the HC900 Controller to a PC with the Designer Software To establish communications between the HC900 controller and the Process Control HC Designer configuration software use any of the following methods e A Direct Serial RS 232 connection See page 123 e B Modem connection See page 126 e C Direct Ethernet connection See page 138 e D Networked Ethernet connection See page 140 These methods are described below ATTENTION Always observe the wiring cabling guidelines on page 45 122 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software A Direct Serial RS 232 Connection Com1 Com 8 j 9 6 38 4 KB Null Modem cable RS 232 Configuration port PC Figure 71 A Direct Serial RS 232 Connection ATTENTION Always observe the wiring cabling guidelines on page 45 Step Procedure 1 Prepare a null modem cable Refer to RS 232 Converter Direct Link to PC Configuration Tool page 124 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 availa
32. 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 8 Mount Rack e Mounting rails or flat panels e for cabinet with multiple HC900 Chassis grounding bus barrier strip for AC power e Master control Relay 56 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 A and Wiring on page 66 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 18 HC900 Process Controller Installation and User Guide 57 02 14 Rack Installation Mount Racks Mount Racks Rack assembly information is given in Table 8 Table 8 Mount Racks Step Procedure Commenis References 1 Mount the Rack in the enclosure as follows e Using the diagrams below as a guide
33. Slot 8 Slot Controls Rack pate Chassis au Powe Saus height height QO Racks onb VO Rack W O Rack CPUs RSM Power Supplies 690 54 A o o o 103 261 6 165 419 22 5 571 Reference Center for Drilled Holes at Top of Rack Ay Figure 25 Rack Dimensions with reserve power supply 40 HC900 Process Controller Installation and User Guide Revision 18 02 14 Pre Installation Planning Remote Termination Panels Figure 26 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 207 Revision 18 HC900 Process Controller Installation and User Guide 41 02 14 Pre Installation Planning Environment 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 of static electricity is minimized or eliminated See Environmental Condit
34. components feature summary Components and 13 Functional features and physical characteristics of the system and of each major Architecture component of the HC900 Process Controller Networking components and methods of interconnection Pre Installation 37 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 66 Procedures for installing I O modules in the controller rack and I O expansion Installation and racks and for wiring field devices to the terminal block associated with each Wiring 1 0 module Communications 117 Guidelines for installing RS 232 RS 485 TO USB CABLE RS 485 and Ethernet Installation cabling and associated components Operating 145 Characteristics of the HC900 Process Controller as they relate to configuration of Characteristics a control strategy and to operation of an installed and running system Redundant 155 Characteristics of redundant operation Operating Characteristics Diagnostics and 161 Mechanisms that detect and react to faults in the operation of HC900 Process Troubleshooting Controller hardware and or software components Analog Calibration 180 Hardware configuration required for calibrating Al and AO modules from the configuration software Removal and 184 Guidelines for replacing system com
35. controller s 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 PC 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 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network v Device Name Honeywell HC900 Controller bd Address 192 168 1254 v Protocol Modbus R TCP Speed bps N A PC Port Setup for Controller Access Network COMI 6 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP add
36. converter providing parallel processing Fast Scan Time 53ms for up to 250 fast 27ms for up to 250 fast 27ms for up to 330 fast 53ms for up to 500 fast logic blocks logic blocks logic blocks logic blocks 67ms for up to 315 53ms for up to 500 fast 53ms for up to 660 fast 67ms for up to 780 fast fast logic blocks logic blocks logic blocks logic blocks 107ms for up to 400 67ms for up to 780 fast 67ms for up to 1040 107ms for up to 1040 fast logic blocks logic blocks fast logic blocks fast logic blocks 107ms for up to 1040 107ms for up to 1380 133ms for up to 1300 fast logic blocks fast logic blocks fast logic blocks 133ms for up to 1300 133ms for upto 1700 267ms for up to 2500 fast logic blocks fast logic blocks fast logic blocks 267ms for up to 3300 fast logic blocks Detection Failover Time from Lead to Reserve CPU N A Up to 4 analog scan cycles Run Mode Edit Transfer Time 3 normal scan times 1 5 sec typical for all configuration edits not including I O changes Operating Modes Run No configuration download in this position Run Program Download allowed Program Outputs Off initialization on download Offline mode is available via software selection for Al calibration Revision 18 02 14 HC900 Process Controller Installation and User Guide 195 Specifications General Specifications Features C30 C50 C70 C75 Maximum user 400 20
37. cossi inairein donin ee aeaaeai aaa aaaea aia re ANSE 154 Table 26 LED Indications on Controller CPUS ssseeeeeeseeeseeeseeeressreetersresstessressresressresstessteseressresseseresereseres 163 Table 27 Controller Status LED Diagnostics 0 0 0 cece eeseceseeesnceceeeeeesseeesaeecsaeecsaeeesaeeesssessseecseeceaesesaeeesaeesas 164 Table 28 LED Indications on Scanner Module 00 ccecesccceeeenceeeeeeeeeeeneeeeesnaeeeceeaeecessaaeeeesnaeeeeeeneeeessnneeeeeeas 171 Table 29 Scanner LED Diagnostics s s2i cccicdeedisiavelidbsseiecdebeeuetechueeesodgentiedual este a e a aride ae daei eas 172 Table 30 LED Indications on I O Module eee ceesceescecesecssceceseeeesseeesaeessaeessaeeesaeessseessseecseesessesesaeeesaeesas 175 Table 31 VO Module LED Diagnostics 00 0 0 eeseesseceseeceseesenceceseeessaeeesaeessaeeesaeessaeessseecsaeecseeseseesenaeeesaeeesas 176 Table 32 Bad I O Channel Diagnostics eeeceesccceseecsscecscecseecssceceseecesaecesaeessaeeesseecsacecsaeeceaeeseneeesaeesnas 177 Table 33 LED Indications on Ethernet Switch ccecesscceessncceeesneeeeesneeeeeenaeceessaeecessnaeeesenaeeeeeeneeeeeeneeeeeeeas 178 Table 34 Power Supply Replacement all except C75 ceescesseesseeseneessncecseeesseeesseecsaeceseecseeessaeeenaeeesaes 185 Table 35 Controller Module Replacement 0 eescceessecssceesseeeeseeesseeeeseeeesaecesaeessseeesseeesseessaeecsneesenaeensaeesses 187 Table 36 Scanner
38. data acquisition software packages OPC server Modbus TCP Initiator non redundant Peer to Peer and Designer Software 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 Port Ports per controller Baud rates Modem RS 485 with Modbus RTU or Honeywell protocol 3 Plug connectors supplied 1200 2400 4800 9600 19 2K 38 4K 57 6 K 115 2K configured by Designer software or Ol For remote connection to Designer software requires external modem at controller 1200 baud to 57 6KB RS 485 Ports Ports per controller Cable type 1042 559 Distance from controller 1042 559 Power to Ol Unit addresses Two connector supplied Honeywell or Modbus RTU protocol Only one port for 1042 559 operator interface support 2 wire plus shield Belden 9271 or equivalent 2000 ft 600 m 24VDC user provided at Ol 1 to 247 RS 485 Ports Parity user selectable Stop bits user selectable Speed user selectable Double Register Format for Modbus RTU Slave and Master data User selectable Odd even none 1or2 1200 2400 4800 9600 19200 38400 57600 115200 Selectable byte order RS 485 Modbus Slave Operation Number of ports per controller Masters per port Principal Function Block Address Range Up to two One
39. diagnostic See Rack Diagnostics dialog box Revision 18 02 14 HC900 Process Controller Installation and User Guide 167 Diagnostics and Troubleshooting Controller CPU indicators Number of Red Strobes Possible Causes Lead and or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication High temperature condition in a Scanner 2 rack has been detected 1 Associated Al blocks that are configured as T Cs set their fail pin on their warn pin off and their output pin to the failsafe value 2 Associated Al blocks that are configured as T Cs set their IO status to either CJ High Temperature if one of the two CJs on an Al card is indicating a temperature greater than 70 degrees C CJ Failure if both CJ sensors are failing to convert 3 Associated rack monitor block s module fail pin is tumed on 4 Associated rack monitor block s RACK OK pin is turned 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 Scanner 2 has a CPU or Memory diagnostic 1 Associated rack monitor block s RACK OK pin is tuned off 2 ASYS and FSYS blocks HW OK pins are turned off See CPU or MEMORY in the associated rack s Rack Diagnostics Overview display See
40. downloading Downloading of Permitted When Controller isin Configuration items PROGRAM Mode RUN Mode OFFLINE Mode Controller Configuration Files Yes No Note 1 No Setpoint Profiles Setpoint Yes Yes Schedule Recipe Files Yes Yes Data Storage Configuration Yes Yes Yes Files Data Storage Non volatile Yes Yes Yes parameters Note 1 Controller files can be downloaded with the controller in Run Mode with the Mode switch set to Run Program but not with the switch set to Run Lock The download from the host processor is directed to an area of controller memory separate from that used for running the controller and hence has no effect on the active process The host signals the controller when the download is complete and requests a configuration validation test and report from the controller The controller then checks the new database and compares it to the current running database Using the test report as a basis the host then presents the operator user with a dialog box containing a set of choices begin using the new database with no cold start use it with a re start or abort the download For downloading procedures refer to the Operator Interface User Manual 5 1 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 func
41. 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 485 interfaces Lead Controller handles communications 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 156 HC900 Process Controller Installation and User Guide Revision 18 02 14 Redundant Operating Characteristics Steady State Operations Execution time HC900 Controllers are designed to execute control functi
42. 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 which can service data requests from any networked PC on a client host server controller basis C75 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 Designer Software for generating and managing configuration files Or HMI Supervisory Data Acquisition Software or Operator Panel with Modbus TCP driver Or Both configuration and HMI software and or panel All communications between a controller and a PC host use Open Modbus TCP protocol whose widespread use is making it an industry standard Modbus TCP is basically an adaptation of the Modbus messaging structure that uses TCP IP for a message carrier In general
43. mounting see page 39 Remote Terminal Panels see page 41 Environmental conditions see page 42 Heat rise de rating see page 43 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 18 02 14 HC900 Process Controller Installation and User Guide 37 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 POI or P02 calculate power requirements below H ATTENTION Using inadequate power supply will cause the controller to cycle power on and off A B c D E Max Max Enter Current Current Calculate 5V current Calculate 24V current Module type Quantity 5V 24 V D A B E A C Controller C30 and C30S 820 mA 0 mA I 0 Controller C50 and C50S 930 mA 0 mA I 0 Controller C70 and C70S 1150mA OmA I 0 Controller C75 1500mA 0mA I 0 Scanner 1 Port 670 mA 0 mA 1 0 Scanner 2 Port 770 mA 0 mA I 0 Power Status Module PSM 22 mA 0 mA I 0 Analog Input 8 pts 40 mA 25 mA I Analog Input 16 pts 75 mA 50 mA I
44. o wires of a heavier gauge it is advisable OP to route some wires through the top of Siep the terminal block and some through ol the bottom as indicated in Figure 36 ge In this case it is necessary to adjust og wire length so as to ensure adequate Clap flexibility of the twisted wires and to AM provide clearance sufficient to remove T the I O module 70 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring Terminal Block to Field Signal Wiring Figure 36 Wire Shield Grounding Revision 18 HC900 Process Controller Installation and User Guide 71 02 14 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 37 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
45. 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 the Ethernet Open Connectivity Network which links an HC900 Process Controller to Peers to HMI Supervisory Stations and to other Ethernet 10 100Base T devices that support TCP IP The Ethernet Open connectivity Network is potentially more complex than the I O expansion network and in some cases may require the services of an IT networking professional Revision 18 02 14 HC900 Process Controller Installation and User Guide 27 Components and Architecture I O Network 1 O Network I O Expansion Network C50 and C50S C70 and C70S CPU only Examples of HC900 Controller I O expansion configurations are shown in Figure 18 CU LETT ae Figure 18 HC900 Controller Configurations In any of the racks shown in each controller configuration can be 4 8 or 12 slot versions The Ethernet cables for the I O expansion links are standard shielded Cat 5 IO 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 u
46. own enclosure Mount RTP cable assembly to HC900 Controller Figure 92 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 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 32 point DC DI label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 73 2 Mount RTPs to DIN rail e Latch to rail See page 244 e Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 16 RTP B to Inputs 17 32 You can write on the RTPs labels to distinguish them 3 C Om Cm CO See page 242 for RTP internal schematic 240 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital I
47. personnel e The protection of property e The integrity of operating processes The first consideration is safety of personnel While there is always an inclination to preserve the materials and time invested in a running process no action should ever be taken that would risk injury to personnel Protection of personnel property is an important consideration that 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 Ay 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 disconnec
48. program the RTC but it was unsuccessful The RTC is unable to be read Usually indicating a serious hardware failure Same actions as described above 1 Use HCDesigner HCUtilities or Ol to program the real time clock RTC 2 If problem persists replace the CPU module One of the following remote I O conditions exist Communications between the CPU and a Scanner 2 is failing Scanner 2 is unable to communicate to a module or a wrong module is installed A module in the I O rack is reporting a diagnostic C75 and Scanner 2 firmware versions are incompatible Scanner 2 VO rack or power supply is defective C75 module is defective Abad channel has been detected on one of the modules 1 Associated blocks set their fail pins on their warn pins off and their output pins to the failsafe value 2 Associated blocks set their IO statuses to either Channel No Comm if the module cannot be communicated to or a message indicating the bad channel condition 3 Associated rack monitor block s module fail pin is turned on 4 Associated rack monitor block s RACK OK pin is turned off 5 ASYS and FSYS blocks HW OK pins are turned off Locate the Scanner 2 that has a status LED indicating a diagnostic and follow the scanner 2 diagnostic section to solve the problem See the associated rack s Rack Diagnostics Overview display for details regarding the
49. shield grounding section page 70 2 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP 208 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Set DIP switch positions SW1 through SW8 Set each input s DIP switch positions according to the input type For Input n use Switch n For example for Input 1 use Switch 1 for Input 2 use Switch 2 etc If an input is not used set its DIP switch positions to OFF Fuses 80mA Time lag Wickmann part 3740080041 UL CSA approved Transmitter Loop Powered Volt millivolt Milliamp Transmitter Externally Powered SW9 is the red power switch for 24 volt supply Module RIUP is not affected by using the RTP See page 214 for RTP internal schematic Revision 18 HC900 Process Controller Installation and User Guide 209 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Connect field wiring Refer to Figure 93 through Figure 99 for field wiring Any input type can be wired to any of the 8 inputs After wiring double check DIP switches settings for ea
50. 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 18 HC900 Process Controller Installation and User Guide 133 02 14 Communications Installation Connecting the HC900 Controller to a PC with the 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 RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232cable 2 Connect power to the modem You will need to supply an external power supply with a DC voltage between 10 and 30 VDC Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected O oa Aa Q 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 comman
51. status diagnostic indicators for communications functions Figure 14 Scanner 1 Module 24 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Hardware Components Scanner 2 Port Module C75 only 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 LED status diagnostic indicator for scanner functions T 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 Input Output Modules T O module types Figure 15 Scanner 2 Module e 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 DC digital output modules sinking type 32 point digital output DC voltage sourcing type 8 point relay output module four form C ty
52. 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 Reference 1 Using Rack Slot Channel data from a P ORANGE WHITE TEXT Designer Software report aaae aa fill in the tag names on the Coler Bar EER cees ware rex Label for each configured Fill it vese I O Module Module slot Toa a PSN me Ton position should take heat ET reo weton de rating into account See Heat Rise De rating EnA DARK BLUE WHITE TEXT page 43 RELAY nr Be sure to use the eo ee socal iota for each AES yneen tov ceva YELLOW DARK GREY TEXT 2 Place the appropriate label DE ENERGIzE MODULE FIELD POWER BEFORE SERVICING Term No N1 1 N1 IpTpi 2 3 N2 4 N2 5 N3 6 74 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 3 Optional Install jumper AC Input combs into designated AG Dipa DG Input Barrier style Terminal Blocks to reduce the wiring required to supply Fo ei power o Two position jumper for the DC Input Module IS and or on the DC Output j Module E p Ten position jumper for the AC Output Module IS TAE Five posit
53. the expansion racks outputs go to configured Failsafe values e Does not impact the other C75 CPU module which will continue to control the process e Contains start up diagnostics after replacement to verify proper operation e If there is a Lead Controller the configuration database is automatically copied from the Lead to the newly replaced C75 CPU module Before replacement 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 35 Controller Module Replacement Step Action 1 If a process is currently in operation bring it to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply in the Controller rack from the site AC power source 3 Observe where communications cables are plugged into the Controller Module and if necessary tag them to identify their functions Unplug all communications cables 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 communi
54. the stored calibration values are compensated by the measured temperature of the terminals Because of this observe the following rules Figure 88 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 After 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 18 02 14 HC900 Process Controller Installation and User Guide 181 Analog Calibration Overview PPETI kA MV or s mV or Vse satel Source jess n Seeccecesees See note eee saaa e r y 4 20 mA f X
55. to comply with these instructions could result in death or serious injury Table 27 Controller Status LED Diagnostics Number Possible Causes Lead and or Reserve Controller User Action Honeywell 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 C75 because the C75 control are disabled communication communication 3 Replace power supply ports are disabled ports are disabled 4 Replace rack 5 Check grounding 6 Ensure system is properly isolated from noise 2 Atleast one function The block s output s is are forced to If itis not desirable to have forced SeeSYSTEM in SeeSystem 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 synchronize The reserve s RSM were corrupted and LED is flashing to indicate it s not are now set toa valid synchronized with the lead empty database Usually this is a result of a firmwar
56. to rail See page 244 e Connect cable to RTP 2 3 Set verify jumper positions as shown C CO C Cm Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 73 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 230 for RTP internal schematic 224 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 aA G 4 4 a X NMN nE SS SG rr ree rer eee Install jumper wires 16 Point DC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 16 point DC Digital 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 92 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 Re
57. to the maximum 1024 parameters per controller Up to 32 Up to 1024 max per controller Selectable per device 1 second fastest load dependent Peer to peer 10 100Base T via Network port No of Peers Controller Update rate Peer Data Supports UDP protocol and Peer Data Exchange function blocks for peer data exchange 32 500 ms to 5 sec selectable Digital and Analog Signal Tags Variables up to 2240 parameters Ethernet Ethernet Network Connection Host Network Protocol 10 100 Base T RJ 45 Modbus TCP Maximum distances per Ethernet specifications Controller rack to I O Rack Ethernet CAT5 shielded cable with RJ 45 connectors Fiber Optic cable with switch Fiber Optic cable with switch and repeater 100m 328 ft 750m 1500m see page 204 Controller to Ethernet Switch Ethernet CAT5 shielded cable with RJ 45 100m 328 ft connectors Ethernet Switch to I O Rack Ethernet CAT5 shielded cable with RJ 45 100m 328 ft connectors Controller to Network Switch Ethernet CAT5 shielded cable with RJ 45 100m 328 ft connectors Network Switch to PC Ethernet CAT5 shielded cable with RJ 45 100m 328 ft connectors Controller to 1042 Operator Interface Shielded cable Twisted pair 610m 2000 ft 198 Revision 18 02 14 HC900 Process Controller Installation and User Guide Specifications General Specificati
58. 0 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 70 2 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP 3 C C Com Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 73 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 233 for RTP internal schematic Revision 18 HC900 Process Controller Installation and User Guide 231 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output 4 Connect field wiring LOADS ARE 0 to 750 ohm RTP A for Inputs 1 to 8 gt EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN External 24VDC supply 24VRTN z A 232 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP A Cable wire positions and color
59. 00 5000 configurable Function Blocks Maximum Control Loops Quantity based on available memory System Blocks Not user configurable 100 not part of 400 2000 or 5000 for Alarm Group blocks 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 cha
60. 00 Process Controller Installation and User Guide Revision 18 02 14 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 C75 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 33 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 4 x 5 Pin connector to Backplane i a 1x 20 or2x 18 Pin connector to Terminal Block SOoosessoosssssss Figure 33 I O Module Installation Ay WARNING AY e Do not use an input output terminal block if the terminal block is damaged if the door is missing or if one or both mounting screws are missing e Always tighten both terminal block screws before applying field power to the module e Do not apply energized live field wiring to an input output module t
61. 000 50 400 C 120 Pt1000 40 500 F Pt1000 50 752 F 121 JIS100 200 500 C JIS 200 500C 78 JIS100 328 932 F JIS 328 932 F 79 JIS100 200 260 C JIS 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 482F 85 YSI405 10 37 8 n a YSI405 50 100 n a Ohms 0 200 Ohms 0 200 86 Ohms 0 500 n a Ohms 0 1000 n a Ohms 0 2000 Ohms 02000 87 Ohms 0 4000 n a MA 4 20 mA 4 20 100 MA 0 20 mA 0 20 99 MV 0 10 mV 0 10 88 MV 0 50 mV 0 50 92 MV 0 100 mV 04100 95 MV 10 10 mV 10 10 89 Revision 18 HC900 Process Controller Installation and User Guide 201 02 14 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 202 HC900 Process Controller Installation and User Guide Revision 18 02 14 Specifications System Sizing and Availability Summary System Sizing and Availability Summary Table 42 System Size and Availability Summary
62. 0M 16 4ft 900RTC L050 DI DO AO Remote Terminal Panel RTP 900RTS 0001 C sowe O Y S SSS High Voltage RTP Cable 2 5M 8 2ft 900RTC H025 High Density RTP Cable 1 0M 3 28ft 900RTC 3210 i 5M 8 2ft Kits amp Accessoes O o o y ooo Ethernet Switching Hub 8 Ports Revision 18 HC900 Process Controller Installation and User Guide 02 14 Introduction Model Selection Guide Operator Interface O Model number 900 Control Station 10 Screen 900CS10 xx 900 Control Station 15 screen 900CS15 xx erator Interface OrAccessoriesa kis o SoSo 10 Screen Protective Films 10 10 Replacement Touch Screen Assy 50038820 501 10 Mounting plate adapter for 1042 replacement 24 VDC Power Supply for 10 900 Control Station User Manual paper 15 Screen Protective Films 10 24VDC Power Supply for 15 New Non SIL System 30004 0200 300R08 0200 300R12 0800 300R0BR 0200 900RT2R 0200 300RR0 000 I O Scanner 2 Port 1 per I O rack I O Scanner 1 Port 1 per I O rack 4 HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Model Selection Guide SIL System Description Model Number Controllers Controller C30 CPU SIL 900C30S 0360 00 Controller C50 CPU SIL 900C50S 0360 00 Controller C70 CPU SIL 900C70S 0360 00 Controller C70R CPU SIL 900C75S 0360 00 I O Scan
63. 1202645583 Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com AMERICA S Honeywell Process Solutions Phone TAC 1 800 423 9883 or 215 641 3610 Sales 1 800 343 0228 Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com Revision 18 02 14 HC900 Process Controller Installation and User Guide 251 For more information To learn more about HC 900 Process Controller visit www honeywellprocess com Or contact your Honeywell Account Manager Process Solutions Honeywell 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell Control Systems Ltd Honeywell House Skimped Hill Lane Bracknell England RG12 1EB Shanghai City Centre 100 Jungi Road Shanghai China 20061 www honeywellprocess com 51 52 25 107 Rev 18 February 2014 2014 Honeywell International Inc Honeywell
64. 17 Table 3 Serial port DIP switch settings ninae ane eea orinar eas eana a ER EEEa nE EREE 36 Table 4 Power Applied by Module Type esceescceeseecsseecsseeeeseeeesseeesaeeesaeeesaeecsseecsseecseecsseeessaesesseeesaeersaees 43 Table 5 Guidelines for Grouping WiIreS ccesceesccesseessseecesceceseeessaeeesaeessaeessseeesseeesaeecseecseeesseeeesaeeesatersaees 51 Tabl 6 Installation TOOLS ner casseadeesccddeveee ctcasescuesotetees gvusteve shasta cevautasesiddbshecesdeaeeentneotensdieedeeeds ohesdecevezeeee date 55 Table 7 Site and Equipment Preparation eecceescccesecsscecsseeeescecesseeesaeeesaecesaeeesseeesseecseeseeesssaeeesaeeesaeessaees 56 Table 3 Mount Racks Cae eea te loans ede does Goes oes deve slesdaesianta seendagSeeces desteosdas oteteed cots cots ojuadeceateseetedieters 58 Table 9 Assemble C30 C50 C70 Controller Rack ceeceesccessessseecsneeceseeeseecseeeeeeceeecesaeceaeeesaeeesaeeesseessaeers 60 Table 10 Assemble C75 Controller Rack ccesceescccsscecsseecsscecessecesnecesaeecsaecesseeesseecsaeecssaesesaeessaeeesaeeesaeesaees 63 Table 11 Assemble I O Expansion Racks 00 cescceescceessessscecsseecesseeescecesaeecsaeessaeeesseecsseeceeecsaeessaesesaeeesateraees 64 Table 12 Minimum Recommended Wire Sizes s cccssscccessseeeeeseneeeseeneeceesneceseseeeeeseeeeseeaeeeeneeeeeeeneeeenaaes 69 Table 13 RIUP Potential Hazards and Recommended Actions
65. 2 for one Common sapanen Ground for all outputs Figure 57 DC Output Jumpers 104 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 58 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 F cacag 10 5 to 32 Vde OP QOPMOL BBDOBOABMOOODO OOOOOOOC 10 5 ta 32 Vde Figure 58 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 59 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 Maximum per module 8 0A Revision 18 02 14 HC900 Process Controller Installation a
66. 4 VDC supply sseesseesseesrseseeereesreerrrsrresrirsereeees 210 Figure 95 Milliamp input connections with 250 ohm shunt resistance eseeeeeeeeeeseneeesneesseerseesseeesaeeesaes 211 Figure 96 Volt millivolt input connections eee eseeeseeeeneecsneeeseceesseeeesaeecsaecesaeeesacecsaeecsacecseesseesesaeeenaeessas 211 Figure 97 Three wire RTD input CONNECTIONS eee eeeeeeesecesseeeseeeesseecsseersaeessaeessseessseecesaecsseeseeesesaeeenaeeesaes 212 Figure 98 Two wire RTD or ohm input connections 00 0 0 eeeeeeseeceseeceneecsceceeeesseeesnaeeeaeessaeeesaeeesaeeesaeeesaee 212 Figure 99 Slidewire feedback connections for aCtUators eee eeseeceseeceseecsseeesneeeseeeeeecsaecesaeceseecesaeeesaeeesaes 213 Figure 100 Voltage input COMMECHIONS ec cceecicscecstaceseseebeotedeneeseecssoteecsneseeceesecenesecnsntsdenssabsssbedenodebessenensees 237 Figure 101 Current connections with 2 wire transmitter cccescessceceseecssceceseeesneeessaeeesaeeesaeeesaeessaeeesaeeesaee 237 xii HC900 Process Controller Installation and User Guide Revision 18 02 14 Purpose Introduction This publication describes the installation operation and maintenance of the Honeywell HC900 Process Controller This publication includes the following sections Chapter Title Page Content Introduction 1 Model numbers how to verify component compatibility function description of
67. 40 Vac 16chan T3C Ta 60 deg C T4 Ta 40deg C Digital Input 120 240VAC 125VDC T3 Ta 60 deg C 16 Channel T4 Ta 40 deg C Power Supply P02 T4 Digital Input Vdc 32 chan 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 C75 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 18 02 14 HC900 Process Controller Installation and User Guide 199 Specifications HC900 Analog Input Ranges vs UMC800 Analog Input ranges HC90 0 Analog Input Ranges vs UMC800 Analog Input ranges Users of UMC800 Controllers from Honeywell will find the analo
68. 4VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 100BaseT X to 100BaseFX multi mode fiber port with SC connectors require 24VDC power Fiber Cable Multi mode Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet cable I O Capacity Combined Analog and 384 1920 Digital Analog Inputs 192 960 Analog Outputs 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 194 Revision 18 02 14 HC900 Process Controller Installation and User Guide Specifications General Specifications C30 C50 C70 C75 12 I O slot chassis with redundant power support Redundant CPU rack 5 4 137mm H x 26 9 683 3mm W x 6 0 151 7mm D rear mounting plate ext
69. 6 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Redundant components Table 2 Descriptions of Major Redundancy Components Key No Component Description Source Name 1 Controller Includes Rack 2 Power Supplies 2 C75 Honeywell Local Rack Controllers 1 Redundancy Switch Module RSM 2 I O Expansion Includes 1 Scanner 2 module 1 Power Supply and Honeywell Rack up to 4 8 or 12 I O modules Optional second Power Supply and Power Status Module PSM on 8 and 12 slot I O racks 3 Operator 900 Control Station operator interface Honeywell Interface communicates via Ethernet or RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Controller Module to a serial port on the PC software is from f Honeywell e For new system The PC Configuration tool connects from the RS 485 port of the Controller Module using an external Honeywell qualified RS 485 to USB converter 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMls other HC900 Controllers and supplier Interface other networks including Internet HMI software is Typically includes HMI operating software available from f f Honeywell PlantScape May also include Designer Soft
70. ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 230 for RTP internal schematic Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 il Install jumper wires DC Supply Revision 18 HC900 Process Controller Installation and User Guide 223 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point AC Digital Input EA 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 92 e Remove appropriate key tabs from terminal board to allow mating with the module See page 75 e Connect desired cable to 16 point AC DI module at controller Choose from 900RTC H010 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 Install 16 point AC DI module label into module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 Mount RTP to DIN rail e Latch
71. Aetna saben tole on E E E debe a 82 Figure 39 Universal Analog Input Wiring Diagram 00 eee eeseceseecsneeeeneeeseeeesnecesaecesaeceseecesaeeesaeeesaeeesaeers 83 Figure 40 Examples of RTD Input Wiring eee eeececeseceseeeesseeesneeesaeeesaeeeseeesseessseecsscecesaecesaesesaeeesaeessaees 84 Figure 41 Analog Input Wiring Eight TCs 0 0 eeeceeessecsseeceseeeeecesaeecsacessseeeseecssaecseecssaeeesaeeesaeeesaeesaees 85 Figure 42 Analog Input Wiring Eight Resistance Inputs ceesseeeseeeeseeeseeeesneeesaeecsaecssaeeesaeeesaeesseeesaeers 86 Figure 43 Analog Input Wiring Eight RTDs eels eeeeceseeceseeeeeessaeecsaeesssceesseecssaecesaecesaesesaeeesaeessaeessnees 87 Figure 44 Analog Input Wiring Slidewire Position Proportion BlOCk e eesseesseeceseeesneeeeneeeesaeeeneeeesaees 88 Figure 45 16 point High Level Analog Input Wiring eee eeeeeeseeceseeeeneeeeneeeesaeessaecesaecssaeessaeeesaeessaeeesaeers 89 Figure 46 4 channel Analog Output Wiring Diagram eee eeeeeeececeneeeeneeceeeeeesaeecsaeecsaecssaeessaeeesaeessaeessaeers 90 Figure 47 8 channel Analog Output Wiring Diagram eee eescceeececsseeeeseeeesceeeaeeesaeecsaecesaeessaeeesaeesseeeeneers 91 Figure 48 16 channel Analog Output Wiring Diagram eee eeeeeseceseeceseeeeneeeesneessaecesaecesaeessaeessaeeeseeenaeers 91 Figure 49 DC Input Module Wiring Diagram cece eeeeeceeeseeceseecseeesaeecsacess
72. B port One 1 additional switch may be used for a total of 2 switches between CPU B and the I O racks 120 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the Operator Interface to the Controller Connecting the Operator Interface to the Controller Using parts in Table 18 connect the Operator Interface to the RS 485 port on the controller for legacy systems For new systems the parts in Table 18 connect to either of the two RS 485 ports on the controller See page 35 for port location Typically the cable that interconnects this port to the Operator Interface must be made during installation because it will probably be necessary to run the cable through conduit On C75 connect cable from each CPU s RS 485 port to the Operator Interface See Operator Interface manual 5 1 52 25 108 for connection details Table 18 Parts needed to make RS 485 Cable Belden 9271 or equivalent Variable Commercially available communication with 120 ohm resistors 2 000 cable feet Maximum Or Belden 9182 or equivalent with 150 ohm resistors 4 000 feet maximum 10 terminal connector Supplied with the operator interface Phoenix 1840379 or Connector 3 pin Supplied with the equivalent for C30 C50 controller CPU module Phoenix 1803581 for C75 047260 1 Ferrite cable clamps Supplied with the operator interface 089037 Nylon cable ties
73. Controller Installation and User Guide 191 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Installation Procedures Table 39 Installing Backup Battery CPU not initialized Step Action L A CAUTION Improper application of site power can cause damage to equipment Ensure that the controller rack is ready and safe for application of AC power Apply site AC power to the Power Supply that is associated with the controller Module Press the latch on the battery cover 1 to release the battery holder and pull on the handle 2 to remove the battery holder Note the orientation of the battery holder assembly battery toward the left The battery is retained in the holder by spring tension of the plastic holder itself Insert the negative end of the battery into the back end of the holder and press on the battery see arrow so that it snaps into the holder To ensure that the battery is seated properly rotate it in the holder using finger or thumb pressure toward the positive front end of the battery While maintaining proper orientation battery toward the left slide the battery holder into the slot in the Controller Module until it snaps into place 192 HC900 Process Controller Installation and User Guide Revision 18 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Replacement
74. E T E SAE ANTEE ETTE EE 55 Mount Racks AAE E EE E EE S 58 Assemble Controler Ra k eicisieteccecctecetanedcctereeadenen ean enean eaae aee EEE ne na Aan a aaan beanie ANRT anaana 60 Assemble I O Expansion Racks cccceeeceeeceeeeeeeeeeeeeeeeeee eee eeeccceeeeeeeeeeeecccaeeeeeeeecegeccaaaeeeeeeesseeenaaees 64 VO Module Installation and W Wing scciscatsciscesiceceeehthe ns beccncelecedecelaiabar tinh oseenneenenls 67 OVEIVICW i ictece tele tcie tent eM Ped rR i eb Ait Med Ses a ade le out ata anhaniyeeed dead ceded dee Guat 67 Revision 18 HC900 Process Controller Installation and User Guide vii 02 14 Introduction Purpose Module Placement in RACKS ccccceeeeeee eee eeeeeee eee terete cea eee ee eee eee aaee sees ee edeeaaaeeeeeeesegecaaeeeeeeeeneeee 67 Remote Termination Panel RTP ccccccccceeeeee eee eeeeeeenee eee eee eee cee steerer eeeecaeeeeeeeeeteeccaaeeeeeeeneeee 69 Terminal Block to Field Signal Wiring cccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeececcaeeeeeeeeeeececieeeeeeeeeneeenaaaes 69 Removal and Insertion Under Power RIUP cccccceeeeeeeeeeeeeeeeeneeeeeeeeeeeeecneeeeeeeeeetececaeeeeeeeennee 73 I O Module Installation Procedures cceeeeeeneee eee eeeeeeeeeeeee eee ee eeeecaeeeeeeeeeeeeccaeeeeeeeeeteeecaaeeeeeeeneeees 74 I O Terminal Block Wiring DiaQraMS ecceeeeeee cece eeeeeeee eter tree teen ee steerer eecee tees ee eteecaaaeeeeeeenneee 82 Communication
75. EE _ SS saa 5 10 e U 6 20 E se 7 19 SEs ee 8 18 anil i 17 17 16 E rt Co E rT a J9 J7 J8 J6 ERN ae E a G D a E A A 15 4 FT M y y or 16 5 ct ct ct ct nl 9 13 Sai 10 12 11 11 a ng 14 3 E E ii 13 2 ee a4 12 1 a EA E oE al 18 15 T mm j7 j C CON40 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 Revision 18 HC900 Process Controller Installation and User Guide 243 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP B J2 J3 J4 J5 E T ee a a swi HC900 i oO Terminal y y y lt Block Ji c1 C1 c1 C1 SW SPST TB1 19 6 E ena a 20 7 DE el Ean haa 5i 3 lt a N a TEE a a r 22 9 lt S _ rp gl 23 10 C 24 20 E ne E T 25 19 TA 26 18 A ETT 36 17 A ia ee eee 35 16
76. Ethernet 10 100Base T Open Connectivity Network port Redundant controllers PC communicates with Lead Controller only NOTE For specific PC requirements and for specific software requirements refer to the Designer Software Users Manual RS 232 Modem Devices The PC configuration tool connects from the RS 232 serial port of the Controller Module to a serial port on the PC For new system the PC Configuration tool connects to the RS 485 port on the Controller Module using an external Honeywell Qualified RS 485 to USB converter The PC can be located remote from the Controller by using Modems and telephone links Modems and suitable cabling are available from third party vendors 26 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Ethernet Devices Considerations Redundant controllers PC communicates with Lead controller only PC Configuration Tool Controller f PC a Modem a Cable Pc N CF modem c Poan A A Modem mj Ne Telephone Telephone Cable Figure 17 RS 232 Modem Devices Ethernet Devices Considerations Ethernet device requirements vary with specific applications Regarding intended use however they fall into two categories 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
77. 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 18 HC900 Process Controller Installation and User Guide 13 02 14 Components and Architecture Components Figure 4 Configuration with Multiple Controllers CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings 14 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Components Table 1 Descriptions of Major Components Figure 4 Key No Component Description Source Name 1 Controller Includes 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 900 Control Station operator interface communicates Honeywell Inte
78. Figure 55 Contact Input Wiring Diagram DC Output Module Wiring The DC Output Module provides 16 current sinking outputs in two groups of eight points per group The two groups are isolated from each other outputs are non isolated within each group Current sinking means that a positive voltage potential is continuously applied to one side of each DC output load and the negative side of the load is switched internally in the module 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 56 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 18 HC900 Process Controller Installation and User Guide 101 02 14 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 Figu
79. HCUtilities or Ol to If the lead s status If thelead 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 jo ASYS and FSYS blocks HW OK CPU Diagnostics Diagnostics in pied it was powered pins are tumed off display a ae 5 Y I I Note If the reserve s battery fails lf the reserve s A 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 166 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Controller CPU indicators Number of Red Strobes Possible Causes Lead and or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication One of the following RTC conditions occurred RTC was previously programmed but when it was last read its date and time were deemed invalid An attempt was made to
80. Honeywell HC900 Process Controller Installation and User Guide Doc No 51 52 25 107 Revision 18 Date February 2014 Honeywell Process Solutions HC900 Process Controller Installation and User Guide Revision 18 02 14 About This Document Warranty Remedy Notices and Trademarks Copyright 2014 by Honeywell Revision 18 February 2014 Warranty Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Honeywell Process Solutions 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners Revision 18 HC900
81. 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 Igrp current sources Also two terminals are jumpered together as they are for two wire RTD inputs Analog channels wired for Ohms inputs differ from RTD inputs in these aspects e Ohms inputs connect to variable resistance devices other than RTDs and e Ohms inputs are configured in Designer Software as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in Figure 42 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section As WARNING AY Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury RTD 3 Wire Z p Input mpag H iol IRTD E DE lt 4 H hae INJ IN 1 T 7 IN 14 i fascasaamie Ni Ni a a Thermocouple Se 1 1 amp 2 law 1 amp 2 Input ny lt A eea mofo ni n X EO o memmen phy 35 IN 3 TZ z Leescanes JN i TE Lj m J 34 lem 3 amp 4 Ohms Trenin IN 4 S IN4 came Input Jumper C____ N4 ri ES hoo 5 amp 6 lew 5 amp 6 geceweeeenemeee IN G4 IN 6 b dosim MS a IN5 mV v mV or V ra t H IN7 eae Input Source AR Aro 7 amp 8 IN 8
82. 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 message frame is embedded into a TCP IP datagram as indicated in Figure 20 Transaction Protocol Length Modbus Identifier Identifier Field Frame J l s r 1 Function Figure 20 Modbus TCP Framing Revision 18 HC900 Process Controller Installation and User Guide 31 02 14 Components and Architecture Ethernet Open Connectivity Network 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 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 a
83. Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Temperature Device Inputs 3 4 5 6 F 1 w Shield Ground typical Figure 43 Analog Input Wiring Eight RTDs Revision 18 HC900 Process Controller Installation and User Guide 87 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Slidewires Figure 44 Analog Input Wiring Slidewire Position Proportion Block 88 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 16 point High Level Analog Input Wiring Figure 45 Be sure to set the module DIP switches for voltage or current mode See page 77 V Source V Input J cA i 2 IN 1 sa ina 4 7 QHO r s 4 20 mA Input GOooas JO IN 15 IN 16 g IN 15 oes IN 16 m32 Nc om Ne s d PBABDAOOO OO O OOOOOO0 C Figure 45 16 point High Level Analog Input Wiring 4 channel Analog Output Module Wiring An example of Analog Output Module wiring is shown in Figure 46 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 Ay WARNING A Hazard
84. Module Replacement ceeeeescceeseecssceessceceneeessceeesaeessaecesaeessseessaeecsaeeceaeesseeseseeesaeeseas 188 Table 37 RIUP Potential Hazards and Recommended Actions ccccccceesseeeeeeeeeeeeeeneeeeesneeceeseeeeeeeeeeenes 189 Table 38 O Module Replacements izsenis aoei a eS ca soa aa lei Sedat tecving a E E EE 190 Table 39 Installing Backup Battery CPU not initialized eels eesecsneeesneeeeneeeseeceaeeeseesseeessaeeeseeeenaes 192 Table 40 Replacing a Backup Battery CPU Powered 0 ceseesseesseecsseecsseeeeseeeseeesaeeesaeceaecssaeessaeeesaeeesaee 193 Table 41 HC900 PV Input Types and Ranges 0 cee eeeceseseceseeeeseeesseecsaeessacesseeeseeesseesesaecsseesseeenseesenaeeenaes 200 Table 42 System Size and Availability Summary eeceeeceesneeesneecsseeesaeessseeesaeeesseesesaeseacesssaeeseessnaeeenas 203 Table 43 Fiber Optics Equipment Recommendations escceeseesseessneecsneessneeesseeesscecsaeceseesseesssaeseseeeesaes 204 x HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Purpose Figures Figure 1 Small HC900 Controller Configuration cee ceesceesceceseecsseeesseeeeseeessaeeesaeeesaeessaeessaeeesaeessaeessaeessneeesea 7 Figure 2 Expanded HC900 Controller Configuration C50 C70 CPU only scesscsseecssceeeeneecsseessaeessaeessaeeee 8 Figure 3 Single process with redundancies eesceesccssse
85. N 3 IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUT OUTPUT2 OUTPUT3 OUTFUT4 COM ENCGDE ENCODE a olay Dd DQ Figure 70 Quadrature Single Ended HC900 Power Wiring Revision 18 HC900 Process Controller Installation and User Guide 02 14 115 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams This page has been intentionally left blank 116 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Overview Overview Communications Installation This section contains descriptions procedures and recommendations for installing communications systems and components Wiring and cabling Table 16 Connect Communications Wiring and Cabling Step Procedure Comments Reference See 1 Determine requirements for communications links e Ethernet Devices Considerations on page 27 e For legacy system serial Ports RS 232 and RS 485 on page 35 For new system two RS 432 serial ports on page 35 e Cabling Wiring Distance Planning on page 45 cabling 2 Refer to the diagram at right and to Table 17 Links to Controller Communication Ports for connection details All ports are shown Availability depends on controller model see Figure 12 page 23 Connect communications For Modbus connections see page 142 RS232 RS485 connectors top to bottom Shield TX R
86. N rail Latch to rail See page 244 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs voltage is still present on the positive side at RTP and module terminals 3 C C C Ca Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 73 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is possible but See page 242 for RTP internal schematic 236 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input 4 Connect field wiring Refer to the appropriate figure for your type of analog input RTP A for inputs 1 to 10 RTP B for inputs 9 to 16 Notice that Inputs 9 and 10 are connected across RTP A and RTP B Figure 100 Voltage input connections RTP B for c inputs 11 d T to 16 D i i B i ED i f 3 D 35 D Not shown recommended external current loop fuses Additionally on RTP A connect the followi
87. NiMo NiCo 0 1371 C MoCo 01400C 110 NiMo NiCo 32 2500 F MoCo 32 2552F 111 NiMo NiCo 0 682 C n a NiMo NiCo 32 1260 F n a NiCroSil NiSil 18 1300 C N 01200C 24 NiCroSil NiSil 0 2372 F N 322192F 25 NiCroSil NiSil 18 800 C N 0 800C 22 NiCroSil NiSil 0 1472 F N 321472F 23 R 18 1704 C R 20 1760C 28 R 0 3100 F R 43200F 29 S 18 1704 C S 01600C 30 200 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 400C 40 T 300 700 F T 328 752F 41 T 129 260 C T 50 150 C 34 T 200 500 F T 58 302 F 35 W_W26 20 2320 C W_W26 20 2320 C 52 W_W26 4 4200 F W_W26 44208F 53 W5W26 18 2316 C W5W26 20 2320 C 54 W5W26 0 4200 F W5W26 44208 F 55 W5W26 18 1227 C n a W5W26 0 2240 F n a Platinel 0 1380 C PLTNL 01380C 118 Platinel 32 2516 F PLTNL 322516F 119 Platinel 0 750 C PLTNL 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 C Pt1
88. O card with correct number of channels Revision 18 HC900 Process Controller Installation and User Guide 177 02 14 Diagnostics and Troubleshooting Ethernet Switch indicators Table 33 LED Indications on Ethernet Switch LED LED State Color Description 10Base T port XMT upper LED Green On Off On while a message is being sent from the Main CPU otherwise Off LINK lower LED Green On 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 178 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting This page is intentionally left blank Revision 18 HC900 Process Controller Installation and User Guide 179 02 14 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 usin
89. OE ooo External Power Wiring Revision 18 02 14 HC900 Process Controller Installation and User Guide 113 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder 5to24Vde 4 Single ended A Internal jumper LL Encoder power ig OUTPUT COM ENOODE ENCODE input 5 to 24Vdc Figure 68 Quadrature Single Ended External Power Wiring Ati ntan For Input4 Inpul 2 and Index faverse polarity to Encoder 200mV to 6 0V Differential 200mV to Z H 6 0V gt Differential Internal jumper 5V Encoder power from Hcgs00 Attention For Input Input 2 and Index reverse polarity to IN 9 PTT IN 1 x rN ee es a re IN3 N4 ER IN 4 pema oO INDEX LO INDEX 7 EA k s ER OUTPUTI oa CUTPUT2 5 AN OUTPUT2 Sy A lay n OUTPUT4 D COM S ENCODE Ss S EA Hea Fe i a b In4 IRDEX INDEX SENSE SENSE OUTPUT1 Figure 69 Quadrature Differential HC900 Power Wiring HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder i At Single ended B 5 Internal jumper OUTPUT1 OUTPUT2 OUTPUTA OUTPUT4 COM ENCODE ENCODE Encoder power IN t IN t IN 2 IN 2 IN 3 I
90. Output Module Wiring Diagram DOOQOOTOOGOOS ase ee tee O9 CTO Revision 18 02 14 HC900 Process Controller Installation and User Guide 107 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Output anne 5 snnnnnns Figure 60 AC Output Module Jumper 108 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 61 Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure 62 p goras O lt O7rO3 Fuses appropriate for load and for wire used are provided by user a o Fuses appropriate for load and for wire used are provided by user Figure 61 Schematic Example Relay Output and External Wiring Contact Rating Maximum current output 4A at 250Vac 30Vdc with resistive load Maximum current per module No de rating per module but ensure compliance with maximum ratings for each output Note specified relay life is 1 000 000 cycles For applications requiring constant cycling of outpu
91. Procedures Table 40 Replacing a Backup Battery CPU Powered Step Action 1 Ay 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 2 Note the orientation of the battery holder assembly battery toward the left 1 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 18 02 14 HC900 Process Controller Installation and User G
92. Process Controller Installation and User Guide iii 02 14 Abstract About This Document This document provides descriptions and procedures for the installation operation and maintenance of the HC900 Process Controller hardware References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title HC900 Process Controller Technical Overview Specification HC900 Module Specification HC900 Controlware Specification Designer Software Specification HC900 Process Controller Operator Interface User Guide HC900 Designer Software User Guide HC900 Process Control Utilities User Guide HC900 Process Controller Function Block Reference Guide HC900 Process Controller Communications User Guide HC900 Controller Redundancy Overview amp System Operation 900 Control Station For use with HC900 Process Controller Station Designer Software manual Revision Information ID 51 52 03 31 51 52 03 41 51 52 03 42 51 52 03 43 51 52 25 108 51 52 25 110 51 52 25 126 51 52 25 109 51 52 25 111 51 52 25 133 51 52 25 148 51 52 25 149 This manual 51 52 25 107 HC900 Controller Document Name Revision Number Installation and User Manual Publication Date SIL updates Shielded cable added Rev 18 February 2014 HC900 Process Controller Installation and User Guide Revision 18 02 14 About This Document Support and C
93. TU TCP master or slave In new systems RS 232 to RS 485 cable is used for link to PC configuration tool e Link to Operator Interface For legacy and new systems RS 485 port used for 2 wire link to the Operator Interface up to 2000 feet or 601 meters 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 and C30S CPU 10 HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Feature Summary Redundancy e Supervisory Network Ethernet 10 100 baseT to PC Applications HC Designer amp HC Utilities communicates to peer HC900 Controllers over Ethernet C75 has two Ethernet ports Lead C75 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 C75 CPU e Device Network RS 232 or RS 485 Serial Interface Modbus RTU Two serial ports available for legacy systems Each port can be set as Modbus Master or Slave Host Serial Interface for Honeywell or third party operator interface For new systems two serial R2 485 ports are available Each port can be
94. U is not powered Controller CPU and Scanner firmware versions are incompatible 7 Defective Controller CPU Scanner power supply or rack either at failsafe or in the power down state If communication was lost while the modules were being scanned then the module outputs are in their failsafe state If communication was never established to the Scanner then the module outputs are in the power off state 12 13 Ensure that the Scanner and Replace the expansion rack s switches on the scanner are set correctly C75 only Verify that the CPU A cable is connected to the A port and the CPU B cable is connected to the B port on the Scanner 2 If a switch is used check that all cables are properly connected to the switch proper crossover cables are used that the switch is powered and it supports 100 Base T Check cable shielding for proper grounding and noise immunity Make sure the cables have the correct pinout Cycle power to the Scanner Cycle power to the switch Cycle power to the controller CPU Replace the expansion rack s scanner module Controller CPU software versions are compatible If not perform a firmware upgrade power supply Replace the expansion rack Replace the main CPU 172 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Scanner indicators
95. X TX RX S14 RS 232 To PC Configuration Tool Se ee f 2 RS 485 port To Operator Interface Ree ee ee a a Y Ei To PC applications oF peer C900 controllers p E2 Ta PC applications or peer HC900 controllers Gr te To single 1 0 Rack or hub ee ae e Communication Ports all ports shown Revision 18 02 14 HC900 Process Controller Installation and User Guide 117 Communications Installation Wiring and cabling Step Procedure Comments Reference Set IP addresses and subnet masks Default IP addresses C30 C50 192 168 1 254 and Subnet Mask of 255 255 255 0 C70 C75 E1 192 168 1 254 E2 192 168 2 254 Must be on different subnets Links to controller communication ports Refer to Table 17 and the figure in Step 2 above Port availability depends on Controller model Controller Port Connector Type RS 232 3 plug connector RS 232 3 plug connector RS 232 3 plug connector RS 232 3 plug connector RS 485 3 Plug connector RS 485 3 Plug connector Table 17 Links to Controller Communication Ports Link Type Controller to Desktop or Laptop PC Modbus master controller is single slave Modbus master controller is one of multiple slaves Modbus slave network controller is master Operator interface Modbus master controller is slave Cable Type RS 232 Null Modem cable up to 50 Or RS
96. a plant network Also ensure that the PC Network Interface Cards have an IP address that allows access to the controller on the subnet after changing the controller s network parameters 7 You may change the controller s IP 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 123 Attention IP addresses for E1 and E2 must be on different subnets 8 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initializat
97. a single screw connection by expanding the connectivity of the shared terminals of the I O modules There are three RTP types See page e 8 Analog Input 208 e Relay Output 215 e 16 point Analog Input Digital Input Digital Output Analog Output 219 HC900 Controller F Cable various a lengths available Shield drain wire RTP mounted on Terminals for field A DIN rail Figure 92 Example installation not shown 2 RTP amp cable for high capacity Al DI DO Revision 18 HC900 Process Controller Installation and User Guide 207 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input 8 Point Analog Input ee 1 ATTENTION RTP is not for use with thermocouples ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 92 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
98. age e Low voltage alarm relay output wiring lt 50 Vdc Vac e Low voltage wiring to solid state type control circuits Revision 18 02 14 HC900 Process Controller Installation and User Guide 51 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 32 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 A 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 s to disconnect power from the power supply at each module
99. allation Planning Electrical Considerations Grounding Barm gr 14 AWG 2 1 mm gt oes Pr L1 H 2 A hA 8 ie L1 H L2 N PE Power Source Figure 30 Cabinet Wiring Multiple Chassis Revision 18 02 14 HC900 Process Controller Installation and User Guide 49 Pre Installation Planning Electrical Considerations Li H L2 N PE PE L2 N L1 H Power Source Power Source For P01 power supply use 3 0A slow blow for 115VAC operation 2 5A slow blow for 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 31 Redundant power supplies each with external fuse and switch 50 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 wiring group connecting wires into bundles see Table 5 and route the indiv
100. an RJ45 connector to each cable end To ensure reliability do not untwist the pairs any more than necessary to complete the crimp connection Use care to ensure that the cable drain wire is securely connected to the shield of the RJ45 connector when the cable is crimped Reference the manufacturer s instructions 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 29 Cabinet Wiring Single Chassis and Figure 30 Cabinet Wiring Multiple Chassis Deviations from the installation conditions specified in this manual may invalidate this product s conformity with Low Voltage and EMC Ay WARNING AY Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources Failure to comply with these instructions could result in death or 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 18 HC900 Process Controller Installation and User Guide 47 02 14 Pre Installation Planning Electrical Considerations L1 H L2 N PE Power Source Figure 29 Cabinet Wiring Single Chassis 48 HC900 Process Controller Installation and User Guide Revision 18 02 14 Pre Inst
101. ane 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 5VDC and 24VDC to satisfy the power requirements of a single controller with T O a Remote I O rack or a Redundant C75 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 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 19 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 WARNING SHOCK HAZARD MORE THAN ONE SWITCH To Figure 10 Power Supply Revision 18 HC900 Process Controller Installation and User Guide 02 14 21 Components and Architecture Hardware Components Power Status Module C75 The Power Status Module PSM Figure 11 sits between redundant power supplies on the I O rack see page20 It is a status module for both power supplies and indicates which are
102. ation An illustration of HC900 Controller Peer to Peer on a Local Area Network LAN is given in Figure 19 Typically a Router is used for interconnection to another network LAN WAN or other t r FPC Host i PC Host PC Host i i 4 1 dmimipima r i i Networking Devices e g Hubs Switches etc Remote PC Host LAN 2 WAN Configuration File Configuration File Functton Blocks Function Blocks PDE Read PDE Read PDE Write PDE Write PDE Control PDE Control Figure 19 Modular Network Structure 30 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Ethernet Open Connectivity Network Connection to PC Hosts For legacy systems connection to PC hosts for example PCs that include HMI supervisory software and or Designer Software configuration software can be via Modbus TCP as well as serial Modbus RTU over either the RS 485 or RS 232 communications ports Both ports support Modbus RTU and are configurable as master or slave For new systems connection to PC hosts can be via Modbus TCP as well as serial Modbus RTU over the RS 485 communication ports 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
103. ber 900TNF 0001 12 In each slot location not Note The Filler Block Cover looks much like an I O Terminal occupied by an I O Block assembly except that it does not include the wire module install a Filler terminating block screw terminals The Filler Block mounts in Block cover Part number the same manner as a Terminal Block with captured screws at 900TNF 0001 top and bottom Blank labels are provided for mounting in the hinged door Revision 18 HC900 Process Controller Installation and User Guide 81 02 14 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 39 shows wiring examples of each of the analog input types An example of wiring for eight TC inputs is given in Figure 41 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 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F AWG No Diameter TypeK TypeJ Typ
104. ble serial port COM1 through COM8 on your PC Refer to RS 232 Converter Direct Link to PC Configuration Tool page 124 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 faster baud rates Refer to the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Utilities Worksheet Set Controller Serial Port for details on this step Current PC to Controller Connection Settings _ Bitit Q Loop Back Statistics Port Protocol Honeywell Inc ELN Speed bps 38400 PC Port Setup Network COM1 6 On the PC use the Utilities Worksheet in the HC Designer software to select the Com port as the current port Revision 18 HC900 Process Controller Installation and User Guide 123 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Softwar
105. can write on the RTPs labels to distinguish them 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 3 Set verify jumper positions on each RTP as shown C C C See page 242 for RTP internal schematic 238 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 Install jumper wire DC Supply RTP B for outputs Q DOAA Install jumper wire DC Supply refers to the switched negative side of the DC supply Note SDC Note Terminals 9 and 11 DC are connected through the RTP cable Same for terminals 10 and 12 DC 239 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Input ATTENTION RTP and cables are intended for permanent installation within their
106. cations Installation Connecting the HC900 Controller to a PC with the 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 e Baud Rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller e Parity None e 1 stop bit e 8 data bits e No handshaking e Ignore DTR e Suppress result codes e Suppress echo e Auto answer e Disable command recognition only necessary if the modem has this capability Some of these settings may be settable via switches Others may require command strings to be written to the modem using a PC terminal program such as Hyperterminal You will need to refer to your modem s documentation to make this determination Those settings that are configured using command strings must be saved to the modem s non volatile RAM NVRAM and the NVRAM must be configured as the profile that gets loaded when the modem is powered up Most modems are equipped with auto recognition to set the baud rate parity stop bits 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 suc
107. cations 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 Designer software to set the proper network 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 18 HC900 Process Controller Installation and User Guide 187 02 14 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 C75 CPU controllers only requires that the source of AC power is removed from the rack Removing power from the Expansion rack has the following consequences e All power to all I O modules in the rack will be lost hence all control outputs from the rack to the process are lost e Redundant controllers will operate with the affected I O in failsafe state during Scanner2 module replacement e Does not impact other I O Racks in the same configuration Table 36 Scanner Module Replacement Step Action 1 If a process is currently in operation then 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 Using an external user supplied switch disconnect the power su
108. cccecccceeesseeeeeneeeeeeneececenaeeeesenaeeeesnneeeeenaees 73 Table 14 Connect Input Output Wiring eee eseeescecsneecssceceseecesaeeesaeessaecesseeesseeesseecssaeseseesenaesesaeeesaeeeaees 74 Table 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F errereen 82 Table 16 Connect Communications Wiring and Cabling eeseesecsseeceseessneeseneeeeseeesaeeesaecseesssaeeesaeeesaes 117 Table 17 Links to Controller Communication Ports cccesccceeeeececeeeneeeeeeaeeeceenneeeseaaeeeesseeeeesneeeeeeeneeeseeee 118 Table 18 Parts needed to make RS 485 Cable eeeeeseecssceceseeeeseeeesaeessaeeesaeeesaeessseecsseecscecseeesseeeesaeensas 121 Table 19 Null Modem Cable Connections cccscccceseeceeeeeneeeeesaeeeeeeneeeeseneeeeseaeceseaeeeeseeeeceeeeeeesseeeenaes 124 Table 20 Redundant Network connections in Figure 74 cesceeseesseecsseeesseeesneeesseeesseecssaeeesaessaesesaeeesaeessaes 136 Table 21 Redundant network connections cceeseccceesenceeeseeeeeeenneeeseeneeeessaeeceseaeeeeseneeceseeeeeeeneeeeeeeeeesaes 137 Table 22 Controller Operating MOdES ccc ssi cee caches ccts tees aya eines ne EE EE AAEE aa TA Ra a ai a 150 Table 23 Mode Swatch Fun ction eer EE A A atte cus E E E a 151 Table 24 Controller Behavior in Mode Tramsition cccesecsceeeeseceeeeneeeeeeeneeeceeneeceesaaeeesenaeeceeeneeeeseneeeeeeeae 152 Table 25 Configuration file downloading
109. ce 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 18 HC900 Process Controller Installation and User Guide 145 02 14 Operating Characteristics Power Down Power Up r Hot Start Copy new configuration in RAM Initialize all control blocks data Controller goes to Initialize modbus RUN mode and PDE tables r Start copying config data to Flash in background Figure 79 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 in Figure 80 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 79 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 sele
110. cesseeesseesseecsaeecsaeeeseecseeeseecesaecsseecesaeeesseeesaeeesaeersas 9 Figure 4 Configuration with Multiple Controllers eeseescceeseecsseeceseeeeseecsneeeeaecssaecesaecssaeessaeeesaeesseeesaeers 14 Figure 5 Redundant Configuration with multiple I O racks 0000 eee eeeeeeeeecsneeeeseeecneeeesneessaeessaeessaeessaeessaeeesseees 16 Figure 6 Controller Rack Components 0 ceescceeseecsssecesceesscecesseecssecesaeessaeeesseeesseecesaecseecsaeeesaeeesaeessaeessaees 18 Figure 7 Redundant Controller Rack Components cssccssscecssceeeseecsseeceneessneeeeaeessnecssaecesaeeesaeeesaeessneeesaeers 18 Figure 8 I O Expansion Rack Components cesccsessecssceesseeeesseeesseessaeesscecsseeesseecssaecsseecesaeeesaeeesaeeseaeessaees 19 Figure 9 Rack Options a yee ses dices ashen ev gots sug ets cee ceah ngs i eista adiantado betty edstedsesthusuarstbayevecebecteateteys 20 Figure 10 Power Supply zese e eee ety sath cays tng a a esd a MET duane wets ended er eee 21 Figure 11 Power Status Module PSM cccsssccesssseceesenceeeesneeeeeseneeecseaeeceeseaeeecssaeeceeseeeeeseaeeeeseeeeeesnaeeeseaaes 22 Figure 12 Controller Module ice seos rehone asen eosa aea aaaea duane oddgtuubeveyotes pony iaaeao taney 23 Figure 13 Redundancy Switch Module eceesceescccescessseeceseeeessecesecesaeecsaeesseeesseecsseecsseesssaeessaesesaeeesaeessaees 24 Figure 14 Scanner 1 Modules oj 3s Saenger cts neste goats
111. ch input type Step 3 _ C yala yN GN VN enx EL oN TO yx X De y ndul lt Red 1 0 Figure 93 Analog input terminals COQOPOCOPPOCPPOLE You must set switches 1 8 for DO OSE OS OH OO OS OHOOHO transmitters G5 Gs Input 1 Q Transmitter Input 5 Input 2 Transmitter Input 4 Transmitter Input 6 Input 7 Transmitter Transmitter Transmitter ansmitter Input 8 Transmitter Figure 94 Two wire transmitter connections with common 24 VDC supply 210 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input al DOPOOPOPOOOPPOOPPOOE Note You must set switches 1 8 for Milliamp OG A AA A Input 8 Figure 95 Milliamp input connections with 250 ohm shunt resistance YVOOOOOVDOOOUOOYOOOOOO Note You must set switches 1 8 for Volts Millivolts C V mV Input 6 V mV Input7 V mV Input 8 V mV Input 1 V mV Input 2 Figure 96 Volt millivolt input connections Revision 18 HC900 Process Controller Installation and User Guide 211 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Input 5 Input 7 Note You must set switches 1 8 for RTD Input 1 Input 2 Input 3 Input 4 Figure 97 Three wire RTD input
112. connections Input 5 Note You must set switches 1 8 for Ohms Install jumper wires 3 23 6 26 8 28 12 32 13 33 16 36 17 37 20 40 Input 6 Input 8 Figure 98 Two wire RTD or ohm input connections 212 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 99 Slidewire feedback connections for actuators Analog Input accuracy specification Range Al Module Accuracy RTP Cable Accuracy Al Module RTP Accuracy 0 1 of Range 0 12 Range 0 824 C 0 1 of Range 0 57 Range 1 540 C 0 1 of Range 0 07 Range 0 140Q 0 10mV LINEAR 0 1 of Range 0 04 Range 0 004mV Revision 18 HC900 Process Controller Installation and User Guide 213 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input RTP Internal schematic HC900 Terminal Block J1 TB1 I A e rai SW 1 2 250 Ohm 22 2 7 o 23 4 3 os 4 6 a 7 OW 26 SW 2 2 250 Ohm q 5 10 e WMM s o a 6 20 a Oo O w E SW 3 2 250 Ohm i 7 19 o 29 10 8 18 oi 9 17 12 OW SW 4 2 250
113. cseeseeeeeseessnaeeesaes 123 Figure 72 RS 232 Remote Access via Modems scccessccesseeesseeeseecseesseesseesseeesseecsaecseeseaesesaeeeneeeesaes 125 Figure lt 73 Modei Connects neien See eho a dae ee tet ee eine 126 Figure 74 Redundant Networks see Table 20 cccccecesseceesseeeeeeeeeceseeeeeeeneeeeesaeeeeesnaeeesenaeecesenneeeeenneeeseeas 135 Figure 75 Two redundant systems with PC supervision eesccceseeceseecssceceseeceneeeesaeeesaeessaecesaeessaeeesaeeesaee 138 Figure 76 RS 485 Modbus slave wiring ceescessecsscecsscecssceceseeesseecesaeessaeessaeessaeecsseecseesssaeseeeseseeeesaeeesas 142 Figure 77 RS 485 Modbus slave wiring with isolation csceesceceseecsseeesseeceseeesseeessaeeeaecesaecesaeessaeessaeeesaes 143 Figure 78 XYR 5000 RS 485 Modbus connections with isolator eecceeesecsseeceseeeseecsaeessaeesseessaeeeseeesaes 144 Figure 79 Warm Start Operation 0 ccccsseseeeecerenscrensetencnectecssnoccenonenseteedoncntecenscenenseesnoetessnessoseesoeseonersese 146 Figure 80 Cold Start Operation osscceyccedseg yebe Lagsuah laceeed eves dees neit ereo a i asai easan aeea e paee ipae itte 147 Figure 81 Mode Switches Controller left RSM right c ccesssssceessnseeeeeneeeeeenneeeeeseeeeeseeeesseeeeeeeeeeeneas 151 Figure 82 Pathways for Upload Download Transactions ccesccessecsseecesceceseeeeseeessaeeesaeessaeeesaeessaeessaeeesaes 153
114. ct instrumentation A CAUTION and literature If present on a product the user must consult the appropriate part of the accompanying product literature for more information This CAUTION symbol indicates a potentially hazardous situation which if CAUTION not avoided may result in property damage gt iF p Ob b 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 ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices CAUTION HOT SURFACE This symbol warns the user of potential hot surfaces which should be handled with appropriate caution Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor 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 cha
115. cted or any transition from PROGAM Mode to RUN Mode 146 HC900 Process Controller Installation and User Guide Revision 18 02 14 Operating Characteristics Power Down Power Up Copy RAM to Flash database invalid database Operate in RUN Mode Operate in PROGRAM wi initialized process values Mode w all outputs off Figure 80 Cold Start Operation Revision 18 HC900 Process Controller Installation and User Guide 147 02 14 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 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 a
116. cted from these screw terminals when switch SW1 is open 0 Install jumper wire DC Supply Note DC Outputs provide electronic overload protection in the module but adding a fuse see picture protects the wiring Revision 18 HC900 Process Controller Installation and User Guide 227 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point AC Digital Output ro 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 92 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 9OORTC H010 Remote Terminal High Voltage Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 9OORTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 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 70 Mount RTP to DIN rail e
117. d Revision 18 HC900 Process Controller Installation and User Guide 185 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Step Action 6 Secure the lugs for AC wiring to the terminals on the new power supply e L1 top terminal Black USA or Brown Europe e L2 N middle terminal White USA or Blue Europe e Ground bottom terminal 7 Ensure power can be applied safely and use the external user supplied switch to re connect power to the power supply 8 Using a meter and the test points on the face of the power supply ensure that voltages measured on the backplane are within specifications 186 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 C75 module 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
118. d User Guide Revision 18 02 14 Removal and Replacement Procedures Safety Considerations 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 18 HC900 Process
119. d string AT amp Y0 amp CO amp DO amp R1 amp S0 amp K0 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 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 134 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Connecting C75 Redundant Ethernet to a PC with HC Designer or other applications Only use Shielded CAT 5 cable IO for network connections See Figure 74 and Table 20 is Figure 74 Redundant Networks see Table 20 ATTENTION Always observe the wiring cabling guidelines on page 45 Revision 18 HC900 Process Controller Installation and User Guide 135 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Table 20 Redundant Network connections in Figure 74 Key No Connection Description la Connect CPU A E1 port to Ethernet switch 3a
120. dem 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 Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected O a Aa Ww Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key The modem should respond with OK 130 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Step Action 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
121. devotes ace ested eare aiaa ioaea aa apia a ea eaaa tenes 24 Figure 15 Scanner 2 Modules ra iseensateasel As iiss dapieed eect egos catagetteeisinigisakatelacs Sa E E AE EE EAS 25 Figure 16 I O Module Terminal BlOcKS 20 0 0 ceeseesceesseceseecescecesseeesaeeesaeecsaeeeseeessceceseecsseecsaeeseaesesaeeesaeeraees 25 Figure 17 RS 232 Modemi Devices orisirisi onsets a E AS EAA ATAA A teal EE a a TSS 27 Figure 18 HC900 Controller Configurations cceesscesseceseceseeeseeesaeecseesseeeseecssaecsseecssaeeesseeesaeessaeessnees 28 Figure 19 Modular Network Structure ees eeseeesecssceceseeceteecesaeessaeeesaeecseessseeesseeceseecsseecssaeseseeeesaeeesaeeesaees 30 Figure 20 Mo db s TCP Framing oii seagitchichiscterdisiess anions aE gic EEE SEa laige ida EEE A Eaa Eaa aA a TENG 31 Figure 21 Typical installation using a Cable Modem esseeeseesesesseseseseseresrresrirerrestessressressrssressessreseresereserest 34 Figure 22 Controller Serial Ports snoite s a enes ae E AAEE A Eaa E Ee EE ENEE 35 Figure 23 Serial Ports DIP Switch default settings ees ceeseceseeceneeceseeeeseeesneeeesaecesaecesaecssaeessaeeesaeeeseessaeers 36 Figure 24 Rack Dimensions C30 and C50 cccssssceeeeneeceeseceeeeesnceecesaeeeceseeeeesnaeeeessaeesessaeeceeseneeceneaeeeeseanees 39 Figure 25 Rack Dimensions with reserve power SUPPLY ceesceeeseecesceesseeeeeseeeneeeesaeessaeeesaeessaeesseeeseessaeees 40 Figu
122. e 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 19 Table 19 Null Modem Cable Connections 9 pin D female connector 3 plug connector 9 5 8 4 1 7 amp 3 2 6 2 3 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 124 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the 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 19 A second Null Modem cable is used between the PC and the internal or external modem at the other end as shown in Figure 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 Designer Software configuration tool can be perfor
123. 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 52 HC900 Process Controller Installation and User Guide Revision 18 02 14 Pre Installation Planning Electrical Considerations Power Supply in HC900 Controller Rack Power Supply i in HC900 O Expansion Rack Ea Multiple V O Expansion Racks Power Supply in HC900 I O Expansion Rack Power Emergency Power ON Sto OFF m di ocr 2 Lt 2 J a e MCR F Input Modules ea e e 2 Y E Input SE Be Output Modules i F Figure 32 Master Control Relay Wiring Example Revision 18 HC900 Process Controller Installation and User Guide 53 02 14 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 blocks are described in the HC900 Function Block Reference Guide 5 1 52 25 109 54 HC900 P
124. e T Type E Type S Type R TypeWw5 Type W inches PY PT110 IPY PT113 W26 W26 10 0 102 0 058 0 034 0 029 0 069 0 018 0 018 0 023 0 020 12 0 081 0 091 0 054 0 046 0 109 0 028 0 029 0 037 0 031 14 0 064 0 146 0 087 0 074 0 175 0 045 0 047 0 058 0 049 16 0 051 0 230 0 137 0 117 0 276 0 071 0 073 0 092 0 078 18 0 040 0 374 0 222 0 190 0 448 0 116 0 119 0 148 0 126 20 0 032 0 586 0 357 0 298 0 707 0 185 0 190 0 235 0 200 24 0 0201 1 490 0 878 0 7526 1 78 0 464 0 478 0 594 0 560 26 0 0159 2 381 1 405 1 204 2 836 0 740 0 760 0 945 0 803 30 0 0100 5 984 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 shown in Figure 38 Figure 39 and Figure 40 For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 Ir p 1 amp 2 This same current source Irtp amp 2 is also used for an RTD input at channel two terminals 4 and 5 RTD 3 Wire Input RTD 3 Wire Input Figure 38 and Figure 42 show examples of RTD input wiring 2 wire and 3 wire RTDs Four wire RTD inputs are not available Figure 38 RTD Inputs 82 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring
125. e actions to prevent all adverse consequences before removing or inserting an I O module under power Table 13 provides some general guidelines for establishing appropriate procedures at a given installation Table 13 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s Potentially lethal voltages on Disconnect all signals at terminal Ay WARNING Terminal Boards associated with blocks from sources of power before 1 0 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 i i specific function Any or all of the Using trained personnel and signals may be vital for safely appropriate control mechanisms controlling a process transfer to manual control for each signal that is necessary to maintain safe process control Or Loss of control or view of a running process Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON HAZARDOUS Revision 18 HC900 Process Controller Installation and User Guide 73 02 14 I O Module Installation and Wiring I O Module Installation Procedures I O Module Installation Procedures Table 14 Connect Input Output Wiring
126. e 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 Le 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 bh a acquired pull out turn it slightly to the proper a If after the power is cycledtoboth position until it can be removed the lead and reserve and the lead is 3 Replace the RSM peston te seleri daai ee ion wi the run program mode of operation gt 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 164 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indicatio
127. ecute 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 84 The Lead and Reserve controllers exchange system status to determine conditions for failover Revision 18 02 14 HC900 Process Controller Installation and User Guide 157 Redundant Operating Characteristics Failover Lead Controller Reserve Controller Get Inputs Get Inputs SYNC SYNC Control SYNC Control SYNC Execute Control Strategy Execute Control Strategy Write Outputs Diagnostic Check Diagnostic Check Communications Figure 84 Lead Controller synchronization Failover Automatic Failover e Triggered on any of
128. ed off NETWORK Lead Port E1 PORT E1 or Network Port NETWORK Diagnostics or PORT E2inthe Lead Port E2 Lead CPU Network Port Diagnostics Diagnostics in display the Lead If the reserve s Diagnostics status LEDis 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 18 HC900 Process Controller Installation and User Guide 169 02 14 Diagnostics and Troubleshooting Controller CPU indicators 170 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Scanner indicators Scanner indicators Figure 86 LED Indicators on Scanners 1 port left 2 port right See Table 28 Table 28 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 29 Scanner LED Diagnostics Solid Green Startup Mode Scan Mode 10Base T port 2 XMT upper LED Green On Off 3 LINK lower LED 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 R
129. eee teen ee etecaaaeeeeeeeteaaaaaeeeeeeecegecaaaaeeeeeeeseeeeeaeeeeeeees 156 FallOwGrssticriticet ce ceacaind al cad aT as ee lin it aA ON Me alae aea ataa a ES 158 File Download Upload Functions cccccccceceeeeeeeceeeeeeeeeeeeeceeeeeeeeeeseeceaeeeeeeeeeeseecccaeeeeeeeeseeessaeeeeeees 159 Diagnostics and Troubleshooting eticcs cee erect hecneeet eet die oe ae eee 161 OVOTVIOW TEATE EE TTT AT EAEE 161 External Indications of Diagnostic Information ssseessssessseerissseeirrtttteettrnrttttttttrrrrtnttsettnrrnnssnant 161 Controller CPU Indicators sei aiii cantecadasasesacanbdadasaddeadaenedanedaacnencasaaaas 161 Scaner d a OA r a aaa a E E aaa aE a a a aaa Mls tata ma a Uy clei aia aeaa erect cae 171 VO Module Indicators itinin a a de i dau aaide aana 175 viii HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Purpose Analog alibratl onian r ite Ge E E AEE 180 OEA AEE E EEE A E A 180 Removal and Replacement Procedures cccccccecceeeeeeeeceeeeeeeeeeeeeeeeeseneeeeeeeeeeeeeeeee 184 DETA A EEEE T TE A E 184 Safety Considerations PLAN AHEADI 0 eeeeecceeeee cece eeeeeeneeee eee eeeeeenaeeeeeeeeeeecccaaaeeeeeeeeesessaaeeeeees 184 SDC CHICATIONS crrctaictettattceraticeeiaasdae cies ra a E aaa e wean ca A EEEIEE 194 General Specifications ccccccccceeeeeecnneeee eee eeeeeeeaeeeee eee eeecaaeeeee eee eaaaaeeeeeeecceaaaaeeeeeeeesseceeaeeeeeees 194 HC900 Analog Inpu
130. eg b 4 20 MA Input Figure 39 Universal Analog Input Wiring Diagram Revision 18 HC900 Process Controller Installation and User Guide 83 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 2un 5 RTD 3 Wire Input EO E 1 AR a H H a0 Ih f H H Leon IN 14 1 Meeeseemememe i D 1 RTD 3 Wire eeenbewees be 1 amp 2 O Input r a o m Ban Pee H p nmas IN 2 an r i E pa 2 N2 EEr 5 leo 3 amp 4 Lith IN4 7 IN 5 4 fn 9 BG EE RTD 3 Wire at i Input IN ae F En E N7 O menpe 7 amp 8 S H _ e m IN B ra 7 i i Bea Pz p H a ee RTD 2 Wire i Input i maa Dela Figure 40 Examples of RTD Input Wiring 84 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Thermocouple Inputs Shield Ground F typical Figure 41 Analog Input Wiring Eight TCs Good QOOOGOO 29 D Deets Revision 18 HC900 Process Controller Installation and User Guide 02 14 85 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Thermistor Inputs W Shield Ground typical Figure 42 Analog Input Wiring Eight Resistance Inputs 86 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O
131. emains 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 18 HC900 Process Controller Installation and User Guide 171 02 14 Diagnostics and Troubleshooting Scanner indicators Scanner Diagnostic LED Indication The scanner uses its LED to communicate diagnostic information These diagnostics are a subset of the main CPU s and are listed below Table 29 Scanner LED Diagnostics Number Possible Cause Scanner 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 2 Repl disabled Module outputs are in the power off Pigeeera et 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 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 communicate to the controller CPU Possible causes include 1 Scanner address switches are not correctly set 2 C75 only The C75 I O port is connected to the wrong Scanner 2 I O port 3 If aswitch is used there may be a problem with it 4 Cables are defective or are not properly shielded Controller CP
132. ends height to 6 9 175 3mm N A 5 4 137mm H x 10 3 261 6mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 6 4 162 6 for 32 DI DO and 16 Al Modules 175 3mm 1 0 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
133. eps 1 and 2 for details 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 64 HC900 Process Controller Installation and User Guide Revision 18 02 14 Rack Installation Assemble I O Expansion Racks Step Procedure Commenis 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 C75 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 Honeywell Repeat steps 1 through 3 for each I O expansion rack Then for each I O expansion rack insert the Scanner Module immediately to the right of the Power Supply and secure it in place with the two captured screws in the faceplate I O will be installed later See Page 66 Revision 18 02 14 HC900 Process Controller Installation and User Guide 65 Rack Installation Assemble I O Expansion Racks This page has been intentionally left blank 66 HC9
134. er Figure 92 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 Output module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long 9OORTC 3250 Remote Terminal Cable assembly 5 0 meters long Install 16 point Analog Output label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 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 2 Mount RTPs to DIN rail Latch to rail See page 244 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs 3 Cm os Cm Co See page 233 for RTP internal schematic 234 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Pa
135. erface or Modbus devices host LED status indicators for communications functions C50 and C50S C70 and C70S C75 only applications or peer HC900 controllers C70 C75 only applications or peer HC900 controllers port S2 left port S1 right controller module Figure 12 Controller Module Redundant controller rack contains two C75s Left CPU is designated CPU A right CPU is CPU B either CPU can be Lead Revision 18 02 14 HC900 Process Controller Installation and User Guide 23 Components and Architecture Hardware Components Redundancy Switch Module C75 only The Redundancy Switch Module RSM is shown in Figure 13 It sits between C75 controllers on rack Left Controller is designated CPU A right Controller is CPU B Features include 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 and C50S C70 and C70S only The Scanner 1 Module is shown in Figure 14 It sits in the I O rack and provides the link between the controller and remote I O Features at the front of the module include Ce 1 LED status indicator for scanner functions 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
136. ernet 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 2460 Cable ft with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint 8 Ethernet CAT5 Connects devices in Ethernet Open Connectivity Third party suppliers or shielded cable network to 900 Control Stations and PC SCADA Honeywell IO applications 9 RS 232 cable For legacy system Null modem cable up to 50 Third party suppliers or 15 24m PC modem cable if used with Modems Honeywell 10 RS 485 to Connects RS 485 port to USB port Third party suppliers or USB converter Honeywell Revision 18 HC900 Process Controller Installation and User Guide 15 02 14 Components and Architecture Redundant components Redundant components 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 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 1
137. ess Controller Installation and User Guide 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 PO1 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 24 and Figure 25 Vertical spacing of racks which is required for rack ventilation and for routing wires is shown in Figure 26 Rear oe al mounting t plate Chassis height height 5 4 137 Total Depth Rack components For 32 D DO amp 175 16Al Reference Center PP aes for Drilled Holes _ ea 9 263 04 6 23 04 153 158 15 Figure 24 Rack Dimensions C30 and C50 Revision 18 HC900 Process Controller Installation and User Guide 39 02 14 Pre Installation Planning Rack Orientation and Mounting Py eeeteeeeeeeee SSP RSS SESE SESE SESE ESET ENE HE SHEET FE Fe 5 Total Depth a AAE y R M ma a gd e r e ar M A 3 ry OX NA components mounting 4E 12
138. essaessseesesaeessaes 107 Figure 60 AC Output Module Jumper 0 ees eeeeeesccsscecsneecsseeceseeessaeeesaeessaecesaeessaeecsaeecseecsseessneessnaeessaeessas 108 Figure 61 Schematic Example Relay Output and External Wiring eeeeseeersesrsesreerreerisrrrsrrrsrrrsreesrresrresresees 109 Figure 62 Relay Output Module Wiring Diagram eeceeeceseseeesseecseeesacesseeesaeeesseecssaecseessseeesseessnaeeesaes 110 Figure 63 Relay Output Module Jumper ecceesccescecsscecssceeeseeesssecesaeessaeecsaeessaeessseesseecseesesaesesaeeesaeersas 111 Figure 64 Pulse Counting Win esiasio a rnoes aea eaea E EEE E E E a aaa 112 Figure 65 P l e Output Wires cic eee eid eid inne E E a EE E Eii 112 Figure 66 Freguency Wiftns3 niet diselie placed aE E anh a iain ied 113 Figure 67 Quadrature Differential External Power Wiring cesceeeeecsseceseeeeseeesseeeesaeeeaeeesaeessaeeesaeeesaes 113 Figure 68 Quadrature Single Ended External Power Wiring ccsseccssceceseeeeeeeeesseeesaeessaeessaeessaeessaeeesaes 114 Figure 69 Quadrature Differential HC900 Power Wiring ceescccesecsseeesseeesneeeseeeesaecesaeeesaeessaesesaeeesaes 114 Figure 70 Quadrature Single Ended HC900 Power Wiring cesccesseccescecsseeeeseeesseeeesaeecsaecesaeessaeeesaeeesaes 115 Figure 71 A Direct Serial RS 232 Connection cceecesescceseeeesneeesseecsseessaeessneeesaeeesseecssae
139. f each of the major components of the HC900 system For environmental specifications refer to the section on Pre Installation Planning HC900 Controller Rack An HC900 Controller local rack is shown in the following figure As indicated in this figure the Controller Rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3 Controller Module 4 Grounding bars for I O wiring optional 5 Input Output modules 6 I O Terminal Blocks Figure 6 Controller Rack Components 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 C75 CPUs designated CPU A left CPU B right 4 Two 900P02 0001 Power Supplies Sp Fw Figure 7 Redundant Controller Rack Components 18 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Hardware Components I O Expansion Rack T O expansion remote racks shown in Figure 8 are available to accommodate additional input output modules and or to enable location of I O modules close to the process and remote from the controller For C75 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 and
140. force acold If thelead s status If the lead s status microprocessor microprocessor resets If it s the start LED is indicating LED is indicating exceptions occurred Lead controller and there is an If the problem reoccurs try the the failure see the failure see e Watchdog timer available reserve a failover occurs following CPU inthe Lead CPU Diagnostics timeout When the microprocessor CPU Diagnostics in the Lead J1 Ensure the system is properly display Diagnostics Address error completes its reset condition it will grounded rege become an available reserve if a l If the reserve s Overview dialog e Prefetch error leadis present or become aleadif 2 Ensure the system is properly status LED is box e Dataaborterror noleadis present isolated from temal noise SOUICES indicating the If the reserve s e Software interupt This diagnostic will cause the 3 Upgrade the firmware failure see CPU in status LED is a on HWOK pins of the AYSY and FSYS 4 Replace the CPU board He deh CPU oe oy blocks to be tumed off egnicele Ue SES instruction error 5 Contact Honeywell Personnel display Diagnostics in the Reserve Diagnostics Overview dialog box 3 One of the exception The exception vector was vectors located in RAM automatically corrected in the became corrupted controller s RAM and the controller continues to operate normally This diagnostic will cause the HWOK pins of the AYSY and FSYS b
141. g 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 A WARNING Hazardous voltages exist at the Power Supply and at the terminal boards on I O Modules Only trained and authorized personnel should perform the procedures in this section Failure to comply could result in death or serious injury H ATTENTION For calibration procedures refer to the Operator Interface manual or Process Control Designer manual Revision 18 HC900 Process Controller Installation and User Guide 180 02 14 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
142. g 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 I O expansion network is automatic it is entirely under control of built in private software that resides in the Controller Module and in each Scanner Module included in the HC900 system The controller examines the control strategy stored in its memory verifies that the physical configuration Rack Numbers and I O Module type by Module Number matches the stored control strategy and establishes communication with each of the I O modules in each of the I O racks I O Expansion Network C75 T O for redundant controllers is the same as I O Expansion Network page 28 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 T 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 applicati
143. g range selections of the HC900 Controller differ slightly from those available in the UMC800 These differences are indicated in Table 41 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 Designer Software 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 41 HC900 PV Input Types and Ranges Type Range Range High EU Reference Corresponding Low UMC800 Input type and range None n a B 18 1815 C B 40 1820 C 58 B 0 3300 F B 1043308F 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 0800C 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 01400 C 50 Ni NiMo 32 2500 F NiMo 322552F 51 Ni NiMo 0 682 C n a Ni NiMo 32 1260 F n a
144. g the HC900 Controller to Modbus device s Connecting the HC900 Controller to Modbus device s 2 RS 485 default S1 RS 232 default RS 485 terminals RS 232 terminals Shield asa Ground TXIRX TX TXIRX nsa DY S1 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 Install resistor as shown for terminated devices except HC900 For terminating HC900 do not install resistor Instead set internal DIP switches for termination page 36 When using the HC900 XYR5000 transmitter function blocks and RS 485 serial communications ports connect Base Stations to the HC900 controller as shown in Figure 76 HC900 Controller Modbus Modbus Modbus Slave 1 Slave 2 Slave 3 s s s RRO r v r K A ep i WTE RX Paa TRS TROON SOI OEA T 420 ohm OTa aa FRAY S Pees Termination TX RX TX RX TX RX Figure 76 RS 485 Modbus slave wiring If the RS 485 network to slave devices is intermittent or fails completely over short durations and recovers after the controller is power cycled use an external isolator with additional port biasing See Figure 77 142 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to Modbus device s 120 ohm Termination Locate on physical last device on network 49 gt Modb
145. gital Input Digital Output Analog Output 16 Point Contact Digital Input Ea 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 92 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 70 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP 2 3 Set jumper positions as shown for the 16 point contact digital input module C CZ Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 230 for RTP internal schematic Revision 18 HC900 Process Controller Installation and User Guide 221 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Contact Digital Input Connect field wiring
146. h If possible transfer control to alternate mechanisms otherwise bring the process to a safe and controlled shutdown A WARNING Disconnect all signals from power sources using user supplied switches at field devices Use a meter to ensure that all voltages are disconnected If a power down replacement procedure is opted also disconnect power from the rack using the user supplied switch in the site AC power source 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 190 HC900 Process Controller Installation an
147. h 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 18 HC900 Process Controller Installation and User Guide 129 02 14 Communications Installation Connecting the HC900 Controller to a PC with the 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 Zoom 56K Dualmode External Modem page 132 e Best Data 56SX Data Fax External Modem page 133 e SixNet VT MODEM Industrial External Modem page 134 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 mo
148. hat 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 18 HC900 Process Controller Installation and User Guide 67 02 14 I O Module Installation and Wiring Module Placement in Racks Terminal Block Styles The terminal block is available in the barrier style shown at left in Figure 34 and the Euro style shown at right Not shown a Euro style with 36 connections is also available for certain high capacity modules Terminal blocks have an embossed numbering key that shows the numbering pattern of the 20 36 connections The frame associated with the terminal block has a transparent hinged door The hinged door is a tool secured cover To open the door insert a flat screwdriver into the slot at the top and bottom of the door while pulling out The door has molded in tabs that hold labels which are uniquely color coded to identify each module type Each label is printed on both sides On the front visible when the door is closed are I O channel numbers with spaces in which tag names can be written On the back visible when the door is open are wiring patterns for the type of module located in the slot Figure 34 Terminal Block Styles The 20 pin inline connectors at the back of the terminal blocks are universal that is any type
149. ic Code refer to Table 27 Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode All models For legacy systems RS 232 RS 485 S1 port 2 For new systems RS Yellow Green Yellow when transmitting green when 485 S1 port receiving XMT RCV All models For legacy systems RS 232 RS 485 S2 port 3 For new systems RS Yellow Green Yellow when transmitting green when 485 S2 port receiving XMT RCV All models E1 port 4 Upper LED Yellow On Off On for 100Base T Off for 10Base T 5 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C70 E2 port C75 6 Upper LED Yellow On Off On for 100Base T Off for 10Base T 7 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C50 I O port ele 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 18 HC900 Process Controller Installation and User Guide 163 02 14 Diagnostics and Troubleshooting Controller CPU indicators Controller Status LED Diagnostic indicators When the Controller Status LED Figure 85 on page 162 item 1 is flashing red consult Table 27 A WARNING A Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources e Disconnect power before servicing More than one switch may be required to disconnect all power Failure
150. idual bundles through separate conduits or metal trays Use shielded cable IO 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 66 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 5 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 Slidewire feedback circuit wiring Communications Low volt
151. in the shield grounding section page 70 Mount RTP to DIN rail e Latch to rail See page 244 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 217 for RTP internal schematic Revision 18 HC900 Process Controller Installation and User Guide 215 02 14 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output Connect field wiring O Zz Q lt O DO 6 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 216 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output RTP Internal schematic HC900 Terminal Block Ji TB arg bk o oo N DOD oO A O D o oo N DOD oO A OO PN 10 10 e 4 N 4 N a ot A O BE els A O 4 ol 4 oOo 4 o 4 o N an N
152. in use PS 1 left or PS 2 right or both typical When the status indicator for either or both of the power supplies is lit it is reporting that the status of the associated power supply is good and that the outputs are within specified limits When the status is off either the power supply is off or the voltages are out of tolerance Figure 11 Power Status Module PSM 22 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Hardware Components Controller Module C30 and C30S C50 and C50S C70 and C70S C75 Controllers share the same features with exceptions noted Connection to I O port of Scanner Module Second Ethernet Host Connection to PC First Ethernet Host Connection to PC LED status diagnostic indicator for serial LED status diagnostic indicator for serial LED status diagnostic indicator for CPU model number C30 and C308 C50 and C508 C70 and C708 C75 Lithium battery beneath cover which is readily accessible for field replacement Mode switch Pgm Run Pgm Not present on C75 see RSM Interfaces to PC For legacy systems two serial ports S1 and S2 each configurable as RS 232 or RS 485 interfaces to a PC For new systems two serial RS 485 ports S1 and S2 interfaces to PC using RS 485 to USB cable External modem or Modbus devices are interfaced using RS 485 to RS 232 converter RS 485 interfaces to PC Operator Int
153. ing 8 HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Functional Description Redundancy Experion H or 3 4 Part Ethernet 100Base T 900 Control Ee Ethernet Station 15 Switches Redundant HC900 Ethernet Switches Th ga Remote I O Racks Redundant I O fill UL communications a S Process f k B c i T y ome 4 yg z 2 fi i ire Figure 3 Single process with redundancies Redundant CPUs Redundancy is provided by two C75 CPUs operating in a controller rack this rack has no I O A Redundancy switch module RSM sits between the CPUs Redundant CPU Power Two power supplies one for each C75 CPU Redundant CPU I O connection Each CPU has its own 100 base T Ethernet physical communication link with one or more racks of I O Multiple I O racks require Ethernet switches 1 0 racks 5 racks shown top to bottom 4 slot w 1 power supply 8 slot w 1 power supply 12 slot w 1 power supply 8 slot w redundant power supplies 12 slot w redundant power supplies A Power Status Module PSM is required with redundant power supplies High and low capacity power supplies are available Revision 18 HC900 Process Controller Installation and User Guide 02 14 Introduction Feature Summary Redundant Networks for Host communications Redundant Networks for Host communications are provided on the C75 CPU Both network ports are conti
154. ing shields shields Special tools 11 e Precision meters If required for testing Analog calibration refer to Analog Calibration in this manual Revision 18 HC900 Process Controller Installation and User Guide 55 02 14 Rack Installation Overview Equipment Preparation A checklist for site preparation is given in Table 7 Table 7 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 C75 CPUs 1 Redundancy Switch Module Each I O Rack 1 Scanner dual port module 1 Power Supply 1 reserve Power Supply optional 1 Power Status Module optional e 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 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 for each 4 slots in each rack e Wiring terminal lugs for connecting I O shields to grounding bars e
155. ion Connecting the HC900 Controller to a PC with the 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 connector be sure to use a DB 25 to DB 9 modem cable H TIP The Null Modem cable used to directly connect a PC running Designer Software to the 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 128 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communi
156. ion 60 61 188 F Battery Installation Replacement 60 61 Battery Replacement 190 Field Signal Wiring 67 Filler Block 79 C Flash 143 Form A relays 107 C30 C50 controller rack assembly 58 Form C relays 107 C7OR controller rack assembly 61 Fuses 104 Cabinet Wiring 46 Fusing 107 Cable length 44 cable segment 28 G Cable Type 116 Cables ground voltage potential 68 how to make shielded CATSE 44 grounding bar 68 captured screws 65 grounding bars 57 CE Conformity 49 Grounding lug 21 Cold Start 143 COM 1 26 Communications Installation 115 H Contact Input Module Wiring 98 HC900 Hybrid Controller 7 Controller access i Heat Rise De rating 42 how to access via serial port when port settings are HMI 31 unknown 149 Hub 28 Controller Modes 146 Hybrid Control Designer 26 Controller Module 23 Controller Module Diagnostics 162 Controller Name 30 Controller Rack 18 custom graphics 32 Revision 18 HC900 Process Controller Installation and User Guide 248 02 14 INDEX Analog Input Digital Input Digital Output Analog Output TO channel numbers 66 T O Expansion Network C50 CPU only 28 TO Expansion Network C70R 29 TO expansion port 24 25 VO Expansion Rack 19 T O expansion rack assembly 62 VO implementation 28 VO Installation Procedures 72 VO Module Diagnostics 173 TVO Module Installation 1 49 55 65 T O numbering assignments 28 TO rack address 63 VO slot 65 TO Wiring 80 VO wi
157. ion 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 18 HC900 Process Controller Installation and User Guide 137 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Two redundant systems with PC supervision OPC Server to PC Software a Controller Rack 3 iz ie Peer to Feer Data Exchange Controller Rack 100 baseT RECCeeeer ae WH O Rack m HOEF VO Rack Ethernet Switeh l E ANH vo naa F FERPRPE Eiee WO Rack Figure 75 Two redundant systems with PC supervision C Direct Ethernet Connection to one HC900 controller Defaults 3 IP Address 192 168 1 254 ee 5 Subnet Mask 255 255 255 0 Default Gateway 0 0 0 0 Crossover cable Host 10Base T Ethernet port RJ 45 connector ATTENTION Always observe the wiring cabling guidelines on page 45 138 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software 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
158. ion jumper 10 E Z position jumper cut in half i Yad a for a Relay Output i Module Naan Refer to terminal block wiring diagrams for specific information 4 For each configured and 120 240 VAC labeled I O Module break 125 VDC IN 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 18 HC900 Process Controller Installation and User Guide 75 02 14 I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 4 cont d NOTE In the diagram below the white cut outs represent the cut outs on the modules that accommodate tabs on the Terminal Block That is all key tabs that line up with the white cut outs on the diagram should be retained and all other tabs should be removed The orientation of the diagrams below corresponds to the picture of the terminal block shown in the previous picture Diagrams for I O Module Key Tabs 120 240 Vac 125 VDC IN 120 240Vac IN 120 240Vac OUT 24Vdc OUT 32 DO Relay OUT Contact IN 24 VdciIN 32DI Analog IN 16Al Analog OUT PFQ 76 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Module Installation Procedures
159. ion program select the port to which the modem is connected O a Ff W DN 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 respond with OK 9 Key in the following command string AT amp Y0 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 WO Then press the ENTER key The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller 132 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software
160. ions and Approvals on page 199 42 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 see Table 4 2 For 240 Vac applications and temperatures above 56 C or 264Vac 52 C de rate the number of ON inputs per AC input module See AC Input de rating data see Figure 27 3 Limit the number of Analog Output modules to a maximum of 10 per rack see Figure 28 Table 4 Power Applied by Module Type Module HC900 Hardware Field Power Total Power Power Watts Watts Watts Controller C30 and C30S 4 2 0 0 4 2 Controller C50 and C50S 4 7 0 0 4 7 Controller C70 and C70S 5 9 0 0 5 9 Controller C75 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 Output 4 points 5 1 0 0 5 1 Analog Output 8 pts interna
161. iring at terminals 9 and 11 or 10 and 12 See Figure 50 Ay WARNING AY Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury 92 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Com 1 IN 1 8 Com 2 in 9 16 Legend External F a Disconnect i User Supplied Safety Devices Figure 49 DC Input Module Wiring Diagram Revision 18 HC900 Process Controller Installation and User Guide 93 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Jumper either 10 12 sami or 9 11 Connect any of 9 to 12 to DC Figure 50 DC Input Module Jumper 94 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 51 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
162. ision 18 HC900 Process Controller Installation and User Guide 139 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software D Network Access to one or more controllers 10 100BaseT LAN Litton Hub Switch 165 125 163 25 165 125 163 26 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 Be sure the NIC has an IP address fixed or DHCP served that allows access to controllers with IP addresses on the same or other subnet Consult your IT department or network administrator for allocating IP addresses to the controllers if required You will need to set each controller s IP address prior to network connection since every HC900 controller is shipped with the default IP address of 192 168 1 254 Placing multiple controllers on the same network before they have been given unique IP addresses will cause problems On the PC 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 addres
163. istance 750M Moxa Media Converter IMC 101 M SC Figure 90 Extended Distance Example 1 204 HC900 Process Controller Installation and User Guide Revision 18 02 14 Specifications Fiber Optics Recommendations Moxa Switch Moxa Switch EDS 308 MM SC 10 100 HegooR 10 100 EDS 308 MM SC Copper Redundant Copper omen Copper HC900R Copper VO Rack1 10 100 10 100 Copper HC900R Copper WO Rack 2 Fiber Cable Fiber Cable Distance 750M Distance 750M Moxa Media Moxa Media Converter 10 100 10 100 Converter IMC 101 M SC Copper HC900R Copper IMC 101 M SC VO Rack 3 Moxa Switch Moxa Switch EDS 308 MM SC HC900R Copper EDS 308 MM SC As a Repeater VO Rack 4 As a Repeater Moxa Media Moxa Media Fiber Cable Converter 10 100 10 100 Converter Fiber Cable Distance 750M IMC 101 M SC Copper HC900R Copper IMC 101 M SC Distance 750M VO Rack 5 Figure 91 Extended Distance Example 2 Revision 18 HC900 Process Controller Installation and User Guide 205 02 14 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
164. isted pair 49 Signal Grounding 68 Simple Mail Transport Protocol 33 Site and Equipment Preparation 54 SMTP 33 sockets 31 Specifications 191 SpecView32 32 Status 143 Subnet Mask 30 System Monitor Function Blocks 52 T tagnames 72 TCP IP 31 telephone links 26 terminal block 65 Terminal Block Colors 66 Terminal Block Styles 66 test points 59 The Fix 32 transmission delays 44 U UDP 30 Universal Analog Input Wiring 81 87 User Datagram Protocol 30 y Vertical Spacing of Racks 41 Voltage test points 21 WAN 30 Warm Start 143 Wire Gage 67 wire size 67 wire tie 77 78 Wiring Rules 67 XYR 5000 141 250 HC900 Process Controller Installation and User Guide Revision 18 02 14 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC Honeywell Process Solutions TAC hfs tac support honeywell com Australia Honeywell Limited Phone 61 7 3846 1255 FAX 61 7 3840 6481 Toll Free 1300 36 39 36 Toll Free Fax 1300 36 04 70 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 EMEA Honeywell Process Solutions Phone 80012026455 or 44 0
165. ition Cable Type Belden 9271 or equivalent CAT5 cable IO up to 100 meters CAT5 cable IO 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 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 software packages and Designer Software configuration software VO Single I O rack Shielded Ethernet C50 C70 Controller s I O 100Base T CAT5 cable IO with RJ port to Scanner 1 s I O port 45 connectors VO Single I O rack Shielded Ethernet C75 CPU A s I O port to 100Base T CAT5 cable IO with RJ Scanner 2 s I O A port 45 connectors C75 CPU B s I O port to Scanner 2 s I O B port Revision 18 HC900 Process Controller Installation and User Guide 119 02 14 Communications Installation Wiring and cabling Controller Link Type Cable Type To Device Port Details Port Controller to Connector Type I O 2 or more I O Shielded Ethernet C75 CPU A s I O port to 100Base T racks CAT5 cable IO with RJ approved switch From this 45 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 C75 CPU B s I O port to approved switch From this switch to each Scanner 2 s I O
166. ks and modules All output modules are configured with Failsafe values Any modules not included in the configuration are configured with default values which cause outputs to be Off While in transition all output modules are Off when transition procedures are completed Function Block processing begins and output values are set to Function Block output values Any calibration process that was in progress is immediately aborted and the results are discarded PROGRAM OFFLINE Same as PROGRAM to RUN transition except that Function Blocks are not processed and outputs remain Off Any calibration process that was in progress is immediately aborted and the results are discarded RUN PROGRAM Set all channels of all output modules to Off Set all output module Failsafe values to the Off state Turn off the LED indications on all output modules OFFLINE PROGRAM Same as RUN to PROGRAM transition Any calibration process that was in progress is immediately aborted and the results are discarded RUN OFFLINE Freeze output module channels Freeze Force LED indications on all output modules OFFLINE RUN Function Block execution starts immediately Any calibration process that was in progress is immediately aborted and the results are discarded 152 HC900 Process Controller Installation and User Guide Revision 18 02 14 Operating Characteristics File Download Upload Functions File Downl
167. l 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 DC In 0 7 7 7 8 3 AC Out 1 1 12 0 13 1 PFQ 6 7 0 1 6 8 Revision 18 HC900 Process Controller Installation and User Guide 43 02 14 Pre Installation Planning Heat Rise De rating 240 VAC wnnsenennnnnnnennns 264 VAC nansnnnnnny Number of ON Points 0 o S 10 15 920 26 30 gt 325 40 45 S0 JF 60 Temperature C gt Figure 27 AC Input Module de Rating 12 3 11 a ie T 10 a 2 9 0 5 10 15 20 25 30 35 40 45 50 33 60 Temperature C Figure 28 Power Supply de Rating 44 HC900 Process Controller Installation and User Guide Revision 18 02 14 Pre Installation Planning Cable Wiring Distance Planning 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 tha
168. lace 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 191 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 18 02 14 HC900 Process Controller Installation and User Guide 63 Rack Installation Assemble I O Expansion Racks Assemble I O Expansion Racks T O Expansion Rack assembly information is given in Table 11 Table 11 Assemble I O Expansion Racks Step Procedure Comments References 1 Insert power supply into If using redundant power your I O rack will contain a second left most slot in the I O smaller compartment see 1 in the following figure Insert first rack See Table 9 steps 1 power supply in the larger compartment as shown to the and 2 for wiring details immediate right of the plate dividing the two compartments f o Z rh 4 8 y 2 Redundant Power See 1 in figure above See Table 9 st
169. ld 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 18 02 14 HC900 Process Controller Installation and User Guide 175 Diagnostics and Troubleshooting I O Module Indicators 1 O Module Diagnostic Indication To indicate the type of diagnostic failure the module s status LED is flashed red with a number of quick strobes followed by a long off time Table 31 outlines the potential module diagnostics Table 31 I O Module LED Diagnostics Number of Failure Description Al AO DI DO PFQ User Action PAS Contact AC DC Reay AC DC 1 FAIL SAFE Themoduleis inthefaisafestate V V V V v v IV JV v t expansion VO rack go to step 2 because itis not receiving message If no expansion I O rack go to requests from the CPU or Scanner step 3 at arate that satisfies the configured 2 Check the Scanner status LED If its flashing 6 times proceed with step 3 If it s flashing some other red status code refer to Table 29 to solve that problem first If it s flashing green the module probably is not required in the configuration If i s not on or steady cycle power to the scanner 3 Make sure the module is the correct one for the configuration
170. le Wiring Diagram Revision 18 96 HC900 Process Controller Installation and User Guide 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Input Jumper either 10 12 aa Figure 53 AC Input Module Jumper Revision 18 HC900 Process Controller Installation and User Guide 02 14 97 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC DC Isolated Input Module Wiring The AC DC Input Module has sixteen isolated inputs An example of AC Input and DC input Module wiring is shown in Figure 54 Specifications for this module and for other modules are given in the Specifications section of this manual Isolation Inputs must be powered from external voltage sources Inputs are isolated from each other and from controller power IN 2 IN 2 IM d IN d IN IN INd IM 4 IN IM 2 IN IN te IH 14 Lf JENSINE alle MAENE i J t LTT TT TT TTT TT RE G BENY i z 5 T po al a 5 D 2 a 3 2 iP a 5 98 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams N d Q Q z 7 N OOOO O OQ OO OOOQOQ00O0C IO O Legend s External r Disconnect acon r s IRA oo User Supplied Safety Devices Fuse Figure 54
171. ll inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The sequence order of the function block determines when in time the actual value will be updated It is important that algorithms that need updated input values for their calculations have the inputs execute first in the sequence e Except for Time Proportioning Output TPO Three Position Step Control TPSC and Position Proportional Output PPO function block types that update their physical output values while the function blocks are being executed all physical outputs are updated at the end of a scan Controller Modes The HC900 Controller includes three operating modes The purpose of each mode is described immediately below and salient characteristics of each are described in Table 22 The functions of the Mode Switch are described in Table 23 and the procedures that the controller performs in transitions between modes are described in Table 24 PROGRAM Mode In the PROGRAM Mode active control processing is suspended This mode is used for safe execution of utility functions such as configuration download and calibration of analog inputs and outputs All outputs are Off RUN Mode The Run Mode is used for normal operation of the controller that is for running the control configuration that was previously downloaded Configuration download and other utility functions can be performed in this mode
172. locks to be tumed off Revision 18 HC900 Process Controller Installation and User Guide 165 02 14 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indication Utilities Indication Strobes 4 Estimated battery life is e ASYS and FSYS blocks HW Replace battery If the lead s status If the lead s status less than 5 days OK pins are tumed off LED is indicating LED is indicating 7 io oft the failure see the failure see Duk upgrade is stil MEMORY inthe Memory i Lead CPU Diagnostics in Diagnostics the Lead display Diagnostics If the reserve s Overview dialog status LED is box indicating the If the reserve s failure see status LED is MEMORY inthe indicating the Reserve CPU failure see Diagnostics Memory display Diagnostics in the Reserve Diagnostics Overview dialog box 4 Battery voltage is low e ASYS and FSYS blocks Replace battery LOWBTRY pins are turned on e ASYS and FSYS blocks HW OK pins are tumed off e Firmware upgrade is inhibited until both the Lead and Reserve batteries are good 4 Flash failed to burn ASYS and FSYS blocks HW OK 1 Force a cold start pins are tumed off 2 If diagnostic does not clear replace CPU module 5 The Real time Clock 1 On power up time and date is Use HCDesigner
173. lt 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 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 18 HC900 Process Controller Installation and User Guide 33 02 14 Components and Architecture Ethernet Open Connectivity Network HC900 Controller LAN gt Legena Ethernet F B Router Cable Modem p gt 2 Controller Figure 21 Typical installation using a Cable Modem 34 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two RS 485 ports for new systems Serial Ports RS 232 and RS 485 for legacy systems and two RS 485 ports for new systems Overview TX RX
174. 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 e Start the mounting screws supplied by the user in the drilled holes e Hang the Rack on the screws at the top e 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 the electrical cabinet When drilling holes prevent metal flakes from falling into the rack or onto any surface within 58 HC900 Process Controller Installation and User Guide Revision 18 02 14 Rack Installation Mount Racks Step Procedure Commenits References racks or ait Reference Center for Drilled Holes at Top of Rack AS Aluminum grounding bars for I O module wiring are optional They can be mounted at top at bottom or at top and bottom of the rack as indicated at right If grounding bars are included attach them with two M3 screws supplied with grounding bars in plastic bag Note The plastic bag also includes four M4 screws for attaching the grounding wire lugs which are attached later Attach the M4 screws loosely to the grounding bars for safe keeping Hang the rack in the enclosure on
175. med over this link Remote access functions include on line monitoring configuration upload and download and firmware upgrade PC Configuration Tool Controller RS 232 Port Nuh 3 Modem i j Cable Null Modem Cable Modem _ Cable DEN Telephone E Cable pt Figure 72 RS 232 Remote Access via Modems Revision 18 HC900 Process Controller Installation and User Guide 125 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software B Modem Connection PC intemal Modem assigned to a COM port Figure 73 Modem Connection 126 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software ATTENTION Always observe the wiring cabling guidelines on page 45 Step Procedure 1 Connect a modem to the HC900 controller s for a list of approved modems their settings and the connection specifics 2 On the PC check on the Utilities Worksheet in the HC Designer software to see if the PC modem is properly installed A modem icon on the associated COM port button indicates the PC modem is properly installed internal or external If the modem icon is not visible on the associated COM port button use the modem supplier s instructions to properly install the modem and verify the installation using the Windows Cont
176. mote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DO label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 Revision 18 HC900 Process Controller Installation and User Guide 225 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output 2 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP 3 Set verify jumper positions as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 73 ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 230 for RTP internal schematic 226 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output Connect field wiring Note SDC in the wiring figure below refers to power that is disconne
177. mtr sees s s Input eene gt 24 V ci Note The following Al types are not available for High Level Analog Input modules RTD Thermocouple Ohms mV Figure 88 Terminal Board Connections for Al Calibration 182 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 89 The specifications of the meter must be consistent with calibration requirements See page 91 for terminal connections for 8 and 16 channel AO Seeeeee s OUT 1 Milliameter LOAD 1 oO Cc 4 z LTETETTETETEETETT OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 89 Terminal board Connections for AO Calibration Revision 18 HC900 Process Controller Installation and User Guide 183 02 14 Removal and Replacement Procedures Overview Removal and Replacement Procedures Overview This section contains procedures for removing and replacing the active components of an HC900 Process Controller It also includes recommendations suggestions and hints as they apply to the circumstances under which the procedures are used Safety Considerations PLAN AHEAD When using the procedures in this section plan the sequence of procedural actions so as to ensure e The safety of
178. n For a HC900 system to be fully compatible all components must have matching model numbers Each component s model number format is XXXXXXX XXYY ZZ For example HC900 CPU is 900C71R 0000 40 For redundant CPU systems component model numbers ZZ numbers must match For non redundant CPU systems component model numbers YY numbers must match See examples below Example of a compatible redundant system Component Model Number XXXXXXX XXYY ZZ HC900 CPU 900C71R 0000 40 Scanner 2 900C73R 0000 40 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 Example of a compatible non redundant system Component Model Number XXXXXXX XXYY ZZ HC900 CPU 900C51R 0040 00 Scanner 1 900C53R 0040 00 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 6 HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Functional Description Functional Description All Controllers The Honeywell HC900 Process Controller is an integrated loop and logic controller that is designed specifically for small and medium scale unit operations It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range of process control applications The HC900 Process Controller can consist of a single rack as indicated in Figure 1 or can be can be networked with other controllers via Ethernet links to expand the dimensions of c
179. n 100m For greater than 100m a switch is required The use of Ethernet cables in excess of 100 meters and or devices other than recommended Switches will cause transmission delays 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 204 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 204 Maximum of 2 switches between each CPU s I O port and all I O racks Cable lengths specified in this manual are absolute When planning for routing of cables and wires be certain to include vertical and horizontal routing within cabinets raceways and conduits It is advantageous to minimize length of I O wiring However it is also a good idea to locate racks and wiring away from adverse environmental conditions such as sources of RFI EMI and away from areas with high levels of moisture dust and corrosive materials Revision 18 02 14 HC900 Process Controller Installation and User Guide 45 Pre Installation Planning Cable Wiring Distance Planning How to make Ethernet cables Ethernet cable shielded cable IO Cat 5 contains 4 twisted pai
180. n Utilities Indication Strobes 2 There are slave blocks e MSTRFAILpins on ASYS and_ 1 Use the Ol HCDesigner or in the configuration FSYS blocks turn on HCuitilities to configure one of the and no communication All Modbus slave and Modbus serial ports S1 or S2 as a master port is configured as a read blocks freeze their output 2 Usethe Ol HCDesigner or Modbus master pins to the last value HCUtities to download a Al slave blocks have their BAD eogfguration that has no slave COMM pin on e All slave blocks have their NO SCAN pin on e IN SCAN STATUS is set to NO for all slaves e COMM STATUS is set to BAD for all slaves in the function block diagram e Statistical counters for all slaves are 0 2 Controller mode is e Controller will not go to 1 Change mode back to RUN In HCD changed to RUN RUN Locked mode mode OR System Locked while there Diagnostics are forces present 2 Clear all safety forces using shows status as on safety HCD through Monitor Invalid Change worksheet gt Forced Blocks OR of Mode 3 Force a cold start 2 Controller mode is e Controller will not go to 1 To clear the diagnostic In HCD changed to RUN RUN Locked mode System Locked when safety 2 Change mode back to RUN Diagnostics configuration is mode OR shows status as changed at run 3 Force a cold start Safety time Configuration mis match 3 One of the following At the time of the exception the To clear the diagnostic
181. nd User Guide 105 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 60 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 As 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 18 HC900 Process Controller Installation and User Guide 02 14 106 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Qul 1 M Out 1 NO Out 7 H Out 7 NO Out 8 H Out 8 NO Legend External Disconnect User Supplied Safety Device Qul 1 H Oul 1 NO Out 2 H Out 2 NO Out 3 H Out 3 NO Out 4 H Out 4 NO Out 5 H Oul 5 NO Out 6 H Out 6 NO Out 7 H Out 7 NO Qul 8 H Oul 8 NO Figure 59 AC
182. nels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Output Connect field wiring RTP A for Outputs 1 to 8 9 and 10 RTP B for Outputs 11 to 16 9 and 10 RE O 6G 088 EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN to 9 External 24VDC supply 24VRTN to 11 16 Point Analog Input EA 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP labeled DI DO AO RTP ASSY with jumpers J2 J9 is the correct one for 16 point Al Mount RTP cable assembly to HC900 Controller Figure 92 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 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 16 point Analog Input label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 Revision 18 HC900 Process Controller Installation and User Guide 235 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input Mount RTPs to DI
183. ner 1 Port 1 per I O rack SIL 900S50S 0360 00 I O Scanner 2 Port 1 per I O rack SIL 900S75S 0360 00 Documentation Full Document set on CD SIL 900ME1S 0060 00 Full document set SIL hard copy English 900ME2S 0060 00 Conventions Throughout this guide where the text Legacy systems is used the following model numbers are applicable e Legacy systems Model Numbers 900C51 00XX 00 900C52 00XX 00 900C31 00XX 00 900C32 00XX 00 900C71 00XX 00 900C72 00XX 00 900C71R 0000 XX 900C72R 0000 XX 900RSM 0001 900C73R 0000 XX 900C53 00XX 00 Throughout this guide where the text New systems is used the following model numbers are applicable e New System SIL and Non SIL Model Numbers 900C30 0360 00 900C50 0360 00 900C70 0360 00 900C75 0360 00 900S75 0360 00 900S50 0360 00 Revision 18 HC900 Process Controller Installation and User Guide 5 02 14 Introduction Model Selection Guide 900C30S 0360 00 900CS5O0S 0360 00 900C70S 0360 00 900C75S 0360 00 900S50S 0360 00 900S75S 0360 00 ATTENTION For the Legacy systems it is specifically mentioned in the guide wherever applicable The other text is applicable to the new HC900 system Modems are not qualified with the new HC900 system Checking HC900 Model Numbers for Compatibility ATTENTION Be sure to check your model numbers for compatibility before installatio
184. ng 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 101 Current connections with 2 wire transmitter Revision 18 HC900 Process Controller Installation and User Guide 237 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 32 point DC Digital Output is limited to 6A per RTP and 0 5A per output Mount RTP cable assembly to HC900 Controller Figure 92 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 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 32 point DC DO label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 70 Mount RTPs to DIN rail e Latch to rail See page 244 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
185. not indicate a diagnostic Table 32 is a list of conditions that can cause a bad channel diagnostic Table 32 Bad I O Channel Diagnostics Module Failure message Description User Action Type indicated on Honeywell Ol or Honeywell HCDesigner Utilities function block monitor Al Burnout Failure The sensor T C RTD or mV source Check terminal block is failing burnout checks connections Replace source 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 If 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 D
186. nput Connect field wiring RTP A for inputs 1 to 16 RTP B for input 17 to 32 QO Q 2 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 18 HC900 Process Controller Installation and User Guide 241 02 14 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 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 242 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTPA J2 J3 J4 J5 sw P Wr qt qT IT Terminal y y y ae Block jJi ci c1 c1 ci SW SPST TB1 3 ee en may Us ee rT 3 8 S ed 4 9 I le eel SS
187. nship with the controller The total number of peers that a controller can have a relationship with is 32 Peer to peer communication uses the Ethernet Open Connectivity network and employs standard User Datagram Protocol UDP for fast and efficient transfer of information Peer to peer 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 Designer Software Controller configuration which includes entry of an IP address and a Subnet Mask and a Controller Name for each controller The Controller Name is used only by the Honeywell proprietary software for network access between controllers it should not be confused with a Network Domain Name or Workgroup Name Peer Data Exchange PDE function blocks which are included in the control strategy configuration file PDE function blocks include PDE Control PDE Write and PDE Read Refer to the HC900 Process Controller Function Block User Guide for additional inform
188. nt 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 14 e Any of the color coded labels will fit into the door of any terminal block Use care to ensure that all hardware components match each other and also match the control strategy in the configuration file 68 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 207 for details Terminal Block to Field Signal Wiring Although both of the two available terminal block styles can be used on all I O module types wiring methods vary with the module type and with the type of field devices connected to the terminal block The descriptions that follow provide details Wiring can be routed through the terminal block at the top at the bottom or both Wiring should be fixed in place u
189. nufacturer s ATEX Declaration of Conformity E3 G ExnAlic CE This Declaration applies to the following apparatus HC900 Modular Control System Low Power Modules per attached list The apparatus fulfills the requirements for Group Il 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 incapable 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 E 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 voitage 3 Modules are not to be inserted or removed unless the area is known to be non hazardous
190. nuously active on the Lead controller The network ports on the Reserve CPU are not available for external communications Experion HS and the 900 Control Station 15 inch model support 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 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 C30S and Remote input output racks C50 C70 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 C75 CPU e Redundancy Switch Module RSM required between redundant CPUs e Redundant Power Supply provides redundant power to any CPU rack or Scanner2 I O rack e Power Status Module PSM required when using a second power supply in Scanner2 I O rack Communications All CPUs except where noted e Serial ports In legacy systems two serial ports RS 232 or RS 485 can be configured In new systems two RS 485 ports can be configured e PC Configuration Tool In legacy systems RS 232 port used for link to PC configuration tool up to 50 feet or 12 7 meters or modem Port configurable as Modbus R
191. oad Upload Functions The following is a general description of file transfers between the controller and computer devices external to the controller A CAUTION Performing download procedures incorrectly could cause loss of control in an operating process or loss of data and program files in a controller Refer to the appropriate User s Manuals for download upload procedures Failure to comply with these instructions may result in product damage Two types of software files can be downloaded to the controller e Configuration files e Firmware files Configuration files can also be uploaded from the controller for archiving Firmware can only be downloaded to the controller Pathways for file transactions between the controller and computer devices external to the controller are shown in Figure 82 PC Configuration Too Ol 300 Control Station Operator Interface Host device w PC Configuration Tool Legend PEE OA Configuration Download Upload Figure 82 Pathways for Upload Download Transactions Revision 18 02 14 HC900 Process Controller Installation and User Guide 153 Operating Characteristics File Download Upload Functions Configuration Download Configuration files include the items indicated in Table 25 Downloading of some items is mode dependent That is downloading of some file types is not permitted in the Run mode or in the Offline mode Table 25 Configuration file
192. 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 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 have gold contacts are for use with 8 point AO 16 poi
193. oller to a PC with the Designer Software Step Procedure 9 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 correc 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 You may now access any controller on the network for configuration access by assigning Network as t Setting Up the Controller Network Parameters See the Designer Software Users Guide Doc 51 52 25 110 or respective HC Designer Help Files for setting up following network parameters IP Address Subnet Mask optional Default Gateway IP Address optional Network Name optionally used in Peer Data Exchange Local Name optional user identifier for controller E mail Server IP Address required if e mail alarms are configured H ATTENTION This setup will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Revision 18 02 14 HC900 Process Controller Installation and User Guide 141 Communications Installation Connectin
194. ommonly 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 name is it enables translation of IP addresses which enables networks with dissimilar network IP addresses to communicate as though they were members of the same network This feature is particularly useful when an HC900 Controller LAN is installed under local addressing rules That is IP addressing can be assigned without approval of or conflict with world Internet governing bodies A default IP address is provided in each 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 Designer Software to configure Alarm Groups and Event Groups Assignment of specific alarms to priority and e mail enabling E Mail address lists SMTP mail server IP address Default gateway must be configured in order to send e mail With redundant controllers two defau
195. on and User Guide 249 02 14 rack address for I O 63 Rack Dimensions 39 rack installation 53 rack mounting 56 Rack Options 20 RAM 143 Redundancy Switch Module RSM 9 18 24 Redundant 2 systems w PC supervision 136 C7OR controller module 23 components 16 controller rack 18 Controller Rack components 18 default gateway 33 determine component compatibility 6 Ethernet connections 133 example of single process 9 failover 156 features hardware 10 LO network 29 VO wiring 44 modes of operation 153 network 29 network connections 135 networks 133 operating characteristics 1 143 153 peer to peer 30 Power Status Module 22 power supplies wiring of 48 power supply installation 62 rack dimensions 40 start up 153 steady state operations 154 Relay Output Module Wiring 107 109 Removal and Insertion Under Power 71 Removal and Replacement Procedures 181 Replacing an I O Module 186 Replacing the Controller Module 184 Replacing the Power Supply 182 Replacing the Scanner Module 185 Reserve Power Supply 19 20 RIUP 71 181 186 Router 30 33 RS 232 121 122 RS 232 Modem 26 RS 232 Port 23 RTD Input Wiring 82 RTD Inputs 80 RTU 31 RUN Mode 146 SCADA 32 Scanner 2 Module 19 20 25 Scanner Diagnostics 169 Scanner Module C50 24 scanner rack assembly 62 Serial port accessing See Controller access Serial ports 35 RS485 RS232 35 S1 S2 35 service provider 33 shielded tw
196. ons 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 Div 2 Groups A B C D Class 1 Zone 2 IIC Module Temperature Classifications Module Type a Module Type S Rating Rating Redundant CPU Rack T6 Scanner 2 Port T6 Redundant PS Ext Rack T6 Analog Input 8 channels T6 8 Slot Redundant PS Ext Rack T6 Analog Input 16 chan T6 12 Slot Redundant PS Ext Rack T6 Analog Output 4 chan T4 4 VO Slot Rack T6 Analog Output 8 chan T4 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 2
197. ons for example those that include inter connection to other networks such as Intranet and Internet a working knowledge of networking is required The Ethernet Open Connectivity Network for a given HC900 Controller enables e Redundant Networks e Peer to peer communication e Connection to other PC hosts e Inter connection to other networks such as for sending Alarm Event messages via e mail 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 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 Designer Software configuration software Redundant ports may be used in a simplex mode non redundant Revision 18 HC900 Process Controller Installation and User Guide 29 02 14 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 relatio
198. ons 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 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 ex
199. ontact Information For Europe Asia Pacific North and South America contact details refer to the back page of this manual or the appropriate Honeywell Solution Support web site Honeywell Organization WWW Address URL Corporate Honeywell Process Solutions HPS Technical tips http www honeywell com www honeywellprocess com https www honeywellprocess com en US explore products control monitoring and safety systems scalable control solutions hc900 control system Pages hc900 controller aspx Telephone and Email Contacts Area Organization Phone Number United States and Canada Honeywell Inc 1 800 343 0228 Customer Service 1 800 423 9883 Global Technical Support Global Email Support Honeywell Process Solutions Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com Revision 18 HC900 Process Controller Installation and User Guide 02 14 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 4 DANGER if not avoided will result in death or serious injury This WARNING symbol indicates a potentially hazardous situation which if AX WARNING not avoided could result in death or serious injury This CAUTION symbol may be present on Control Produ
200. ontrol over a wider range of unit processes as indicated in Figure 2 Figure 1 Small HC900 Controller Configuration Revision 18 HC900 Process Controller Installation and User Guide 02 14 Introduction Functional Description A Controller Rack with 4 slot VO Expansion VO I 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 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 1 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 wir
201. or 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 cannot be changed at any operator interface While in PROG position the S1 serial port is set to Honeywell ELN protocol This temporarily overrides the configured settings for S1 port With your PC s serial com port connected to S1 use Designer Software s Utilities to view any setting of any controller port such as network IP address and change if needed Refer to Designer Software documentation for details Placing the Run Program switch in RUN or RUN PROG mode returns S1 to its configured protocol and settings Failover N A Transfers all primary tasks to the Reserve Controller establishing this controller 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 18 HC900 Process Controller Installation and User Guide 151 02 14 Operating Characteristics Controller Modes Table 24 Controller Behavior in Mode Transition Initial Mode New Mode Controller Behavior PROGRAM RUN Validate configuration database Reset all I O scanners Upon startup initiate Cold Start sequence Diagnostic Identify and configure all I O rac
202. ous 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 18 HC900 Process Controller Installation and User Guide 89 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams OUT 1 OUT 1 wa OUT 1 OUT 1 OUT 2 OUT 2 OUT 2 OUT 2 OUT 3 OUT 3 Sirs OUT3 OUT 4 OUT 4 OUT 4 OUT 4 Figure 46 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 47 and Figure 48 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 38 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 90 HC900 Process Controller Installa
203. ove ventilation to rack reading is indicating a thermal 2 Replace Al module problem The scanner determines this problem not the Al module therefore the module s status LED will not indicate this diagnostic Possible reasons for this diagnostic are One of the two 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 6 The scanner determined that a No action is taken Refer to the Bad I O Channel module has a bad channel In this Diagnostics on page 177 to condition the module s status LED determine the nature of the will not indicate the failure problem and possible user because the Scanner determines actions the condition not the module itself 7 One of the power supplies failed No action is taken Replace the power supply 174 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting I O Module Indicators I O Module Indicators Figure 87 I O Module LED indicators Table 30 LED Indications on I O Module Figure 87 item LED LED State Color Description Module Status Off Solid Red Blinking Red Blinking Yellow Solid green Blinking Green No power Hardware failure Diagnostic Code refer to Table 31 I O Module LED Diagnostics At least one output is Forced Co
204. pe and four form A type relays 8 point Universal Analog Input module 4 channel Pulse Frequency Quadrature I O module 01010 0100 010 0010060000 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 Revision 18 02 14 HC900 Process Controller Installation and User Guide 25 Components and Architecture Hardware Components For more information on I O modules and associated terminal blocks refer to the section in this manual on Input Output Installation and Wiring Personal Computer A Personal Computer is required for creating the control and data acquisition strategy configuration file that runs in the controller using the Designer Software configuration software The PC can also be used to download upload configuration files to from the controller and can be used to download program updates to firmware in the Controller Module and or Scanner Modules e A PC can be connected to the controller via the RS 232 port for legacy system e For the new system a PC can be connected to the controller via the RS 485 TO USB cable connected to RS485 Port which can be connected to external Honeywell qualified RS485 to USB converter and can also be networked to the controller via the
205. ponents includes Cautions and Warnings as Replacement applicable Procedures Specifications 194 Details of HC900 Process Controller design and functioning Appendix 207 The Remote Termination Panel RTP provides an easy way to connect the Installation of HC900 controller to the field wiring The RTP integrates some of the typical Remote externally connected components reducing wiring and setup time It also Termination Panels RTPs 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 18 02 14 HC900 Process Controller Installation and User Guide Introduction Model Selection Guide Model Selection Guide Legacy System Ras y Comos O SSS S SSS I O Scanner 2 Port 1 per I O rack PowerSupplies ss SSC dSSC OOC C C CNCN d VO Modules 2 HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Model Selection Guide WO Components CSS VO Components e Relay Output Remote Terminal Panel RTP 900RTR H001 Description JModeinumber High Density Terminal Block 900TCK 0001 Analog Input Remote Terminal Panel RTP 900RTA L001 High Voltage RTP Cable 1 0M 3 28ft 900RTC H010 z Low Voltage RTP Cable 1 0M 3 28ft 900RTC L010 Low Voltage RTP Cable 2 5M 8 2ft 900RTC L025 Low Voltage RTP Cable 5
206. pply or supplies in the expansion rack from the site AC power source Unplug the cable s from the scanner port s At the top and bottom of the Scanner Module loosen the captured screws that secure the module in the rack and remove the module from the rack Configure the scanner address jumpers DIP switches on the replacement module to match those of the removed module 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 Re install the cable s 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 Check status indications at the Scanner Module at the Controller Module and at the OI 188 HC900 Process Controller Installation and User Guide Revision 18 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing an I O Module CAUTION Read and understand all of the following information regarding RIUP before attempting to remove and or replace any I O module particularly in a system that is actively controlling a process All of the I O Module types in the HC900 Controller System include
207. 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 with redundant and non redundant networks 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 32 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 c
208. 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 161 Scanner indicators 171 I O Module Indicators 175 Ethernet Switch indicators 178 e Screen items on The Operator Interface connected to the RS 485 port See Operator Interface manual 51 52 25 108 A PC with Designer Software Process Control Utilities connected to the controller module via the RS 232 Converter or the Ethernet 10Base T Open Connectivity port See the Diagnostics section in the application s help Controller CPU indicators Revision 18 HC900 Process Controller Installation and User Guide 161 02 14 Diagnostics and Troubleshooting Controller CPU indicators Figure 85 LED Indicators on Controller CPUs See Table 26 162 HC900 Process Controller Installation and User Guide Revision 18 02 14 Diagnostics and Troubleshooting Controller CPU indicators Table 26 LED Indications on Controller CPUs CPU Figure LED LED State Color Description model 79 item All models 1 Controller Status Off No power Solid Red Failed Blinking Yellow Failed Blinking Red Diagnost
209. quirements 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 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 ey yer Honeywell International Inc ge Cee va ane 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 246 HC900 Process Controller Installation and User Guide Revision 18 02 14 ATEX Certification Analog Input Digital Input Digital Output Analog Output ATEX Certification Honeywell HON 08 ATEX 0001X Revision A Ma
210. rack will remove all DC voltages from the rack that powers the Controller Module or Scanner Module and from all I O modules within the rack NOTE The power supply includes an internal fuse rated at 5 amperes This fuse is not replaceable in the field If desired the user can provide an external fuse that has a current rating lower than that of the internal fuse See page 61 Table 34 Power Supply Replacement all except C75 Step Action 1 ATTENTION This procedure does not apply to C75 power supplies If the power supply to be replaced is powering a rack that is currently controlling a running process then Either e Ensure that powering the rack down will not have adverse consequences on any running process Or e Bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply from the source of site AC power Use a meter to ensure that power is off 3 Depending on the type of wire lugs used loosen or remove the three screws on the terminal board and remove the three wires from the terminal board NOTE DO NOT remove the nut that secures the lug for the PE Ground wire green to the grounding stake at the bottom of the rack 4 At the top and bottom of the module loosen the captured screws that secure the module in the rack and remove the power supply from the rack 5 Place the new power supply in the rack cont
211. racters Steps 64 Time Units Minutes or Seconds Digital Outputs 16 Analog Output 1 configurable value step Step Execution On Time Event 1 Event2 or via Advance Next Step Any step Sequences Number of 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 196 Revision 18 02 14 HC900 Process Controller Installation and User Guide Specifications General Specifications Communications C30 C50 C70 C75 Network Communications Ports Number of Ethernet 1 1 2 2 10 100Base T connections Ethernet 10 100Base T RJ 45 connection Max number of concurrent Ethernet host connections Supports Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Initiator Peer to Peer and Designer Software configuration software Supports redundant Modbus TCP Protocol to PC supervisory and
212. rameters on displays operator interface Designer Software In some cases mode transitions also restart Cold Start or Warm Start controller operation e Results of diagnostics in case of system hardware or software fault the controller automatically alters operation as appropriate for the diagnosed conditions Power Down Power Up The HC900 Controller is designed to facilitate restoration of process operation after a power outage The active control configuration is maintained in battery backed RAM and the last configuration update performed in the program mode is also stored in Flash memory on the Controller Module When power is restored the system automatically enters a diagnostic procedure that checks the integrity of hardware software and the control 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 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 79 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 Noti
213. re 26 Vertical Spacing of Racks all models 0 eee eeseeesseeesneecsseeeseecsneeseeecesaecesaecseecesaeeesaeessaeessaeers 41 Figure 27 AC Input Module de Rating 0 eee eecceesceceseecsneeeeseeceseecessecesaeessaeessseeessecesseecseeceseeseseesesaeeesaeesaees 44 Figure 28 Power Supply de Rating eee eeecesscccsscecsscecsneecssceesseeeesseeesaecesaeeeseeesaeecsseecsseeeseesssaeeesaeeesaeessaees 44 Figure 29 Cabinet Wiring Single Chassis 0 ccesscsesseceseeceseeeesseeesseeesaeecsaeecsseeesseecssaecseecesaesesaecesaeessaeesaees 48 Figure 30 Cabinet Wiring Multiple Chassis ceceesscessecssceceseecsseeesaeesseessseeeseecesaecseecssaecesaeessaeessaeessaees 49 Figure 31 Redundant power supplies each with external fuse and switch eee eeseeeseecsseeeeseeeeneeeeseeeeneeeesaees 50 Figure 32 Master Control Relay Wiring Example ceeseesccesecceseecssceeeeecsseecesaeceseeceaecesaeeesaeeesaeeesaeeseaeers 53 Figure 33 I O Mod le Installations inis iinei iiie aa i ie ea eea 67 Figure 34 Terminal Block Stylesin nien ei a iA E E R S 68 Figure 35 Signal Wire Grounding sinisesse iie ieee iaie aii i ei aeaa 70 Figure 36 Wire Shield Grounding occ niinniin t eeii a a E eieiei 71 Figure 37 Terminal Block Jumper Installation 0 ee eeeeeeseseneecsneeceseeesacecseeeeseecsaeeceaeceeesesaesesaeeeseessaeers 72 Figure 38 RFD Inputs inte sdivaees bo sibs dt deen ican suena ca
214. re 57 V Terminals The V1 terminal 9 and V2 terminal 11 are the positive power supply input to power the output circuits for the two groups of eight inputs per group The V supply must provide minimum 24 Vdc at 65 mA min per group A WARNING 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 102 HC900 Process Controller Installation and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Output OUT 1 OUT 1 lt D OUT 2 OUT 3 OUT 4 OUT 5 OUT amp OUT7 OUT 8 V1 Com 2 Out 1 8 V2 Com 2 Out 9 16 OUT 9 OUT 10 Za e COM 2 Out 9 16 OUTS Do MHo o 7 OUT 10 DOOGOGS ODSAD oO HE ONO fe ou ea 12 er ae OUT 12 Sarr iz OUT 13 24 Vdc i OUT 15 O o MMH miS i OUT 15 OUT 16 a OUT 16 Legend 5 External r Fuse Disconnect j s boo User S Supplied Safety Devices Figure 56 DC Output Module Wiring Diagram Revision 18 HC900 Process Controller Installation and User Guide 103 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Output Jumper 9 11 for one V Supply to both s groups of outputs Jumper 10 1
215. ress within a plant network Also ensure that the PC Network Interface Card has an IP address that allows access to the controller on the subnet after changing the controller s network parameters 7 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 123 8 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controllers 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 Rev
216. rface via Ethernet or RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Controller Module to a serial port on the PC software is from Honeywell e For new system The PC Configuration tool connects from the RS 485 port of the Controller Module using an external Honeywell qualified RS 485 to USB converter 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMIs other HC900 Controllers and supplier HMI software is Interface other networks including Internet available from Honeywell Typically includes HMI operating software PlantScape or f s SpecView32 or from third May also include Designer Software configuration party supplier tool and utility software i 6 Ethernet Enables connection of the private Ethernet 100Base Honeywell 100Base T T port on a Controller Module to the Scanner Switch 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 10 100Base T Ethernet devices in an Ethernet network Devices Switch or include other HC900 Controllers HMls and can also Router include routers brouters servers and other devices in wider networks 7 Eth
217. ring shields 68 Input Output Modules 25 Installation Tools 53 Intellution 32 IP address 30 El 117 E2 117 kp 81 isolation capacitor 68 IT networking professional 27 J jumper 73 Jumper Comb 90 94 100 104 107 Jumper Combs 70 jumpers 29 Kepware 32 key tabs 73 Label 72 labels 66 LAN 30 LED Indications on Ethernet Hub 175 LED Indications on I O Module 172 LED Indications on Main CPU 161 LED Indications on Scanner Module 168 LED Indicators 160 168 lithium battery 23 Local Area Network 30 Master Control Relay 50 Modbus mapping structure 32 MODE switch 149 Mode Transitions 149 Model number 2 compatibility 6 Model selection guide 2 Modem 126 127 128 Module Placement 65 Module Wiring 80 mounting racks 56 Null Modem Cable 122 OFFLINE Mode 147 OHMs Inputs 81 OPC 32 OPC server client software 32 Open Modbus TCP protocol 32 Operating Characteristics 143 Operating Modes 143 operator interface connect to controller 119 Parallel processing 10 PC hosts 31 PC Hosts 31 PC Modem Cable 123 PDE 30 Peer Data Exchange 30 Peer to peer communication 30 Personal Computer 26 PlantScape Vista Software 32 Power DOWN 143 Power Down Power Up 143 Power Status Module 19 20 Power Supply 21 58 59 61 Power transitions 143 Power UP 143 PROGRAM Mode 146 PV Input Types and Ranges 197 200 202 Revision 18 HC900 Process Controller Installati
218. rocess Controller Installation and User Guide Revision 18 02 14 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 6 Table 6 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 or gun for attaching filter For attaching filter capacitors on I O wiring capacitors to I O wir
219. rol Panel Modem property page to confirm proper installation 3 Set up the phone book in the HC Designer software This list includes the phone numbers for each of the HC900 controllers that can be connected using a modem The phone book can be accessed from the Main Menu View Phone Book or from the Utilities Worksheet by selecting the modem port as the current port Refer to the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Remote Access for details on this step Select the number to call x Phone Number 215 822 3001 Add to List Name Remove from List Cancel HC3900 Furnace 1 Comments Plant 3 Location Phone Number List oe ee E 4 Hc300 Furnace 2 9 610 726 4530 Plant 3 Location 12 HC900 Furnace 1 215 822 3001 Plant 3 Location 4 On the 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 ni a S Loop Back Statistics Dial Xircom CardBus Ethernet 100 Modem 56 Modem Interface Protocol Honeywell Inc ELN Speed bps N A Port Oe ER lee z PC Port Setup Network COM1 Revision 18 HC900 Process Controller Installation and User Guide 127 02 14 Communications Installat
220. rs of wires and a drain wire Each pair consists of a solid color wire and a color wire with 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 46 HC900 Process Controller Installation and User Guide Revision 18 02 14 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
221. s 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 Controllers 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 Designer software 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 140 HC900 Process Controller Installation and User Guide Revision 18 02 14 Communications Installation Connecting the HC900 Contr
222. s for cable assembly drawing applies to 8 AO Twisted Pair Number of HC900 Module TB Position RTP A J1 Plug Connector Color Cable A 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 36 17 Black 35 16 Blue 5 36 15 Black 35 14 Yellow 6 10 12 Black 11 11 Brown 7 12 1 Black 13 2 Orange 8 15 4 Red 16 5 White 9 3 8 Red 8 18 Green 10 9 13 Red 14 3 Blue RTPA J2 J3 J4 J5 kee SS HA Sal E sm HC900 l f Terminal S4 y y Block J1 ci ci ci ci SW SPST TB 1 6 SS st 2 7 Ses See TT eee 3 8 a es SE SS ia A 4 9 DEN G N T gt 5 10 SSS Oe es CS ed 6 20 oo 7 19 ee 8 18 a 36 17 T E es SY 35 16 ed E ee TE 2 i i 01 e lt a ae fi al e ee O N 7 15 4 i a y A N yv ry 16 5 ct ct c c pee 9 13 EI 10 12 C A E FE Pe We a 11 11 oe 14 3 il m_i 13 2 Sn 12 1 a a 77 37 36 15 m T S nE _ 35 14 CONd Revision 18 HC900 Process Controller Installation and User Guide 233 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controll
223. s Installation xg cyctox scat sie ec exeverss bees tees thecezectveterevese tens teacereceeates ao ocetee peas 117 CVS OW eased ceo co ta eae aes eeieae ate acceded ted dade hc cad an a bata aana aAA AOE aA AEA aE REA Eika 117 Wiring and Mer 0 a n ee eer 117 Connecting the Operator Interface to the Controller eecccesceeeeeeeeeeeenneeeeeeeeeeeeceeeeeeeeeeesesenneeeeees 121 Connecting the HC900 Controller to a PC with the Designer Software c cccccesseeeeeeeeeeeeeeteees 122 Connecting the HC900 Controller to Modbus device s cc eceeeeeseeeeeeenneeeeeesaeeeeeeseeeeeesneeeeeeaas 142 Operating Characteristics co ahr coon sakes pian aul penesauatmrin cp aaseuees cenenese eeu av ntiutoa ers 145 ATROCUICTIONN oy Sacer sees Se Peeper AAA ney we eee lee cet dal lan ee tsa 145 CVV OW A EA E E T E 145 Power Down Power UD aier aniano aa eaae va aE pa naa eaaa Vonage ere ace ieee 145 Controller Modes sir eenean a a a ea aaa aaa a ae aE 148 File Download Upload Functions c ccccceeceeeeecenceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseegcaaeeeeeeeeeseeciaeeeeeees 153 Redundant Operating Characteristics cis inset Sere caer eceeldeace ee 155 OVODVICW EEE EE EEEE stad tedeven veel wetlentletevetd ectecerseeatavadertdectecubvactuewtucctyacdy geeleccuseeesvaetngeteeess 155 Start Up vies SS at neat Ceca Ae 155 Modes of operation Figure 83 ssiri iiiaae a a a ianiai 155 Steady State Operations cccccccccceceecececeeee eee eeeee
224. sary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING Potentially lethal voltages on Disconnect all signals at terminal Terminal Blocks blocks from sources of power Human contact with high before removing the terminal voltage sources will result block from the I O module in death or serious injury Ensure that the Protective Earth PE ground is properly connected and properly functioning Revision 18 HC900 Process Controller Installation and User Guide 189 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Table 38 I O Module Replacement Step Action Ay 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 eac
225. sed as a repeater at the midpoint See page 204 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 CPU Controller Module and the Scanner Module ATTENTION For 2 or more I O expansion racks a switch is required Use only Honeywell recommended switches part no 50008930 001 The total number of switches is limited to 2 in series between a CPU and its scanners 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 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 28 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Ethernet Open Connectivity Network e Physically assigning Rack Numbers by positionin
226. seeeseecesaecsseecesaecesaeeesaeeesaeessaees 93 Figure 50 DC Input Module Jumper ees eesceeseceseecsneecssceceseeeesseeesaeessaeeesaeeeseecsseecseecseeesseeeesaeeesaeessaees 94 Figure 51 32 point DC Input Module Wiring eee eeecesseeesneecsneecsneeesaeeessceceseeceseeceaecesaeeesaesesaeessaeessaeers 95 Figure 52 AC Input Module Wiring Diagram cee eeeesecescecesneeeseeesaeecsseeesaeeesseecssaecseecesaesesaeeesaeessaeessaees 96 Figure 53 AC Input Module Jumpet eesceesccessecsseecsscecssceceseecessecesaeessaeessseeeseecseecsseecsseessseesesaeessaeessaees 97 Revision 18 HC900 Process Controller Installation and User Guide xi 02 14 Introduction Purpose Figure 54 AC DC Isolated Input Module Wiring e cc eeeeeesceceseeesneeceseecsseeesneeeesaecsseecssaecssneeesaesesaeeeseessaeers 99 Figure 55 Contact Input Wiring Diagram 00 cee eesceeseeceseeceseeceseececeeesaeessaecssaeessaeecsaeecsaeesseecseesesaeeesaeessas 101 Figure 56 DC Output Module Wiring Diagram eeceeeceeseeceeneeeeneecsseeesacesseesseeesseesesaessacecssaessseesenaeessaes 103 Figure 57 DC Output Jumpers d hcctievacindii E R a e ee aaa a ena aaa E AN R REER 104 Figure 58 32 point DC Output Module Wiring cece eeeceescceeneeeseecsseecsacessseeeseeesseecssaeceseecssaesssaeessaeeesaes 105 Figure 59 AC Output Module Wiring Diagram eeceeecceesecesneeeseecsseeesaeesseessaeecsaeecssaessse
227. serve 2 2 The scanner port used to 2 If a 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 Replace the expansion rack s scanner module 9 Ensure that the Scanner 2 and reserve software versions are compatible If not perform a firmware upgrade 10 Replace the expansion rack s power supply 11 Replace the expansion rack 12 Replace the main CPU 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 Revision 18 HC900 Process Controller Installation and User Guide 173 02 14 Diagnostics and Troubleshooting Scanner indicators Number Possible Cause Scanner Action User Action of Strobes 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 176 6 An Al module s CJ temperature No action is taken 1 Impr
228. serve status is determined at start up First available C75 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 83 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 a command 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 18 HC900 Process Controller Installation and User Guide 155 02 14 Redundant Operating Characteristics Steady State Operations Reserve a gt Figure 83 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
229. 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 194 Revision 18 HC900 Process Controller Installation and User Guide 02 14 Introduction Feature Summary This page is intentionally left blank 12 HC900 Process Controller Installation and User Guide Revision 18 02 14 Components and Architecture Overview Components and Architecture Overview This section provides a description of each of the major components that can be included in an HC900 Controller physical configuration and indicates some of the methods by which they can be combined Components The Honeywell HC900 Process Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications Some of the modules are required in all configurations Others are optional they are selected as appropriate to provide optional functions and or to size the system either in initial planning or in modifying and or expanding the system to meet changing requirements An HC900 Controller configuration with multiple controllers is illustrated in Figure 4 This illustration includes key numbers that identify components that are described in Table 2 CAUTION Communications lockout is possible in high network traffic conditions
230. set to RS 232 or RS 485 For new systems the serial ports S1 and S2 are RS 485 unterminated Functionality is determined by DIP switch setting on see the following figure To change either port s setting use the switch settings in Table 3 Use a small slotted screwdriver or paperclip to gently move the DIP switches If you push too hard you could damage the switches or nearby circuitry Avoid using pencils because the point could break and cause damage Table 3 Serial port DIP switch settings RS 485 unterminated RS 485 terminated last link in network Honeywell a Ke sw ee ee Y _ fey 3 ce Se 14 Ead Figure 23 Serial Ports DIP Switch default settings 36 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 configuration and or poor system performance Factors to consider in your pre installation planning include C75 CPUs require the 900P02 Power Status Module T O Rack can use AC Power Supply 900P01 900P02 see page 38 or 24DC Power Supply 900P24 see page 39 Limit of 10 Analog Output modules per rack Limit of 4 PFQ Power Supply rack space if using redundant I O power see page 40 Rack orientation and
231. sing 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 IO will improve noise immunity if wire routing is suspect Wire Gage Observe all local codes when making power connections Unless local electrical codes dictate otherwise the recommended minimum wire size for connections is given in Table 12 Table 12 Minimum Recommended Wire Sizes Wire Wire Application Gauge 14 Earth ground to common power supply 14 to 16 AC to power supply 10 to 14 Earth ground wire 20 DC current and voltage field wiring 22 DC current and voltage wiring in control room Routing and Securing Wires Typically field wiring is routed to connections at a terminal panel near the controller and then from the terminal panel to the terminal blocks on the I O modules Whatever method of routing is used wiring must be mechanically supported along its length and must be protected from physical damage and electromagnetic noise interference See Electrical Considerations page 47 Also all wires must be securely terminated using appropriate wiring practices Revision 18 HC900 Process Controller Installation and User Guide 69 02 14 I O Module Installation and Wiring Terminal Block to Field Signal Wiring
232. sion 18 02 14 HC900 Process Controller Installation and User Guide 61 Rack Installation Assemble Controller Rack Step Procedure Commenis References 3 Ay WARNING AY Ensure that AC power to the rack is disconnected Set controller module s communication ports to desired settings page 36 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 191 I O will be installed later See Page 66 62 HC900 Process Controller Installation and User Guide Revision 18 02 14 Rack Installation Assemble Controller Rack Table 10 Assemble C75 Controller Rack Step Procedure Commenis 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 See page 36 A WARNING AY Ensure that AC power to the rack is disconnected Carefully p
233. ssis 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 vi HC900 Process Controller Installation and User Guide Revision 18 02 14 Introduction Purpose Contents VRIES TION sag stcns casos TE E Co umtugas pieced cate ee tent conden sseseuet seseuusns coswal A 1 AEN O 0L tases ete cc teed Cacetaca tae te Oe hats AA E a ute nd ody doug tose nce Mats Maestasc a 1 Medel Selection Guides iciss2f cccefeyelevezeet eee datadadadede fade feted alte iys ih aw Slee eaaa aan aa T ah aaa aaa aa aa 2 Functional Descriptio Merana Meee ee edie ee ee OL a a Ue 7 Feature SUMMaly is la aana aaa aaae ena eG Wes pi a eae sea hence aes cesta eee bce setae ees 10 Components and Architecture raise ciate tet cae cee en ta ile sleeve eed ne beatae tee 13 OVO OW este cease alice ea eB Pa se Beas aaaea aaa a Sern Heeler e aiaei 13 COMPOMEINS eases ihceahec eee A fata taed es pated nee aoe adh AA E 13 FRECUNGANT COM pO NEN S is save ea a ev vee adadecetetvivansiviadede feds tagadiladids a a a aiak 16 Hardware Components cccceeeeeeecceeeee eee ee ee eee e anette ee enna eter eee eta ee eee aaee eee aaaeee seen eee 18 Ethernet Devices Considerations cccccccecccecceeeeeeeeeeeeneeeeee eee eteecnaeeeeeeeeeteecaaaeeeeeeeteeeaaaeeeeeeenneee 27 VO NOMO a a aara anana aaa aa ai a ta aaaea aaa aaa a a a aa aaaea ina 28 Ethernet Open Connectivi
234. stics 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 153 Revision 18 02 14 HC900 Process Controller Installation and User Guide 159 Redundant Operating Characteristics File Download Upload Functions This page is intentionally left blank 160 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 operating conditions particularly in the event of a system fault e Provide external indications that enable operating and maintenance personnel to react appropriately when external actions are required External Indications of Diagnostic Information The following diagnostic indicators are
235. t 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 63 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common Revision 18 HC900 Process Controller Installation and User Guide 109 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Relay Output Form C Ou No Quit Ne Di COM o Quel Ne Ou Ne Form C Ono Que COM cmommemee PR Form A ui L2 N Cul 3 Na Outs No rat or Form A OUA No someme res Not Form 4 gt ul No memme Sars No ules COM Oui No Out COM Qul No fos Forms on Form A K a of Cw CO Out 7 Not sees a mazes ee terres Our Na Form C Oul Gon Out Com QUE NE meme mnn Form C Ou Ne LOAD 8 Ouk No Oul 6 Ne To N O Ou Com om Tom Outi Ne Dut N Form C EA 30 Vdc Z Legend lt Eemal N Disconnect To
236. t Analog Output eee 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 92 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 9OORTC LO50 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 70 2 Mount RTP to DIN rail e Latch to rail See page 244 e Connect cable to RTP Revision 18 HC900 Process Controller Installation and User Guide 219 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 4 Point Analog Output Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 230 for RTP internal schematic Connect field wiring LOADS ARE 0 to 750 ohm 220 HC900 Process Controller Installation and User Guide Revision 18 02 14 Appendix Installation of Remote Termination Panels RTPs Analog Input Di
237. t Ranges vs UMC800 Analog Input ranges cccceceeeeeeeeteeeeeeeeeeeeetneeeeeeeees 200 System Sizing and Availability SUMIMATPY 00 0 2 ce eee eeeeeee eee eeeeeeeneee eee eeeeeeeeaaeeeeeeeeeeccaaeeeeeeeeseeetaaeeeeegs 203 Fiber Optics Recommendations ccceeeeeeeeeeeteee eee eeeeeeeeeneeeeeeeeeeeeceaaaeeeeeeeeeeceaaaeeeeeeesteeenaeeeeeeees 204 Appendix Installation of Remote Termination Panels RTPS cceeessseeeesesneeeeeeeeaes 207 DT AN EEE E AAE A cent teas we AAA abe toute tone shart cart lala te 207 Analog Inputa a ene Mee A St au a a ed a aiaa 208 Relay Outpt a a ana we a a Wace a a aaia Tn ee 215 Analog Input Digital Input Digital Output Analog Output sssssssseeeeeeesesssiirrrreeeerrenrrtteseeernernteeseenne 219 Lateh Wnlatel RTP to rail sorseccccceeesehaeict vec ebeveasancedce aa aaa E a aa Ea A A EEES 244 Declaration of Conformity ssssssseeereeessseeererrrrntttssserrrrnnnnnnnnnsstrtrnntrnnnnnnserennnne sie aad 246 ATEX Cerf AO aaa E ETE 247 NICO X ennea R E te etter Error Bookmark not defined Revision 18 HC900 Process Controller Installation and User Guide ix 02 14 Introduction Purpose Tables Table 1 Descriptions of Major Components Figure 4 0 0 cesceesecceseeceseeceseeeeeeeeeseeeesaeecsaeeesaeessaeeesaeeesneeeeaeers 15 Table 2 Descriptions of Major Redundancy Componentts sscccsscceeseeceseeeeseeeeseeessaeecsaecesaeeesaeessaeeeseeseneers
238. tallation and User Guide Revision 18 02 14 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 155 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 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 pa
239. ted using a user supplied switch at the field device before removing or inserting the module For all other components of the controller AC power to the controller must be removed before removal or replacement of the component A WARNING A 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 18 184 HC900 Process Controller Installation and User Guide 02 14 Removal and Replacement Procedures Safety Considerations PLAN AHEAD A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I DIVISION 2 A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN NOT TO BE HAZARDOUS Replacing the Power Supply The power supply for the HC900 Process Controller is available in two models and is used in the local controller rack and in the remote I O expansion racks in 4 8 and 12 module sizes This reduces required inventories of spare parts and also simplifies removal and replacement procedures Removing the power supply from a
240. 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 37 provides some general guidelines for establishing appropriate procedures at a given installation Table 37 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s Ay CAUTION Each signal at each of the Either L control terminals for an I O module has a f 9095 01 LOM oF VIEW Ol a specific function Any or all of the Using trained personnel and damage to equipment trolli transfer to manual control of each controlling a process i ee and or to process product signal that is neces
241. the following conditions of the Lead Controller Loss of communications with I O Rack s Processor exception conditions e Error conditions that occur in the following areas will not cause a failover Loss of communications to a Host on a network Loss of communications to Modbus Slave devices Loss of communications to Operator Interface Loss of communications with a Peer controller e During the transition from the Lead to the Reserve analog and digital output status is maintained at the T O racks 158 HC900 Process Controller Installation and User Guide Revision 18 02 14 Redundant Operating Characteristics File Download Upload Functions Manual Failover Via Key Switch on the Redundancy Switch Module in the Redundant Controller Rack When doing manual failover with keyed switch turn key to Failover and hold it there until both Reserve lights are on then release the key Via Software Command from HC Designer amp HC Utilities PC Software Via Software Command from Modbus TCP amp Serial Modbus RTU Hosts Via Software Command from OJ 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 Diagno
242. 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 C75 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 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network Device Name Honeywell HC900 Controller Address ise 1681 254 bd Protoc l Modbus R TCR u Speed bps N A uii Q Loop Each Statistics PC Port Setup for Controller Access A Network COM COM2 COME CONS cCOMS Come COMP COME 6 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within
243. 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 18 02 14 HC900 Process Controller Installation and User Guide 59 Rack Installation Assemble Controller Rack Assemble Controller Rack C30 C50 C70 Controller Rack assembly information is given in Table 9 C75 Controller Rack assembly information is given in Table 10 Table 9 Assemble C30 C50 C70 Controller Rack Step Procedure Commenits 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 A WARNING AY Hazardous Voltage e Ensure that wiring to the Power Supply is disconnected from the site AC source before installing wiring e Do not remove Yellow Green wire from grounding stud on the power supply Failure to comply with these instructions could result in death or serious injury 60 HC900 Process Controller Installation and User Guide Revision 18 02 14 Rack Installa
244. tion Assemble Controller Rack Step Procedure Commenis 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 14 AWG 2 4 mm Copper 75 C ATTENTION Do not connect PE Ground Green Wire directly to terminal on Power Supply gh See Brown Black i Eure USA White 2 Eure USA pa PE Ground ir Yellow Green 14 AWG 2 1 mm Copper 75 C Revi
245. tion and User Guide Revision 18 02 14 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 1 LI Li Li LI LI Li Li O G F PAN OO LOAD Kg mmm OUT 1 z Li V AQOH AN N OOCMOCWIOE OOOOO OOOOOODOOOOOY 6 QO 24VDC 24VDC RE aes 24VDC LI LJ j F VIO OOK COCHO OOOOOOCOQOQOQOQOQOQOQQO OOHO me 24VDC 24VDC ro 24VDC 1 J Figure 48 16 channel Analog Output Wiring Diagram Revision 18 HC900 Process Controller Installation and User Guide 91 02 14 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 49 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 w
246. tion is accessed from the Designer Software For details of uploading configuration items refer to Designer Software 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 154 HC900 Process Controller Installation and User Guide Revision 18 02 14 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 power from a Reserve Controller will initiate a diagnostic prompt in the Lead Controller but will have no impact on the process under control The detection of a fault or removing power from a Lead Controller will initiate failover that is transfer all primary tasks to the Reserve Controller establishing this controller as the new Lead Following a failover the new Lead Controller will remain the Lead even if the condition that caused the failover is corrected Start Up e Assignment of Lead and Re
247. to be inverted when necessary Requires Low Voltage Euro style 36 terminal terminal block BOWOOIOMIO OOOODOMDOO OOOOOOOOUD OOO Fed 9 BOOS Legend c2ma A Figure 51 32 point DC Input Module Wiring AC Input Module Wiring The AC Input Module has sixteen inputs An example of AC Input Module wiring is shown in Figure 52 Specifications for this module and for other modules are given in the Specifications section of this manual Revision 18 HC900 Process Controller Installation and User Guide 95 02 14 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 53 A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Com 7 IN 1 3 Com 2 In 9 16 DDOODADOS Kk Legend External p ie Disconnect repo User Supplied Safety Devices Figure 52 AC Input Modu
248. ty N twork cccccccccccccccsceceeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 29 Serial Ports RS 232 and RS 485 for legacy systems and two RS 485 ports for new systems 35 Pre lnstallation Planning s sees cex teas ies nsec aae aa aa a aaa aaa Aa AATRE aAA ERARE 37 VET OW E AE A E E AA 37 AC Power Supply Selection for racks with N O sssssssssssssssssessssirittsestrrrrtttsetttrrnttttssrtrrrnnsssssennnnnn 38 DG Power Supply irren ente pate Hiei ted tele oa eee tal a a a 39 Rack Orientation and MOUNTING cccceeeeeeceeeeeee etree eeeeeenee teeter reece ccaeee eter ee eeeaaaeeeeeeeeeeeeeaaaeeeeeeeneeee 39 Remote Termination Panels c cccccecceeeeeeeeeeeee eee eeeeceeaeeeee eee eeeeccaeeeeeeeeeegeaaaaeeeeeeeetteecaaeeeeeeeeneeee 41 ENVirOnime nites is ticrvieek ee cee ae ne ora ite take ee vana te de 42 Heat Rise DeE ratingeieickesicteteteeedevedeudited sted enee a leerarea EEEN rE etaar raaa aaan aa iniaa ieaiaia ia saaan 43 Cable Wiring Distance Planning cccccccceeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeeecaaeeeeeeeeeeeecaaeeeeeeeeeseeniiaeeeeeees 45 Electrical Consideration Ssns cree ceedaseeecacedeesevssastedececetasusasadsdeiadedededenndaduaadadenaacantisstarsienies 47 System Monitor Function BIOCKS cc ccccceeeeeeeeeneee cece ee eeeeeneeeeeeeeeeeeecaaeeeeeeeesgecaaaaeeeeeeeseenecaaeeeeeees 54 PACK Installaatio Maisons ennaa alcoho E ea sds seit Ate eE 55 OAA OW EE E
249. uide 193 Specifications General Specifications Specifications General Specifications C30 C50 C70 C75 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 Il Pollution Degree 2 IEC 664 UL840 Installation coordination Controller I O 4 8 or 12 I O slots per Rack None requires support remote I O racks Remote I O racks None 1 w o switch using Ethernet direct cable Up 1 wo switch using to 4 with recommended Honeywell switches Ethemet direct cable Up part no 50008930 001 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 and maximum distance 750m 2460 ft Fiber optic cable controller to remote rack or controller to switch Up to two switches per connection 1500m 4920 ft maximum distance Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 2
250. urations 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 local and expanded racks Detection of I O Modules Other functions permitted e Al calibration e Indications of Force at Status LEDs of I O modules Other function NOT permitted AO calibration Note 1 The Off state of the module outputs are defined as e Digital output low state e Time proportional Output TPO 0 duty cycle e PPO and TPSC Outputs Both Fwd and Rev are Off e Analog output 0 0 mA Note 2 The Frozen states of module outputs are defined as e Digital output same state as previous last active state
251. us Slave Devices HC900 Controllers oe B amp B electronics or equivalent 4850PDR 120 ohm Termination i t j t I I VDC GND Figure 77 RS 485 Modbus slave wiring with isolation For XYR 5000 base stations if the RS 485 network is intermittent or fails completely over short durations and recovers after the controller is power cycled the need for additional port biasing may be required Revision 18 HC900 Process Controller Installation and User Guide 143 02 14 Communications Installation Connecting the HC900 Controller to Modbus device s Figure 78 shows recommended installation procedure for using an external isolator and additional port bias 120 ohm Termination Locate on physical last device on network _ p HC900 Controllers Base Stations XYR 5000 i A F B amp B electronics or equivalent 4850PDR 120 ohm HA Figure 78 XYR 5000 RS 485 Modbus connections 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 36 for RS 232 DIP switch settings Table 19 page 124 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 144 HC900 Process Controller Ins
252. utomatically 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 included in the Fixed Modbus Map To access the registers of these function blocks the Custom Modbus Map must be used and the block data manually inserted into the custom Modbus map HMI Supervisory SCADA software is available from various suppliers and functionality and setup requirements vary with suppliers and with specific products In all cases the software selected must be compatible with Open Modbus TCP protocol 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 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
253. vailable memory Steps per schedule 50 50 50 50 Steps per sequence 64 64 64 64 Support of dual port scanner No No No Yes Tag descriptor Quantity based on available memory Text bytes Quantity based on available memory Variables 2000 2000 2000 2000 Variables in a Recipe 50 50 50 50 Revision 18 02 14 HC900 Process Controller Installation and User Guide 203 Specifications Fiber Optics Recommendations Fiber Optics Recommendations Honeywell recommends that you use the following equipment for extended distances Table 43 Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 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 cable FO Connector SC Type Figure 90 and Figure 91 are examples of Extended Distance configurations Moxa Switch 10 100 EDS 308 MM SC 10 100 HC900 Main Rack Copper kappar Rack 1 Fiber Cable Distance 750M 10 100 Copper Fiber Cable Distance 750M Moxa Media Converter IMC 101 M SC 10 100 Copper Moxa Switch EDS 308 MM SC As a Repeater Fiber Cable D
254. ware configuration or SpecView32 or from 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 party 10 100Base T Ethernet devices in an Ethernet network Devices 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 It also connects Honeywell IO to 900 Control Stations and PC SCADA software applications Fiber Optics Controller to remote rack distance up to 750m 2460 Cable ft with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint 9 RS 232 For legacy system Null modem cable up to 50 Third party suppliers or 15 24m PC modem cable if used with Modems Honeywell 10 RS 485 to USB Connects RS 485 port to USB port Third party suppliers or converter Honeywell Revision 18 HC900 Process Controller Installation and User Guide 17 02 14 Components and Architecture Hardware Components Hardware Components This section contains general descriptions o

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