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Honeywell HC900 User's Manual

1. 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 Table 31 Power Supply Replacement If the power supply to be replaced is powering a rack that is currently controlling a running process then Either Ensure that powering the rack down will not have adverse consequences on any running process Or Bring the process to a safe and orderly shutdown 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 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 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 Place the new power supply in the rack 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 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Removal and Replacement Procedures Safety Consider
2. Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING AN 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 68 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams RTD 3 Wire Input Thermocoup Input RTD 3 Wire TE Input I Ne ae IN 7 e 7 amp 8 oo pes IN 8 RTD 2 Wire a Input T Jumper Figure 32 Examples of RTD Input Wiring Ohms Input mV V Input 4 20 mA Input i e ele RTD 3 Wire Input UT OU aim RTD 3 Wire aoe oe ee bY O Input paesca E m a are O g IN 4 O i Ho lave 5 amp 6 163 0 JN 6 HC900 Hybrid Controller Installation and User Guide 69 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Thermocouple Inputs IN 1 1 lt IN 1 Shield Groun F typical Figure 33 Analog Input Wiring Eight TCs Resistance Thermistor Inputs Shield Ground typical Figure 34 Analog Input Wiring Eight Resistance Inputs 70 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I
3. ASIA PACIFIC Honeywell Asia Pacific Inc Room 3213 3225 Sun Kung Kai Centre N 30 Harbour Road Wanchai Hong Kong Tel 852 829 82 98 AUSTRALIA Honeywell Limited 5 Thomas Holt Drive North Ryde Sydney Nsw Australia 2113 Tel 61 2 353 7000 AUSTRIA Honeywell Austria G M B H Handelskai 388 A1020 Vienna Austria Tel 43 1 727 800 BELGIUM Honeywell S A 3 Avenue De Bourget B 1140 Brussels Belgium Tel 32 2 728 27 11 BRAZIL HONEYWELL DO Brazil And Cia Rua Jose Alves Da Chunha Lima 172 Butanta 05360 050 Sao Paulo Sp Brazil Tel 55 11 819 3755 BULGARIA HONEYWELL EOOD 14 Iskarsko Chausse POB 79 BG 1592 Sofia BULGARIA Tel 359 791512 794027 792198 CANADA Honeywell Limited The Honeywell Centre 300 Yorkland Blvd Toronto Ontario M2j 1s1 Canada Tel 800 461 0013 Fax 416 502 5001 CZECH REPUBLIC HONEYWELL Spol S R O Budejovicka 1 140 21 Prague 4 Czech Republic Tel 42 2 6112 3434 DENMARK HONEYWELL A S Automatikvej 1 DK 2860 Soeborg DENMARK Tel 45 39 55 56 58 FINLAND HONEYWELL OY Ruukintie 8 FIN 02320 ESPOO 32 FINLAND Tel 358 0 3480101 FRANCE HONEYWELL S A Batiment le Mercury Parc Technologique de St Aubin Route de l Orme CD 128 91190 SAINT AUBIN FRANCE Tel from France 01 60 19 80 00 From other countries 33 1 60 19 80 00 GERMANY HONEYWELL AG Kaiserleistrasse 39 D 63067 OFFENBACH GERMANY Tel 49 69 8
4. Maximum length of Ethernet cabling Controller to I O expansion rack is 328 feet 100 meters Controller rack connected via Ethernet Hub to up to four I O expansion racks C50 CPU only Length of Ethernet cable e Local Rack to Ethernet Hub lt 328 feet 100 meters e Hub to any I O expansion rack lt 328 feet 100 meters Revision 5 HC900 Hybrid Controller Installation and User Guide 41 9 03 Pre Installation Planning Electrical Considerations Controller rack connected via two Ethernet Hubs to I O expansion racks C50 CPU only Length of Ethernet cable each o segment 328 feet 100 meters i 100 m To other E gag Ethernet H se i devices oom e on O Note The use of Ethernet cables in excess of 100 meters and or devices other than approved Hubs 2 Maximum will cause transmission delays that could have adverse affects on Controller performance 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 Electrical Considerations The HC900 Controller should be mounted in an appropriate metal enclosure A diagram that shows recommended wiring practice for the cabinet enclosure is given in Figure 20 Cabinet Wiring Single Chassis and Figure 21 Cabinet Wiring Multiple Chassis
5. ccccccccccccccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees fi Table 2 Simultaneous serial port configurations 95 ci 9 sei dva raicanetcuentuvsaniiddite Lua laatenesddentsue rue teaiaddee iia teatalsaleusisaantecud deed 19 Table 3 Open System Interconnection MICK I viaies said seins sca rauicuniacssie ease cid dele EE E A A E rune cual diel ae E dallas Aion ctl dea 25 Tablete Networkin Device Types vecsalaesicn nds E E rata anata ck dial E liiat secu ctd diets 26 Table 5 Gilossarysol Neiworkine Pemns s deg er sicaad ies sas EE diel cas rosie dias Aiea ald A T A TENE 2i Table 6 Operating Limits and Installation Guidelines cccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeesesesseeeeeeeeeeeeeeeeeeeeeeeeeeeees 38 Lable 7 Power Applied by Module Ty pe cgi chats ie enoe E EEE e T E E AOR 39 Table 3 Guidelines for Grouping Wires iscsi tau os svelssctanaeaisslealsadatdaas ESA E EA E EO 44 Table S Tis tall ation Loole T A Garces aes 49 Table 10 Site and Equipment Preparations eec e Ee AE eatin ada E E R a ee 50 Table 11 Install HC900 Controller Components cccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseseeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 52 Table 12 Minimum Recommended Wire S1Zes cccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 59 Table 13 RIUP Potential Hazards and Recommended Actions cccccccccccceceseeeeeeeeeeeeeeeeeeeeeeeeeeee
6. 7 Application Identifies communications PC Networking FTP Networking software partners quality of service Software e g packages in PC hosts authentication and privacy Windows Client SMTP and syntax constraints Novell Client32 Modbus drivers Translation between application format and network format including data encryption also compression de compression Establishes manages and terminates connections between applications client to server or peer to peer 4 Transport Transparent transfer of data PC Software e g Networking between hosts Error recovery Windows packages in PC hosts and flow control NT 2000 Novell and in controllers NetWare Routing and Forwarding Software e g IP Routers addressing inter networking Modbus TCP error handling congestion control packet sequencing 2 Data Link MAC Frame NIC drivers Ethernet Network nodes assembly disassembly error 802 3 devices with MAC Includes 2 sub detection correction addresses usually layers addressing Network Interface i T Cards and 1 Ni a ol LLC call setup termination networking devices such as Switches 2 LLC Logical Link Control 1 Physical Electrical transmission of bits Cable NICs Ethernet from one node to another 802 3 6 Presentation Revision 5 HC900 Hybrid Controller Installation and User Guide 25 9 03 Components and Architecture Networking Basics Reference 26 Table 4 Networking Device Type
7. 9 0 5 10 15 20 25 30 35 40 45 50 55 60 Temperature C gt Figure 19 Power Supply De rating 40 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Equipment Placement Considerations Equipment Placement Considerations Factors that determine where equipment should be located within the site include at least the following e Environmental conditions see above e Wiring cabling characteristics The HC900 Controller includes optional I O expansion racks C50 CPU only which provide options regarding methods of connecting field devices into the system That is the length of I O wiring can be reduced significantly by locating I O expansion racks remote from the Controller rack but close to process equipment Following are samples of valid system architecture NOTE 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 For planning hints refer also to Appendix A of this manual Controller Rack with Local I O only In this case all wiring is from field devices to I O modules in the local rack 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 Controller rack with one I O expansion rack C50 CPU only
8. Deviations from the installation conditions specified in this manual may invalidate this product s conformity with Low Voltage and EMC Directives A WARNING AN 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 42 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Electrical Considerations 5 14 AWG 2 1 mm L1 H Field Wiring L1 H L2 N PE Power Source Figure 20 Cabinet Wiring Single Chassis Grounding Bar Shields D o o ol P L1 H L2 N PE Power Source Figure 21 Cabinet Wiring Multiple Chassis Revision 5 HC900 Hybrid Controller Installation and User Guide 43 9 03 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 e Supplementary bonding of the controller enclosure to a local ground using a No 12 4 mm copper conductor is r
9. Failing to convert Channel Failure Table 29 Bad Channel Diagnostics Module Failure Description User Action Type The sensor T C RTD or mV source is failing burnout checks The signal at the terminals is less than 10 below the range of the sensor The signal at the terminals is more than 10 over the range of the sensor When attempting to take a reading the ADC fails This could result if the incoming signal is either too large or small It also could result if the ADC circuit is failing If the problem is the ADC circuit most likely other channels will have the same failure The board indicates that the channel is failing to output the correct value 1 Check terminal block connections 2 Replace source element 3 Replace card Check the signal level being applied to the terminals Replace card Check the signal level being applied to the terminals Replace card Check the signal level being applied to the terminals Replace card Check terminal connections Replace module HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Diagnostics and Troubleshooting User Interface Scanner Diagnostic LED Indication The scanner uses its LED to communicate diagnostic information These diagnostics are a subset of the main CPU s and are listed below Table 30 Scanner Diagnostics Table 30 Scanner Diagnostics Diagnostic Number Possible Cause Scanner Act
10. Note Consult your service provider for availability of access to network local cable or DSL in your area HC900 Controller LAN Controller Router Cable Modem gt Controller Figure 15 Typical installation using a Cable Modem 18 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Serial Ports RS232 and RS485 Serial Ports RS232 and RS485 Overview e Ports configurable as ELN Modbus RTU or Modbus TCP protocol e Controller can act as Modbus master or slave through either port e Controller can be master to slaves such as Honeywell Operator Interface 1040 559 Must be on 485 port Will not work on 232 port with 232 485 converter Honeywell HC Designer PC software Third party PC HMI software Third party Operator Interface e Controller can slave to masters 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 RS232 and RS485 both as master ports e For multiple slaves on RS232 port a 232 to 485 converter is required e Baud rates to 57 600 Table 2 shows the ways the two ports can be configured simultaneously Table 2 Simultaneous serial port configurations se _nsro2Poncontudas _ RSMSFortconuredas Figure 16 5 Controller is Modbus master to multiple ELN device slaves Figur
11. state Check that cable is connected to expansion rack C50 CPU only If a hub is used check that all cables are properly connected to the hub proper crossover cables are used and that hub is powered Cycle power to the rack Cycle power to the hub Replace the expansion rack s C50 CPU only power supply Replace the expansion rack Replace the expansion rack s scanner module Replace the main CPU Ethernet port data The communications to the Does no scanning of Verify that the jumpers on the link failure main CPU is resulting in alot of modules Modules scanner are setup for the DLL errors remain in their failsafe correct rack address state If a hub is used check that all cables are properly connected to the hub proper crossover cables are used and that hub is powered Cycle power to the rack Cycle power to the hub Replace the expansion rack s C50 CPU only power supply Replace the expansion rack Replace the expansion rack s scanner board Replace the main CPU Ethernet port The power up test of the Does no scanning of Replace scanner module hardware failure Ethernet controller failed modules Modules remain in their failsafe state 136 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 30 Scanner Diagnostics Diagnostic Possible Cause Scanner Action U
12. 115VAC In rush current 7 amps peak to peak for 150 ms at 240 Vac Variable depends on I O Module complement 156 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Controller Module Design Controller Module Design Controller Module Description Feature Module design Plug in module CPU memory RAM and Flash PROM DUART for RS 232 and RS 485 communications connectors backplane connector Real Time Clock and support components on a single wiring board NetArm 40 33 MHz RISC based processor Includes embedded MAC for Ethernet support 6 DMA channels including 2 dedicated for MAC support Model C30 16 bit Address and Data Bus PROM and RAM Model C50 32 bit Address and Data Bus PROM and RAM Model C30 RAM 8 megs SDRAM Flash PROM 2 megs Dual Backed Model C30 RAM 16 megs SDRAM Flash PROM 4 megs Dual Backed Real Time Clock On board RTC output is distributed in system Battery Backup Lithium AA cell 3 6 Volt TADIRAN or equivalent protects RAM for 100 days Input Output I O Backplane connector 40 pin Samtec connector Receives power 5 Vdc and 24 Vdc from power supply Serial Peripheral Interface SPI for I O Modules in Local Rack diagnostic sensing for I O slots in this rack Status Indicators Controller Status Bi Colored LED Communications status two indicators per communications port Communications RS 232 Port 1 2 DUART 9 pin D connecto
13. 68 RTU 16 RUN Mode 110 9 SCADA 16 Scanner Diagnostics 135 Scanner Module 10 service provider 18 shielded twisted pair 44 Signal Grounding 60 Simple Mail Transport Protocol 18 Site and Equipment Preparation 50 site diagrams 176 Site Plan Documentation 48 49 OPC server client software 17 SMTP 18 Open Modbus TCP protocol 16 sockets 15 Operating Characteristics 107 Source 22 208 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications 156 SpecView32 17 Star topology 22 Status 107 Status indicator 10 Subnet Mask 15 Switch 26 System Monitor Function Blocks 45 T tagnames 63 TCP IP 16 22 telephone links 12 terminal block 57 Terminal Block Colors 58 Terminal Block Styles 58 test points 54 The Fix 17 transmission delays 42 Revision 4 5 03 Index UDP 14 Universal Analog Input Wiring 69 uplink port 13 User Datagram Protocol 14 _y Vertical Spacing of Racks 47 Voltage test points 9 W WAN 15 Warm Start 107 Wire Gage 59 wire shield 67 wire size 59 wire tie 66 Wiring Rules 59 HC900 Hybrid Controller Installation and User Guide 209 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ARGENTINA Honeywell S A 1 C Belgrano 1156 Buenos Aires Argentina Tel 54 1 383 9290
14. An I O expansion rack includes l 2 U a Scanner Module a Rack available in 4 8 or 12 slot versions a Power Supply Grounding bars for I O wiring optional Input Output modules I O Terminal Blocks Figure 5 I O Expander Rack Components C50 CPU only HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 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 IO expansion rack C50 CPU only and all three versions shown in Figure 6 are available for either purpose Power Supply The POI Power Supply shown in Figure 7 provides 5 Vdc and 24 Vdc to the backplane connectors in the local and remote racks The Power Supply is identical for the Controller Rack and for I O expansion racks C50 CPU only and for all rack versions 4 slot 8 slot and 12 Slot The less expensive lower capacity P02 power supply is available for reduced I O applications See page 37 to determine correct power supply Each power supply includes an internal 5 0 amp fuse that is not field replaceable An external fuse may be added by the user 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 Revision 5 pa 4
15. Cycle power to the rack Cycle power to the hub Replace the expansion rack s power supply 10 Replace the expansion rack 11 Replace the expansion rack s scanner board 12 Replace the main CPU Upgrade the scanner software either by replacing the module or doing a code download Update Main CPU software either by replacing the module or doing a code download 125 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Item Item Value LED Strobes MODULE 1 through MODULE 16 HI CJ TEMPERAT URE WRONG MODULE Possible causes of this diagnostic are 1 One of the two CJs on the module is indicating a temperature reading greater than 70 degrees C 2 Both cold junction sensors are failing to convert 3 The CJs are converting properly but their differential is greater than 10 degrees C The module does not agree with the module required for the control scenario 126 HC900 Hybrid Controller Installation and User Guide B Control File Action User Action N A N A 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 CJ High Temperature for reason 1 or CJ Failure for possible cau
16. 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 Table 33 Scanner Module Replacement el If a process is currently in operation then Either Ensure that powering down the expansion rack will not have adverse consequences on any running process Or Bring the process to a safe and orderly shutdown Using an external user supplied switch disconnect the power supply in the expansion rack from the site AC power source 3 Unplug the 10Base T cable from the scanner Configure the scanner address jumpers on the replacement module to match those of the removed module 4 At the top and bottom of the Scanner Module loosen the captured screws that secure the module in the rack and remove the module from the rack 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 10Base T cable Using the external user supplied switch connect the power supply 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 rE Check status indications at the Scanner Module at the Controller Module and at the OI Revision 5 HC900 Hybrid Controller Inst
17. monitor block s RACK OK pin is turned off 3 ASYS block s HW OK pin is turned off Bad date and time See NOT 1 Program RTC PROGRAMMED 2 Cycle power 3 Replace CPU 4 Replace boards in rack 5 Replace rack 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action User Action Item Item Value LED Strobes FAILED N A One of the Comm Refer to related Comm 1 Check connections ports is reporting a port diagnostic below 2 Access the Comm physical or data link port diagnostics failure screen 3 Replace CPU MODULE One of the module Refer to related Module 1 Access the I O ERROR diagnostics in the diagnostic below Module diagnostics associated rack is set screen to WRONG MODULE NO COM MISSING MODULE if the 3 Replace faulty communications is module failing due to the module not installed BAD MODULE or BAD CHANNEL One of the module Refer to HI CJ See module diagnostics in the TEMPERATURE in diagnostic actions for associated rack is set Module diagnostics HI CJ TEMP to HI CJ TEMPERATURE RACK The Main All associated module Remove modules BACKPLANE CPU Scanner is diagnostics are set to and check for bent FAIL unable to successfully MODULE NO COMM pins on connectors ee ne Refer to MODULE NO Reinsert modules Ji Sa epee COMM diagnostic for one at a time and i ead further details note
18. results row DOWN Disables auto answer Modem sends CD signal when it connects with another modem Loads YO Y4 configuration from user defined nonvolatile memory NVRAM 8 ON DOWN Enables recognition smart mode 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 Configure the port to these settings baud rate 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 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 HC900 Hybrid Controller Installation and User Guide 95 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Step 8 10 11 12 13 14 15 16 17 18 96 Action 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
19. 1 1 7 a 4 4 7 on T T O i 9 9 a I 11 13 o o 14 E 15 O O 16 _ M _ 18 o o 19 _ 20 Revision 5 HC900 Hybrid Controller Installation and User Guide 193 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output Digital Input Digital Output Analog Output The DI DO AO RTP is for use with the following modules See page e 4 point Analog Output 194 e 16 point Contact Digital Input 195 e 16 point DC Digital Input 197 e 16 point AC Digital Input 198 e 16 point DC Digital Output 200 e 8 point AC Digital Output 201 4 Point Analog Output 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to AO module at controller Choose from 2 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 9OORTC LO25 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 60 Mount RTP to DIN rail e Latch to rail See page 205 e Con
20. 2 position or 10 position for designated Terminal Blocks Tie Wraps 1 or 2 for each Terminal Block I O Label one per terminal block by module type Filler Block Cover 1 for each slot not occupied by an I O Module Blank label 1 for each Filler Block Cover Grounding Bars for I O wiring shields 1 or 2 for each 4 slots in each rack Wiring terminal lugs for connecting I O shields to grounding bars Sheet metal screws steel 10 or M4 for mounting racks in enclosures 4 screws for 4 slot racks 8 screws for 8 or 12 slot racks Install or verify correct installation of enclosures for HC900 Controllers and ancillary equipment e Mounting rails or flat panels e for cabinet with multiple HC900 Chassis grounding bus barrier strip for AC power e Master control Relay Install or verify correct installation of enclosures closets for networking devices HC900 Hybrid Controller Installation and User Guide Procedure Reference Site Planning Documentation In this Manual e Section on Pre Installation Planning e Sections on installation e Appendix A Site Plan Documentation and this section of this manual Appendix A Note Some networking devices may share enclosures with HC900 Controller components Revision 5 9 03 Installation Guide Overview Step Procedure Reference Revision 5 9 03 Install or verify correct installation of I O Module Instal
21. 28 Bad Module Diagnostics Revision 5 9 03 Control File Action See WRONG MODULE Associated block sets its fail pin on its warn pin off and its output pin to the failsafe value Associated block sets its IO status as denoted in Table 29 Bad Channel Diagnostics Associated rack monitor block s module fail pin is turned on Associated rack monitor block s RACK OK pin is turned off ASYS block s HW OK pin is turned off See WRONG MODULE HC900 Hybrid Controller Installation and User Guide User Action Action is based on the IODIAG indication If IODIAG is not MODULE ERROR then follow the prescribed action defined for that diagnostic For MODULE ERROR do the following 1 Verify configuration 2 Install module See Table 29 Bad Channel Diagnostics User should inspect the module s status LED to determine the nature of the problem The information in Table 28 Bad Module Diagnostics describes the user action for the various LED diagnostics 127 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Item Item Value GOOD XIO PORT DLFAIL 128 Number of Possible Cause The communications to a particular rack is resulting in a lot of DLL errors Control File Action 1 Related rack monitor block s RACK OK pin is turned off Depending on the nature of the DLL errors the associated
22. Control Relay Wiring Example 46 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Electrical Considerations Rack Dimensions Rack dimensions including overall dimensions and patterns for drilling holes for mounting are given in Figure 23 Vertical spacing of racks which is required for rack ventilation and for routing wires is shown in Figure 24 Rear _ mounting Chassis plate height height 5 4 ae 6 90 Reference Center 12 eA rc an a AN for Drilled j ai Ee RA Figure 24 Vertical Spacing of Racks Revision 5 HC900 Hybrid Controller Installation and User Guide 9 03 47 Pre Installation Planning Electrical Considerations Site Plan Documentation Documenting the plan for installing a process control structure yields significant benefits e The task of installation planning itself is facilitated e Properly organized documentation greatly facilitates each step of the installation process particularly when planners and installers are different persons e After initial installation good documentation facilitates modification and troubleshooting e For ong term maintenance good documentation aids in the orderly transfer of knowledge required for safe and secure process operations Time and effort spent at the beginning of a project is quickly recovered in the efficient execution of each planning and installation procedure To reduc
23. Controller Module or to a port on a Hub that connects to the Controller Module 3 Status indicators for communications functions Figure 9 Scanner Module 10 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Hardware Components Input Output Modules Eight input output types are available e Analog Universal Analog Input 8 point Analog Output 4 point e Digital 120 240 Vac input 16 point 24 Vdc input 16 point Contact input 16 point 120 240 Vac output 8 point O O O O O O O O O O O O O O O O 24 Vdc output 16 point Relay output 8 point Figure 10 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 on the left in Figure 10 and the Barrier style on the right For more information on I O modules and associated terminal blocks refer to the section in this manual on Input Output Installation and Wiring Revision 5 HC900 Hybrid Controller Installation and User Guide 11 9 03 Components and Architecture Hardware Components Personal Computer A Personal Computer is required for creating the control and data acquisition strategy configuration file that runs in the controller using the Hybrid Control Designer configuration software The PC ca
24. I O Slots 1 4 mien Slots E 7 j 12 1 0 Slots E 12 oo Controller or Scanner Module Slot Leneerereees Power Supply Slot Figure 6 Rack Options WARNING SHOCK HAZARD MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT 24V 5V GND Figure 7 Power Supply HC900 Hybrid Controller Installation and User Guide 9 9 03 Components and Architecture Hardware Components Controller Module The Controller Module is shown in Figure 8 with the hinged protective door open Features at the front of the Controller Module include 1 a lithium battery beneath cover which is readily accessible for field replacement 2 RS 232 Port interface to the PC configuration tool external modem or Modbus device 3 Mode switch Program Lock Run Program Run 75 Lock 4 RS 485 Port for Honeywell Operator Interface or Modbus device ws np a m 5 Ethernet 10BaseT Port interface to peer controllers HMIs and other networks 6 Private Ethernet 10BaseT Port interface to I O 6 oe expansion racks C50 CPU only 7 Status indicator for controller functions 8 Status indicators for communications functions Figure 8 Controller Module Scanner Module C50 CPU only The Scanner Module is shown in Figure 9 features at the front of the module include 1 Status indicator for scanner functions 2 Private Ethernet 10BaseT Port connects to the I O expansion port on
25. Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action User Action Item Item Value LED Strobes DATA CPU failed when See PREFETCH See PREFETCH ABORT attempting to access ABORT ABORT data Software Interrupt See PREFETCH See PREFETCH occurred which is not ABORT ABORT supported by the software Corrupted interrupt Interrupt vectors were See WATCHDOG vectors in RAM restored Estimated battery life 1 Associated rack Replace battery is less than 5 days monitor block s RACK OK pin is turned off ASYS block s HW OK pin is turned off SOFTWARE INTERRUPT ERROR VECTOR ERROR MEMORY GOOD 5 DAY LOW BATTERY WARNING Battery voltage is low Associated rack Replace battery monitor block s RACK OK pin is turned off ASYS block s LOW BATTERY pin is turned on ASYS block s HW OK pin is turned off LOW BATTERY FLASH ERROR GOOD OES BAD DATA RAMMING RTC failed to program See NOT See Bad Data Filet PROGRAMMED ae Unable to read RTC See NOT See Bad Data ae PROGRAMMED Revision 5 HC900 Hybrid Controller Installation and User Guide 123 Flash failed to burn Associated rack Force a cold start monitor block s RACK Another Flash burn is OK pin is turned off attempted if FLASH _ASYS block s HW OK aaa aa replace pin is turned off oara RTC not programmed 1 Time and date is set to Program RTC 00 00 00 January 1 1970 2 Associated rack
26. Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Output Module Wiring The AC Output Module provides eight output circuits Each output is isolated from the other outputs An example of AC output wiring is shown in Figure 45 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 NOTE When exceeding 1 0 A per output it 1s 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 46 Replaceable Fuses Each output circuit on the AC Output Module includes a plug in replaceable fuse Replacement fuse is from Wickmann part 3741315041 This is a 3 15 Amp time lag fuse with UL CSA approval for 250 VAC A WARNING AN 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 80 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Revision 5 9 03 I O Module Installation and Wiring
27. Volt or Milliamp Figure 31 shows wiring examples of each of the analog input types An example of wiring for eight TC inputs is given in Figure 33 Specifications for this module and for other modules are given in the Specifications section of this manual 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 ee se meme source as shown in Figure 30 in Figure 31 and in ae AE Figure 32 oe ae For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 Irro 1 amp rtp 3 wire 2 This same current source Iptp 1 amp 2 is also used nPut for an RTD input at channel two terminals 4 and 5 Figure 32 and Figure 35 show examples of RTD input wiring 2 wire and 3 wire RTDs Four wire RTD inputs are not available Figure 30 RTD Inputs OHMs Inputs Ohms inputs are wired similar to 2 wire RTD inputs That is they require a current source and thus must use one of the Iprp current sources Also two terminals are jumpered together as they are for two wire RTD inputs Analog channels wired for Ohms inputs differ from RTD inputs in these aspects e Ohms inputs connect to variable resistance devices other than RTDs and e Ohms inputs are configured in Hybrid Control Designer as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in Figure 34
28. a network HTTP Hypertext Transfer Protocol Application Layer protocol that controls transactions between the web client and the web server Internet A system of networks Access to the Internet is governed by a world wide local regional national set of rules IP Internet Protocol addresses are and international linked by assigned by Internet Corporation for Assigned TCP IP Names and Numbers ICANN Revision 5 HC900 Hybrid Controller Installation and User Guide 29 9 03 Components and Architecture Networking Basics Reference Internet Protocol Address Guaranteed unique address assigned by the Internet Corporation for Assigned Names and Numbers ICANN IP address includes four octets eight bits translating to integers from 0 to 255 separated by periods IP Address ICANN assigns three classes of addresses Class A first leftmost octet is assigned the three rightmost octets are assignable to the owner of the Class A address Class B first and second leftmost octets are assigned the remaining two are assignable by the owner of the Class B address Class C the three leftmost octets are assigned only the rightmost octet is user assignable The number 0 is reserved for router connections to another network 127 for loopback testing and 255 for broadcast to all computers on the network ISDN Integrated Services Digital Digital service provided by telephone companies Network Jabber C
29. aS 90 Figure 51 RS 232 Remote Access vid Modems oh ssi cechides chsctinaeten sade ecctinccetinh ceus ereinen iinne ie annann esee dai iaaa kaat 9 AOU 5 2S VV At tad GAR Operationen an e ln ic ais tc la a att crass ness all aa ds 108 Bh OM OIG LRU GO MC RAO Uses aries actesd uate ne ge ind neg tne tens caste ee ned nica eta ange Ean deen neato ens cae tances 109 9 03 Figure 54 Pathways for Upload Download Transactions cccccccccsssscceccccsccccscseeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 114 Pooc 55 EDU MAI CA ON saws nctesieccacnasanningncuiicasa a a S a S 118 Figure 56 Terminal Board Connections for AI Calibration ccccccccccccccecccceececcececceceecceeeeeeeeeseeeecceeeeeseeeeeeeseeeess 142 Figure 57 Terminal board Connections for AO Calibration cccccccccccccccccceessseseessssnnneeeeeeeeeeeeeeeeesssseaeeeeeeeeeeeeees 143 Figure 58 Example Site Map Equipment Placement ccccccccccccsccccecceeeceeceeeeeceeceeceeecceeeeeeeeeeceeeeeeeeeeeeeeeeeeeseeess iT Figure 59 Example Network System Diagram cccccccsssessssssnneeeeeeeeeeeeeessseseeesnssaeeeeeeeeeeeeeesseseeesaaeeeeeeeeeeeeees 178 Piere 60 Example insta laione A e E auesatacs 183 Figure 61 Analog input terminal and DIP switch designations essssssssosoesseseeeessssssssssssssrrreeeessssssssssssrereeesssss 186 Figure 62 Two wire transmitter connections with common 24 VDC supply 000ooooooooooonnnnnnnnnnennnnnnnenennn
30. 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 38 Specifications for this module and for other modules are given in the Specifications section of this manual Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section Common Terminals Two common terminals are provided for each group of eight inputs Terminals 9 and 10 are connected in the input module and terminals 11 and 12 are connected in the module Jumper Comb A two position jumper comb is available as an option for barrier style terminal blocks only for connecting digital common wiring at terminals 9 and 11 or 10 and 12 See Figure 39 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 DC Input IN 1 IN 3 uname eee 10 32 Vdc G IN 8 Com 1 ints LE cont m ae In 9 16 In 9 16 Com 1 IN 1 8 Legend External es Disconnect User Supplied Safety Devices Figure 38 DC Input Module Wiring Diagram Revision 5 HC900 Hybrid Controller I
31. at terminal A WARNING AN Terminal Boards associated with blocks from sources of power before I O Modules removing the terminal block from Hazardous Voltages the I O module rT Each signal at each of the Either At CAUTION terminals for an I O module has a l l 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 Loss of control or view of a running process Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON HAZARDOUS 62 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Installation Procedures I O Installation Procedures Revision 5 9 03 Table 14 Connect Input Output Wiring Procedure Comments Reference Using Rack Slot 120 240 VAC aaa ORANGE WHITE TEXT Channel data from a pg NEARED led nest Select Label 1 1 with correct Hybrid Control Designer es report and or from i Fill in documentation aids in Tagnames CONTACT GREEN WHITE TEXT Appendix A for reference fill in the tagnames on the RED WHITE TEXT OUTPUT 8 PT Lab
32. connection s application error count is non zero NETWORK SETUP ERROR Rack 1 monitor block s COMPORT DIAG is set to FAILED Rack 1 monitor block s RACK OK pin is turned off 3 ASYS block s HW OK pin is turned off Controller network names determined on network are illegal At host determine which message is causing the exception code and fix Correct the setup problem NO IP DHCP and IP address SEE NETWORK SETUP Enter an IP address ADDRESS are not configured ERROR HARDWARE FAILURE SEE NETWORK SETUP ERROR Ethernet port tests failed during power up 132 HC900 Hybrid Controller Installation and User Guide Replace CPU module Revision 5 9 03 Diagnostics and Troubleshooting User Interface I O Module Diagnostics 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 The table below outlines the potential module diagnostics Table 28 Bad Module Diagnostics Failure Description DO of User Action Vee oS lay FAIL SAFE The module is inthe V vV Viv If expansion rack C50 CPU only check failsafe state because communication link connection to main CPU it is not receiving Remove the module and check for a bent eer aue requests pin then reinsert the module from the main CPU Scanner at a Measure Power Supply voltage if not within rate equal to the specifications replace t
33. 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 5 HC900 Hybrid Controller Installation and User Guide 153 9 03 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Replacement Procedures Table 37 Replacing a Backup Battery CPU Powered Ay CAUTION If the battery 1s 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 3 Open the plastic door at the top of the Controller Module Press the latch on the battery cover to the right to release the battery holder and use the molded in extension on the battery holder to extract the holder Note the orientation of the battery holder assembly battery toward the left The battery is retained in the holder by spring tension of the plastic holder itself Extract the battery from the holder by using your thumb to apply pressure to the front end of the battery and rotating it to the left Insert the negative end of the new battery into the back end of the holder and press on the battery so that it snaps into the holder T
34. host to network connections over both synchronous and asynchronous circuits Print Server A PC dedicated to printer Services print requests from other nodes on the management network Protocol A system of rules for communicating over a network Remote Access Access to a network from a Remote access usually uses a telephone line or the remote computer Internet The remote computer becomes a node on the accessed network by assuming control of a node actually on the network Repeater Receives signals on an A Repeater can extend the distance over which a incoming cable reshapes message can be transported but it also expands the signal form and restores time for transport timing then repeats the signal on an outgoing cable 32 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Networking Basics Reference RJ 45 Style of connector at end of Ethernet twisted pair cable A device that is capable of Routers differ from Bridges and Switches in that filtering messages based on those devices can only read MAC addresses IP addresses Shared Ethernet Configuration that binds See Port Multiplier several network segments in a single collision domain Enables transmittal of E Mail Details are Protocol available in RFC 821 Enables a TCP IP Host to collect network statistics Management Protocol from other Hosts Signal Quality test Often referred to as he
35. 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 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 13 The HC900 controller LAN may be very simple or it may include many devices in a complex and very sophisticated structure In any case it must always be regarded as a single modular entity that can be protected from intrusion by any other networking device to which this LAN is connected Various types of networking devices that enable selective connection to other networks are available A Router is commonly used for this purpose The feature that gives the Router its name is its ability to examine and filter message packets permitting passage of wanted messages and denying passage of all others Many Routers have a secondary but important feature in that they enable 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 C
36. indicates actions that would be taken by the controller in case of fault Notice that if primary diagnostic testing determines that RAM or firmware is faulty all process control functions cease and the Status LED red color strobes one blink periodically If RAM and firmware tests pass but the database in RAM 1s faulty the controller initiates the Cold Start operation Revision 5 HC900 Hybrid Controller Installation and User Guide 107 9 03 Operating Characteristics Power Down Power Up Power ON Diagnostics RAM Firmware Strobe 1 at Status LED Disable all Communications Diagnostics Database RAM RUN Locked PROG Locked Mode Switch position Operate in RUN Mode using process values stored prior to power down Operate in PROGRAM Mode w all outputs off Figure 52 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 53 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 52 e Ona Mode transition from PROGRAM to RUN This Mode transition can be initiated by operating the Mode switch on the
37. 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 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 provided in a kit bagged in a plastic bag with the rack The power supply has an internal fuse that is not replaceable A second external fuse may be added if desired For PO1 power supply use 3 0A slow blow for LISVAC 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 Apply power and then 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 HC900 Hybrid Controller Installation and User Guide ATTENTION Do not connect PE Ground Green Wire directly to terminal on Power Supply p STA caution A 1 SHOCK HAZARD L MORE THAN ONE DISCONNECT SWITCH Brown Black Eure USA _BEFORE SERVICING 24V 5V GND 14 AWG L2 N 2 1 mm o Blue White Coppen i
38. 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 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 TPSC Outputs Both Fwd and Rev are Off e Analog output 0 0 mA Note 2 The Frozen states of module outputs are defined as e Digital output same state as previous last active state e Time Proportional Output TPO Same duty cycle as in last active state e TPSC Outputs digital outputs are Off to freeze the motor position e Analog ou
39. 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 International Inc 525 East Market Street York PA 17405 USA Honeywell International Inc A J bitin 1100 Virginia Drive sam Arcara Fort Washington PA 19034 Director Control Products Engineering Issue Date 4 ZZ 20 2 31452401 doc Industrial Measurement and Control Honeywell 1100 Virginia Drive Fort Washington PA 19034 51 52 25 107 Rev 5 0903 Printed in USA www honeywell com imc Honeywell
40. of the controller AC power to the controller must be removed before removal or replacement of the component A WARNING 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 5 HC900 Hybrid Controller Installation and User Guide 145 9 03 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 146 The power supply for the HC900 Hybrid Controller is available in two models and is used in the local controller rack and in the remote I O expansion racks C50 CPU only in 4 8 and 12 module sizes This reduces required inventories of spare parts and also simplifies removal and replacement procedures Removing the power supply from a rack will remove all DC voltages from the rack that powers the Controller Module or Scanner Module and from all I O modules within the rack
41. rack monitor block s module diagnostics and pins could be affected 3 Associated rack s COM Port is set to FAILED Rack 1 COM Port diagnostic is set to FAILED HC900 Hybrid Controller Installation and User Guide User Action Use the OI or Hybrid Control Designer software to determine which rack is experiencing the DLL errors Verify that the expansion rack C50 CPU only should be in the configuration Verify that the jumpers on the scanner are setup for the correct rack address lf a hub is used check that all cables are properly connected to the hub proper crossover cables are used and that hub is powered Cycle power to the rack Cycle power to the hub Replace the expansion rack s power supply Replace the expansion rack Replace the expansion rack s scanner board 9 Replace the main CPU Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Item Item Value LED Strobes XIO PORT HWFAIL The power up test of the expansion rack C50 CPU only Ethernet controller failed Revision 5 9 03 Control File Action All rack monitor block User Action Replace main CPU XIO PORT DIAG are module set to HWFAIL and COMPORT DIAG is set to FAIL All rack monitor block RACK OK pin are turned off All modules in the configuration hav
42. start use it with a re start or abort the download For downloading procedures refer to the Operator Interface User Manual Configuration Upload Controller configuration files setpoint profiles and recipe files can be uploaded for storage and archiving in a PC and or to a disk in the Operator Interface Using the PC the Upload function is accessed from the Hybrid Control Designer For details of uploading configuration items refer to Hybrid Control Designer and Operator Interface manuals Revision 5 HC900 Hybrid Controller Installation and User Guide 115 9 03 Operating Characteristics Software Download Upload Functions 116 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 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 maint
43. suppliers Third party suppliers or Honeywell Third party suppliers or Honeywell RS 485 cable Belden 9271 or equivalent up to 2000 601m Third party suppliers Null modem cable up to 50 15 24m PC modem Third party suppliers or cable if used with Modems Honeywell HC900 Hybrid Controller Installation and User Guide Components and Architecture Hardware Components Hardware Components This section contains general descriptions of each of the major components of the HC900 system For environmental specifications refer to the section on Pre Installation Planning HC900 Controller Rack An HC900 Controller local rack is shown in Figure 4 As indicated in this figure the Controller Rack includes l a Power Supply a Controller Module Grounding bars for I O wiring optional 2 Input Output modules a Rack available in 4 8 or 12 slot versions I O Terminal Blocks Figure 4 Controller Rack Components I O Expansion Rack C50 CPU only I O expansion remote racks shown in Figure 5 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 Most of the components in an I O expansion rack are identical to those used in the Controller Rack The only difference is the Scanner Module item 3 that occupies the same rack location as the Controller Module in a Controller Rack
44. the Source or the Destination of a message When it is manufactured every node is given a hard coded Media Access Control MAC address that can be sensed by other nodes on the network When it is placed on an Ethernet network each node is also given an Internet Protocol IP address which is stored in non volatile memory and which identifies it uniquely on that network Open Systems Interconnection Reference Model OSI The OSI Model provides a reference source of all the methods and protocols needed to connect one computer to another over a network Although details of networking systems often differ from those specified in the OSI Model this model is used widely for design and manufacture of networking components as well as networking systems from networks are constructed The Features of the OSI Model are summarized in Table 3 Networking Protocols A network protocol is a set of rules or syntax for exchanging data between nodes In a very simple system a single protocol is required For most networking systems used in commercial and industrial applications several protocols are required Some protocols operate in one layer of the OSI model while others operate in more than one layer For example Transport Control Protocol Internet Protocol TCP IP is commonly on the Internet and is used in private networks such as an HC900 Controller LAN TCP 22 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Ar
45. which module the diagnostic reoccurs and replace that module Cycle power to the rack Replace the power supply 5 Replace the rack 6 Replace the CPU 2 Install proper module HI TEMP board 124 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Item Item Value LED Strobes RACK COMM FAIL RACK SW INCOMPATILITY Revision 5 9 03 Possible Cause The Main CPU is unable to successfully communicate to an expansion rack C50 CPU only that is in its configuration The Main CPU determined that its software is not compatible with the scanner module Control File Action See RACK BACKPLANE FAIL All associated module diagnostics are set to MODULE NO COMM Refer to MODULE NO COMM diagnostic for further details HC900 Hybrid Controller Installation and User Guide User Action Verify that the expansion rack should be in the configuration Verify that the jumpers on the scanner are set up for the correct rack address Check that expansion rack Is on Check the expansion rack s status LED for diagnostic information Check that cable is connected to expansion rack If a hub is used check that all cables are properly connected to the hub proper crossover cables are used and that hub is powered
46. with the Hybrid Control Designer Software 88 To establish communications between the HC900 controller and the Hybrid Control HC Designer configuration software use any of the following methods A Direct Serial RS 232 connection B Modem connection C Direct Ethernet connection D Networked Ethernet connection These methods are described below HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software A Direct Serial RS 232 Connection Com1 Com 8 RS 232 Configuration port VA RS 232 9 6 38 4 KB PC Null Modem cable Procedure Prepare a null modem cable Refer to RS 232 Direct Link to PC Configuration Tool page 90 for specific instructions on the null modem cable Connect one end of the null modem cable to the HC900 controller s RS 232 configuration port Connect the other end to an available serial port COM1 through COM8 on your PC Refer to RS 232 Direct Link to PC Configuration Tool page 90 for specific instructions on the null modem cable If a configuration is not available start a new configuration in HC Designer by selecting File New After selecting controller type and revision select OK 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 M
47. 0 64444 HUNGARY HONEYWELL Kft Gogol u 13 H 1133 BUDAPEST HUNGARY Tel 36 1 451 43 00 ICELAND HONEYWELL Hataekni hf Armuli 26 PO Box 8336 128 reykjavik Iceland Tel 354 588 5000 ITALY HONEYWELL S p A Via P Gobetti 2 b 20063 Cernusco Sul Naviglio ITALY Tel 39 02 92146 1 MEXICO HONEYWELL S A DE CV AV CONSTITUYENTES 900 COL LOMAS ALTAS 11950 MEXICO CITY MEXICO Tel 52 5 259 1966 THE NETHERLANDS HONEYWELL BV Laaderhoogtweg 18 1101 EA AMSTERDAM ZO THE NETHERLANDS Tel 31 20 56 56 911 NORWAY HONEYWELL A S Askerveien 61 PO Box 263 N 1371 ASKER NORWAY Tel 47 66 76 20 00 POLAND HONEYWELL Sp z 0 0 UI Domaniewksa 41 02 672 WARSAW POLAND Tel 48 22 606 09 00 PORTUGAL HONEYWELL PORTUGAL LDA Edificio Suecia II Av do Forte nr 3 Piso 3 2795 CARNAXIDE PORTUGAL Tel 351 1 424 50 00 REPUBLIC OF IRELAND HONEYWELL Unit 1 Robinhood Business Park Robinhood Road DUBLIN 22 Republic of Ireland Tel 353 1 4565944 REPUBLIC OF SINGAPORE HONEYWELL PTE LTD BLOCK 750E CHAI CHEE ROAD 06 01 CHAI CHEE IND PARK 1646 SINGAPORE REP OF SINGAPORE Tel 65 2490 100 REPUBLIC OF SOUTH AFRICA HONEYWELL Southern Africa PO BOX 138 Milnerton 7435 REPUBLIC OF SOUTH AFRICA Tel 27 11 805 12 01 ROMANIA HONEYWELL Office Bucharest 147 Aurel Vlaicu Str Sc Z Apt 61 62 R 72921 Bucharest ROMANIA Tel 40 1 211 00 76 211 79 RUSSIA HONEYWELL I
48. 0 Hybrid Controller Installation and User Guide Revision 5 9 03 A AC Input Module de Rating 40 AC Input Module Wiring 75 AC Input terminal block 9 AC Output Module Wiring 80 Alarm Groups 18 Alarm Event messages 14 Analog Calibration 140 Analog Input Calibration 141 Analog Output Calibration 143 Analog Output Module Wiring 72 ASCII 16 B backplane 54 57 barrier style 58 Barrier style 11 Battery Installation 55 152 Battery Installation Replacement 55 Battery Replacement 154 Bridge 26 Bus topology 22 p Cabinet Wiring 42 43 cable segment 13 Cable Type 86 captured screws 57 CE Conformity 44 Cold Start 107 collision 22 COM 1 12 Communications Installation 85 concentrator 22 Configurator Templates 176 Contact Input Module Wiring 77 Controller Modes 110 Controller Module 10 Controller Module Diagnostics 121 Controller Name 15 Controller Rack 8 CSMA CD 22 custom graphics 17 D DC Input Module Wiring 73 DC Output Module Wiring 78 Destination 22 Diagnostics and Troubleshooting 117 Download Upload 114 DSL 18 F each I O expansion rack 56 Revision 5 9 03 Index E Mail 14 E Mail Communications 18 Emergency Stop switches 45 enclosure 42 Environmental Operating Limits 38 equipment enclosures 39 Equipment Placement 41 Ethernet 22 Ethernet 10BaseT Port 10 Ethernet Devices 13 Ethernet Open Connectivity Ne
49. 00 Hybrid Controller are listed Table 6 Table 6 Operating Limits and Installation Guidelines Condition Specifications Ambient Temperature 32 F to 131 F 0 C to 55 C or 0 C to 60 C with derating Relative Humidity 10 to 90 RH at 40 C 104 F Vibration Frequency 14 Hz to 250 Hz Acceleration 1g Mechanical Shock Acceleration 1g Duration 30 ms Electromagnetic Interference EMI and Meets the requirements of the EMC directive 89 336 EEC Radio Frequency Interference RFI Evaluated to EN61326 1997 A1 for emissions and immunity Voltage 100 Vac to 240 Vac Frequency Hz 47 to 63 Hz Power Consumption Typical 110VA 115VAC maximum 130VA 264VAC Class 1 Division 2 Installations CONTROLLER RACK MUST BE MOUNTED INSIDE A SECURE ENCLOSURE General Installation Install per NEC requirements for Open Type Equipment 38 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Orientation of Rack Mounting The HC900 Controller must be mounted in suitable equipment enclosures That is all components such as the Controller rack IO Expander Racks and the Operator Interface manufactured by Honeywell must be mounted in approved furniture designed for industrial applications Orientation of Rack Mounting Racks must be mounted as indicated in illustrations throughout this manual so as to provide for vertical airflow through the racks That is ra
50. 12 n 7 14 IN 15 pA 20 IN 16 Legend 7 7 External W Disconnect User Supplied Safety Devices Figure 40 AC Input Module Wiring Diagram Revision 5 HC900 Hybrid Controller Installation and User Guide 75 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Input Jumper either 10 12 s or 9 11 m Connect any Of 9 12 fe to L2 N Figure 41 AC Input Module Jumper 76 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 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 42 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 AN 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 o
51. 16 point DC DO module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 9OORTC LO25 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 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 60 Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP 3 Set verify jumper positions as shown 0 8 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 62 for more details See page 203 for RTP internal schematic 200 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point DC Digital Output sel 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 DC Supply 8 Point AC Digital Output ef ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION AC Digital Output is limited to 6A
52. 2 and for connecting 24Vdc between terminals 9 and 11 See Figure 44 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 WARNING AN 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 78 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Output OUT 1 e t a 7 a z a OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 V 1 Com 2 Out 1 8 V2 Com 2 Out 9 16 OUT 9 OUT 10 OUT 11 OUT 12 OUT 13 OUT 14 OUT 15 OUT 16 COM 2 Out 9 16 ae _OUT9 OVrO VWVV SS E OUT 10 Forres OVO AM o OUT 11 V 2 DE OUT 12 F OUT 13 24 Vdc awe protege i OUT 14 External N w Disconnect a a User Supplied Safety Devices Figure 43 DC Output Module Wiring Diagram DC Output Jumper 9 11 for one V Supply to both groups of outputs Jumper 10 12 for one Common Ground for all 16 outputs Figure 44 DC Output Jumpers Revision 5 HC900 Hybrid Controller Installation and User Guide 9 03 19 I O
53. 232 port of the HC900 using a DB 9 male to DB 9 male RS 232 cable Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Hybrid Control Designer software Set up the PC software to dial the HC900 Controller Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software SixNet VT MODEM Industrial External Modem Revision 5 9 03 Step 1 O oa A O 10 11 12 13 14 15 16 17 Action Connect the modem to a PC If your PC s RS 232 port has a 25 pin connector use a DB 9 male to DB 25 female modem cable If your PC s RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232 cable 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 Configure the port to these settings baud rate 9600 19200 38400 57600 must match baud rate configured in HC900 controller data bits 8 parity none stop bits 1 flow control none In the program s terminal window restore factory default
54. 4 Range 0 357 C 0 14 of Range JIS RTD 0 1 of Range 0 12 Range 0 824 C 0 22 of Range 10Q Cu RTD 0 1 of Range 0 57 Range 1 540 C 0 67 of Range 2009 OHMS 0 1 of Range 0 07 Range 0 140Q 0 17 of Range 0 10mV LINEAR 0 1 of Range 0 04 Range 0 004mV 0 14 of Range Revision 5 HC900 Hybrid Controller Installation and User Guide 189 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input Analog Input RTP Internal schematic HC900 Terminal Block J1 TB1 SW 2 2 250 Ohm SW 4 2 250 Ohm SW 5 2 250 Ohm SW 6 2 250 Ohm E E EEIE SW 8 2 250 Ohm SW SW SW SW SW SW sw sw 8 1 7 1 6 1 5 1 4 1 3 1 2 1 101 SW Q O co nm s iiit 190 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Relay Output Relay Output Relay Output 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to relay output 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 2 9OORTC H050 Remote Terminal High Voltage Cable assembly 5 0
55. 4 Events E Mail notification of Alarms and Events to up to three addresses per controller by alarm priority 1 5 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Overview This section provides a description of each of the major components that can be included in an HC900 Controller physical configuration and indicates some of the methods by which they can be combined Components The Honeywell HC900 Hybrid Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications Some of the modules are required in all configurations Others are optional they are selected as appropriate to provide optional functions and or to size the system either in initial planning or in modifying and or expanding the system to meet changing requirements An HC900 Controller configuration with multiple controllers is illustrated in Figure 3 This illustration includes key numbers that identify components that are described in Table 1 CAUTION Communications lockout is possible in high network traffic conditions When inter connecting your HC900 controller sub net to a plant network where there may be significant network traffic not directed to the HC900 controllers or to related supervisory control or data acquisition software interfaces we highly recommend you use a router to protect the controller from
56. 4 volt supply Module RIUP is not affected by using the RTP See page 190 for RTP internal schematic Connect field wiring Refer to Figure 61 through Figure 67 for field wiring Any input type can be wired to any of the 8 inputs After wiring double check DIP switches are set correctly for each input type Step 3 Revision 5 HC900 Hybrid Controller Installation and User Guide 185 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input rf i i lt 0 O 0 OG 80 00 00 a Nig 5 3 3 3 77232322725 Dr oS S n z a iz ni ees a Ge ee nen ae en ee cope 2 So ee OLE te oe eee Sa ioe Si XL K Ai WK Ai K Ai WK i UN ele oe oe DAA Z 4 32 2 44 a AZZ A SZZ S52 eee ae gt i Nn ri 1 oOo Sie On Oris Sot B VS 28 DO O18 B S OOQO _ 3 Use Use Use Use Use Use Use Use Use SW9 SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 power switch Red 1 0 Figure 61 Analog input terminal and DIP switch designations Note 29 You must set switches 1 8 for transmitters Input 1 p Input 3 Input 5 Transmitter Input 2 Transmiter a tl oput S Transmitter Input 8 Transmitter Transmitter Figure 62 Two wire transmitter connections with common 24 VDC supply 186 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B
57. 9 pin D connector RS 232 9 pin D connector RS 232 9 pin D connector RS 232 9 pin D connector RS 485 3 pin Phoenix Table 16 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 Cable Type RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS232 to RS485 converter RS232 to RS485 converter RS232 to RS485 converter Belden 9271 or equivalent To Device Port Serial port of PC w Null Modem cable or Modem Refer to RS 232 Remote Connection to PC Configuration Tool on page 91 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 Reference Data For Wiring details of Null Modem cable 9 pin Male Female connector see Figure 50 Null Modem Cable Construction Page 20 Figure 16 amp Figure 17 2 7 9 Page 20 Figure 16 amp Figure 17 6 Page 20 Figure 16 amp Figure 17 4 5 8 Page 20 Figure 16 amp Figure 17 1 2 4 5 6 11 1840379 or equivalent RS 485 Mod
58. A button will appear to allow you to dial a selected controller r Current PC to Controller Connection Settings sjaja Feci CordBus Ethemel 100 Modem 56 Modem interace Protocol Hommel Inc ELN Speed bps MA 92 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem requirements Most commercially available modems can be used with the HC900 Controller The modem must have the following capabilities RS 232 interface Auto answer Can operate at 9600 or 19200 or 38400 baud 8 data bits 1 stop bit and no parity Hardware handshaking can be disabled Software handshaking can be disabled Data Terminal Ready DTR input can be disabled Result codes can be suppressed Echo can be disabled Must be equipped with non volatile memory NVRAM so that settings that are configured using command strings can be retained during a power outage Must be able to load the NVRAM settings automatically on power up Cable requirements You will need an interface cable to connect the modem to the DB 9 female on the controller If your modem has a 25 pin connector be sure to use a DB 25 to DB 9 modem cable A TIP The Null Modem cable used to directly connect a PC running Hybrid Control Designer software to the controller may typically not be used to connect the PC to the modem or to connect the modem
59. CPU only Revision 5 HC900 Hybrid Controller Installation and User Guide 3 9 03 Introduction Feature Summary Control Functions Comprehensive set of Function Blocks includes PID Model C50 up to 32 loops Model C30 up to 8 loops Setpoint Programmers up to 8 SP Profiles pool of 99 with up to 50 Segments Profile SP Schedulers 1 or 2 Setpoint Schedules up to 20 with up to 50 Segments Schedule Sequencers up to 4 Sequences up to 20 Steps per Sequence up to 64 Recipes up to 50 up to 50 parameters per recipe Logic Fast Logic Counters Timers Math Calculations Signal Selector Auxiliary Communications Up to 400 Model C30 or 2000 Model C50 user configured blocks per control strategy Input Output Al Model C30 Up to 96 analog inputs 0 1 of span accuracy Model C50 Up to 256 analog inputs 0 1 of span accuracy AO Model C30 Up to 48 analog outputs Model C50 Up to 64 analog outputs Up to 512 inputs and outputs 192 for Model C30 combined local and remote analog and digital Analog Module Types Universal Analog Input 8 point Analog Output 4 point Digital Input Module Types 120 240Vac amp 24Vdc Input 16 point Contact Input 16 point Digital Output Module Types 120 240Vac Output 8 point 24Vdc Output 16 point Relay Output 8 point Alarms Events Up to 240 Alarms 20 groups of 12 Up to 6
60. Contact type 16 channel Digital Input 24Vdc type 16 channel Digital Input 120 240 Vac 16 channel T3C Ta 60 C T4 Ta 40 C 170 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Environmental and Operating Conditions HC900 Analog Input Ranges vs UMC800 Analog Input ranges Users of UMC800 Controllers from Honeywell will find the analog range selections of the HC900 Controller differ slightly from those available in the UMC800 These differences are indicated in Table 38 in the column identified Reference Corresponding UMC800 Input type and range The number to the right of the range data indicates the range number reference for the UMC800 range table When using the Hybrid Control Designer configuration software to convert UMC800 configuration files to HC900 configuration files the HC900 range to the left of the UMC800 data will be used by the conversion program There may also be UMC800 ranges that are not supported by the HC900 Controller For these ranges the conversion process will default the range data to a null not programmed range Table 38 HC900 PV Input Types and Ranges Type Range Range High Reference Corresponding Low UMC800 Input type and range 18 o eo e Geess oo as fee dK omc o 200K eater ro te00 e eet w fo e er Ni NiMo 0 682 n a Ni NiMo NiMo NiCo w 1371 MoCo 01400C 110 NiMo NiCo NiMo NiCo o 682 NiMo NiCo NiCroS
61. E varen EEK PaE aia EEEN ENEE ea 146 Table 32 Controller Module Replacement 4 2 sissverctasecasesessvastossevdsadisavorsnse Goossens Rok ae ane 148 Table 33 S5canner Module Replacement is ceed sensvsvesteteareranrsteaceeeseeecactstresuatateranitkesendtar aw ous eae 149 Table 34 RIUP Potential Hazards and Recommended Actions cccccccccccccccccccccecceeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 150 Table 35 0 Module Replacement ainarra e E EAE EE NEEE E asia AW ee a 151 Table 36 Installing Backup Battery CPU not initialized cccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 153 Table 37 Replacing a Backup Battery CPU Powered nnnnnnnnnnnnnnsnnrenrrererssssssssssssssssssssssssssssssssssssssssssssssssss 154 Table 38 HC900 PY Input Types and Ranges neneciirpsisiemii a a a ainai aeii A viii HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Figures Figure 1 Small HC900 Controller Configuration cccssceeeenssccccecessesssssesccccnssccccceeessessesesssseaccesssaccceeeseeeees 2 Figure 2 Expanded HC900 Controller Configuration C50 CPU omnly ccccssssssccccceeeeceeeeseesssnnneeeeeeeeeeeeeeseeeeeeeas 2 Figure 3 Configuration with Multiple Controllers tess escccedsnssnusucnacanhasacanarasivasedatarduarcaecantavencwa teeseilveidetenitashaanhdeeaies 6 Picute 4 ontroller Rack C Oimpone nus eaa toasts dtnscuereeahcantaralauniesed dua ndnsanntashanedd
62. Honeywell HC900 Hybrid Controller Installation and User Guide Doc No 51 52 25 107 Revision 5 Date 9 03 Industrial Measurement and Control Notices and Trademarks Copyright 2003 by Honeywell Revision 5 Sept 2003 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 Industrial Measurement and Control Honeywell 1100 Virginia Drive Fort Washington PA 19034 Honeywell is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners ii HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 About This Document Abstract This document provides descr
63. Hybrid Controller Installation and User Guide 83 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Relay Output Module One half j 10 position jumper To Relay Loads via external disconnect switches fuses Figure 49 Relay Output Module Jumpers 84 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Overview This section contains descriptions of and procedures and recommendations for installing communications systems and components Table 15 Connect Communications Wiring and Cabling Step Procedure Comments Reference Determine requirements for communications links by referring to the site diagrams Refer to Appendix A Expansion I O C50 CPU only Refer to the diagram of the controller at right and to Table 16 Links to Controller Communication Ports for connection details Connect communications PO Configuration Tool cabling as indicated by the site cabling diagram Operator Interface e s o Ethernet To Host and Peer e 10Base T devices and to The Ethernet port for the Configuration Tool expansion rack is only present for Model C50 i To Ethernet 10Base T I O Expansion For Modbus connections see page 105 Revision 5 HC900 Hybrid Controller Installation and User Guide 85 9 03 Communications Installation Overview Controller Port Connector Type RS 232
64. I O Terminal Block Wiring Diagrams Out 1 H Out 1 NO Out 2 H Out 2 NO Out 3 H Out 3 NO Out 4 H Out 4 NO Out 5 H Out 5 NO Out 6 H Out 6 NO Out 7 H Out 7 NO Out 8 H Out 8 NO tT Ud DO OOO L FO Legend Ro External Disconnect User Supplied Safety Device Figure 45 AC Output Module Wiring Diagram AC Output Figure 46 AC Output Module Jumper HC900 Hybrid Controller Installation and User Guide 81 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 47 Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure 48 c uses appropriate for load and for wire used are provided by user Fuses appropriate for load and for wire used are provided by user Figure 47 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 Required Output Fusing Outputs are not fused in the Relay module Install a fuse for
65. I9 PO Wer Supp y LICH AIO ere ani AE E EE E E AE EE E AEE AAE A EAA 40 Fiure 204 Cabinet Wining omele Chassis ecserin a E EEE A E O EE ER A EA OTR 43 Figure 2 Cabinet Wirme Multiple CHASSIS nrerin E E EEE E EEE EEE AERE A eee AEEA 43 Figure 22 Mast r Control Relay Wiring Example seirer ane E AEE EERE e ee ec 46 Pigute 2 gt Rack DIMENS ONS oe T AA O E A A A E OAE EEE 47 Feue 24 2 Vertical spac in or RICK a E A AET AE O A ces E A E AE 47 Feur 25 1 Module Tista laom nanen a a a a A ORS 57 Figure 261 criminal BIOCK Sm Si a a E a O 58 Figure 2 resena Wire Grondig sorrisu a a aa E a a a NOR 60 igure 28 Wire Shicid Grounding sorrires a a E a a A NORN 60 Figure 29 Terminal Block Jumper Installation nsien a E A ENOR 6l Paure 0 IRD TU aaa a T a A anmetamasnes 68 Figure 31 Universal Analog Input Wiring Diagram ccc cccccccccseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeess 69 Figure 32 Examples of RTD Input Wiring cccccccssseesssssenececcsecesesesenssesescencassceceseestesesenssscssceensassaceseessasens 69 Figure 33 Analog Input Wiring Eight TCs seeeeeesessssssssssssssrereecesssssssssssssreereecoessssssssseeeeeecesssssssssssssssseeeeeeeeessss 70 Figure 34 Analog Input Wiring Eight Resistance Inputs ccccccccccccccccceeesseeeessnnsnneeeeeeeeeeeeceseesseeesneaaaaaeeeeeeeeeeeees 70 Figure 35 Analog Input Wiring Eight RTDs ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee
66. IUP Removal and Insertion Under Power RIUP A 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 1s the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 13 provides some general guidelines for establishing appropriate procedures at a given installation Table 13 RIUP Potential Hazards and Recommended Actions Potentially lethal voltages on Disconnect all signals
67. 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 5 9 03 Diagnostics and Troubleshooting User Interface Table 26 LED Indications on Ethernet Hub LED State Color Indicates Condition 10Base T port I O Expansion C50 CPU only 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 User Interface Table 27 lists Controller Module diagnostic indications Operator Interface messages and Status LED along with causes of the indications automatic control file actions and suggested user actions WARNING AN Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources e Disconnect power before servicing More than one switch may be required to disconnect all power Failure to comply with these instructions could result in death or serious injury Table 27 Controller Module Diagnostics Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action User Action Item Item V
68. Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Step QOG Oe eee ee Ge Ge Qo CD ED OAA SE OSL BIS G AA a Figure 63 Milliamp input connections with 250 ohm shunt resistance YOOOOOOOOOODOOYVOOOMOM Note You must set switches 1 8 for Volts Millivolts z CF V mV V mV Input 6 V mV Input 1 V mV Input 2 V mV Input 8 Figure 64 Volt millivolt input connections Revision 5 HC900 Hybrid Controller Installation and User Guide 187 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Step Action Note You must set switches 1 8 for RTD Input 2 Input 3 Input 4 Input 6 Input 8 Figure 65 Three wire RTD input connections Input 5 Input 7 You must set switches 1 8 RTD OHMS RTD OHMS for Ohms D OQOOOOOQOOQOOOHO OOOOS RTD OHMS RTD OHMS Input 2 Input 3 Input 4 Input 6 Input 8 Figure 66 Two wire RTD or ohm input connections 188 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Action Note You must set switches 1 8 for Ohms Input 2 Input 3 Input 4 Input 6 Input 8 Figure 67 Slidewire feedback connections for actuators Analog Input accuracy specification Range Al Module Accuracy RTP Cable Accuracy Al Module RTP Accuracy 100Q Plat RTD 0 1 of Range 0 0
69. Key in the following command string AT EO Q1 amp W0 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 Pe Fon f oom Wen rom Rr Verbal word a a po om Suppresses ecto 5 OFF UP Modem answers on first ring 6 oN DOWN CD always ON Override T OFF UP Loads Y0 Y4 configuration from user defined nonvolatile memory NVRAM 8 amp 8 OFF u Disables command recognition dumb mode Connect the modem to the RS 232 port of the HC900 using a DB 25 male to DB 9 male RS 232 cable Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Hybrid Control Designer software Set up Hybrid Control Designer software to dial the HC900 Controller Verify that communications is established with the remote HC900 Controller HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Zoom 56K Dualmode External Modem Revision 5 9 03 Step 1 ao oa fF OO N 10 11 12 13 14 15 16 17 Action 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 RS232 port has a 9 pin connector use a DB 25 male to DB 9 female modem cable Connect power to the mo
70. NC 4 th Floor Administrative Builiding of AO Luzhniki Management 24 Luzhniki 119048 Moscow RUSSIA Tel 7 095 796 98 00 01 SLOVAKIA HONEYWELL Ltd Mlynske nivy 73 PO Box 75 820 07 BRATISLAVA 27 SLOVAKIA Tel 421 7 52 47 400 425 SPAIN HONEYWELL S A Factory Josefa Valcarcel 24 28027 MADRID SPAIN Tel 34 91 31 3 61 00 SWEDEN HONEYWELL A B S 127 86 Skarholmen STOCKHOLM SWEDEN Tel 46 8 775 55 00 SWITZERLAND HONEYWELL A G Hertistrasse 2 8304 WALLISELLEN SWITZERLAND Tel 41 1 831 02 71 TURKEY HONEYWELL A S Caryiryolu Sok No 7 Ucgen Plaza Kat 5 6 7 Icerenkoy 81120 Instanbul Turkey Tel 90 216 575 66 00 UNITED KINGDOM HONEYWELL Honeywell House Arlington Business Park Bracknell Berkshire RG12 1EB Tel 44 0 1344 656000 U S A HONEYWELL INC INDUSTRIAL PROCESS CONTROLS 1100 VIRGINIA DRIVE PA 19034 3260 FT WASHINGTON U S A Tel 1 800 343 0228 VENEZUELA HONEYWELL CA APARTADO 61314 1060 CARACAS VENEZUELA Tel 58 2 239 0211 Honeywell 51452403 Revision A DECLARATION OF CONFORMITY CE We declare that the following product HC900 Racks Models 900R04 900R08 900R012 is in conformity with the protection requirements of Council Directives 89 336 EEC as amended by 92 31 EEC and 93 68 EEC on the harmonization of the laws of the Member States relating to Electromagnetic Compatibility and 73 23 EEC as amended by 93 68 EEC on th
71. O Terminal Block Wiring Diagrams Resistance Temperature Device Inputs IN 1 IN 1 lar 1 amp 2 IN 2 IN 2 IN 3 IN 3 ler 3 amp 4 IN 4 IN 4 a ee Me e s i Ms KA t a i IN 5 IN 5 lmn 5 amp 6 IN 6 IN 6 IN7 IN 7 ler 7 amp 8 IN 8 IN 8 Shield Ground typical Figure 35 Analog Input Wiring Eight RTDs Slidewires Figure 36 Analog Input Wiring Slidewire Position Proportion Block Revision 5 HC900 Hybrid Controller Installation and User Guide 71 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Analog Output Module Wiring An example of Analog Output Module wiring is shown in Figure 37 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 A WARNING AN 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 OUT 1 OUT 1 OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 37 Analog Output Wiring Diagram 72 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation
72. S 232 port on any one Controller module Includes Honeywell Hybrid Control Designer configuration software Optional PC link to Ethernet network which may include other HMls other HC900 Controllers and other networks including Internet Typically includes HMI operating software May also include Hybrid Control Designer configuration tool and utility software Enables connection of the private Ethernet 10BaseT port on a Controller Module to the Scanner modules on 2 3 or 4 I O Expansion racks C50 CPU only If a single I O expansion rack is connected directly to a Controller Module the Hub is not required Enables inter connection of several 10BaseT Ethernet devices in an Ethernet network Devices include other HC900 Controllers HMIs and can also include routers brouters servers and other devices in wider networks Connects I O expansion racks C50 CPU only to controllers and or to 10baseT Ethernet hubs 10 or 20 3 04 or 6 08m Connects devices in Ethernet Open Connectivity network Cross over cable is used for Controller to PC connection straight through for Controller to Hub connection 20 6 08m Honeywell Honeywell Honeywell PC is from third party supplier Configuration software is from Honeywell PC is from third party supplier HMI software is available from Honeywell PlantScape or SpecView32 or from third party supplier Honeywell Third party
73. SCAN pins e parity tumed on e number of stop bits _ IN SCAN STATUS is ence set to NO for all slaves interference experiencing the failure e grounding i e termination resistor if COMM STATUS is set at end of link to BAD for all slaves o experiencing the failure 7 The diagnostic is l cleared by clearing i The slaves with the data the port s statistics link errors have a non zero data link error count The slaves experiencing the failure are moved to the background scan rate 130 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action User Action Item Item Value LED Strobes RS 232 HW The DUART failed its 1 Rack 1 monitor block s Replace CPU module FAILURE power up tests COMPORT DIAG is set to FAILED 2 Rack 1 monitor block s RACK OK pin is turned off 3 ASYS and FSYS blocks HW OK pins are turned off 4 If configured as a Modbus master 1 ASYS and FSYS blocks Modbus Master Fail pins are tumed on 2 All Modbus slave and Modbus read blocks have their read pins frozen to the last value read 3 All slave blocks have their BAD COMM and NO SCAN pins tumed on 4 IN SCAN STATUS is set to NO for all slaves 5 COMM STATUS is set to BAD for all slaves in the function block diagram 6 Statistical data for all s
74. See Table 28 Bad Module Diagnostics 138 HC900 Hybrid Controller Installation and User Guide User Action 1 Improve ventilation to rack 2 Replace Al module 1 Verify configuration 2 Replace module with the correct one 1 Verify configuration 2 Install or replace module 3 Check for bent pins on the module 4 Replace the backplane See Table 29 Bad Channel Diagnostics User should inspect the module s status LED to determine the nature of the problem The table in Table 28 Bad Module Diagnostics describes the user action for the various LED diagnostics Revision 5 9 03 Diagnostics and Troubleshooting User Interface Revision 5 HC900 Hybrid Controller Installation and User Guide 139 9 03 Analog Calibration Overview All calibration data for Analog Input Modules and Analog Output Modules is stored in non volatile memory in the I O modules Calibration data is stored for each channel of each AI or AO module Calibration data for each channel can be either e Factory calibration which is stored permanently in the module and e Field Calibration which is entered from an HMI OI on the RS 485 Port and or a PC on the RS 232 Port and or the Ethernet 10Base T Port using Hybrid Control Designer software A field calibration procedure consists of two parts e Connecting a calibration device to each channel of an AI or AO module and e Using the Operator Interface to select actions and ent
75. T devices that support TCP IP e Components of the I O expansion network C50 CPU only which is an independent private network that is designed to work exclusively with the HC950 expansion racks Installation of the I O expansion network is relatively straightforward it includes only a few devices and requires only configuration of jumpers in Scanner modules 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 I O Expansion Network C50 CPU only Examples of HC900 Controller I O expansion configurations are shown in Figure 12 LUE SLE Straight Cable Crossover Cable en miil mijili HI Figure 12 HC900 Controller Configurations In Figure 12 any of the racks shown in each controller configuration can be 4 8 or 12 slot versions Note that in configuration 2 C50 CPU only the Ethernet cable connects directly from the 10BaseT connector on the Controller Module directly to the Scanner Module on the single I O expansion rack In configuration 3 C50 CPU only the Ethernet cable goes from the 10BaseT port on the Controller Module using a crossover cable to the Hub and a straight through cable from each of the Hub ports to the 10BaseT port on the Scanner Modules The Ethernet cabling for the I O expansion links C50 CPU only are standard shielded Cat 5E cabling with standard RJ45 connectors Each
76. Verify that the replacement module is of the proper type Then carefully insert it into the slot in the rack so as to make proper contact with the connector in the backplane Replace the terminal block on the module If the rack was powered down for the procedure restore power to the rack Re connect signals to field devices HC900 Hybrid Controller Installation and User Guide 151 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 1s 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 se
77. _ _ _ _ z E p gt 7 3 02 76 HC900 Hybrid Controller Installation and User Guide 6 04 _ 153 as a k A ab I Revision 5 9 03 Installation Guide Overview Procedure Comments References 2 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 3 Hang the rack in the enclosure on the top screws Start all screws in the bottom of the rack then tighten all screws 4 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 Revision 5 HC900 Hybrid Controller Installation and User Guide 53 9 03 Installation Guide Overview 54 WARNING AN Hazardous Voltage e Ensure that wiring to the Power Supply is disconnected from the site AC source before
78. able Ethernet network Example 10BaseT is 10 Mbps Twisted Pair FTP File Transfer Protocol Use for send and receive files between an FTP eieepee E Filtering Selection process used by a The Switch or Bridge reads the content of a packet Switch or a Bridge to such as destination address to determine whether forward a message or block the message should be blocked or forwarded its passage Firewall Inter network security Application software that runs in a computer or a system dedicated firewall device that includes a dedicated computer and software In either case it is placed in the data path between networks Firmware Semi permanent storage In some cases the content of firmware 1s fixed and medium cannot be altered In other firmware e g Flash the content can be re written Forwarding Bridge or Switch passing a See Filtering message from one network to another based on packet filtering Framing Dividing messages into Framing techniques vary with protocols used groups of bits each group Typically message data is preceded by an having specific significance identifying header and is followed by an error check sequence Host Name The name assigned to The name is resident in each Host computer identify a computer connected to a network Host Table A list of TCP IP Host Names IP Addresses for a network hostid Host Identifier The portion of the IP address right part that uniquely identifies a Host device on
79. aceable Wickmann part 3741315041 3 15 Amp time lag fuse with UL CSA approval for 250 VAC 168 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Relay Output Module Relay Output Module a OO Description O S Relays per Module Form A 4 Form C 4 Output Device Electro mechanical relay Voltage 120 250 Vac 30 Vdc Contact Current Rating 4 A 250 Vac 30 Vdc resistive load Max Leakage Current 1 mA 350 Vdc Base Power Required 140 mMA 5V 100 mA 24 V Revision 5 HC900 Hybrid Controller Installation and User Guide 169 9 03 Specifications Environmental and Operating Conditions Environmental and Operating Conditions Parameter Reference Rated Transportation and Storage Ambient Temp 1245 32 to 131 32 to 140 40 to 151 25 3 0 to 55 O to 60 40 to 66 Ambient Relative 10 to 55 RH Humidity non condensing Mechanical Acceleration Duration 10 Hz to 60 Hz amplitude 0 07 mm peak to peak Vibration 60 Hz to 150 Hz acceleration 1 g Voltage Frequency Power Consumption 10 to 90 RH non condensing 5 to 90 RH 5 to 95 RH non condensing non condensing 0 Hz to 14 Hz amplitude 2 5 mm peak to peak 14 Hz to 250 Hz acceleration 1 g 100 V to 240 V 24 V optional 50 60 Hz 110 VA typical 115VAC Relative Humidity is de rated above 40 C Module T Rating for Class 1 Div 2 groups A B C D Digital Input
80. addresses configured to the list This will allow selection of any of these Addresses for downloading or uploading configurations You may now connect the controllers to your network for access by the Hybrid Control Designer software 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 hub 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 hub switch You may now access any controller on the network for configuration access by assigning Network as the Port and the respective IP Address as the Address of the controller ATTENTION When multiple controllers are on the network be careful to check for the correct IP address of the destination controller prior to download of a new configuration or when downloading edits to a configuration while in RUN mode Otherwise you may inadvertently download a configuration to the wrong controller HC900 Hybrid Controller Installation and User Guide 103 Communications Installation RS 485 Link to Operator Interface Setting Up the Controller Network Parameters See the HC900 Hybrid Control Designer Users Guide Doc 51 52 25 110 or respective HC Designer Help Files for setting up following network parameters 104 e IP Address Subnet Mask op
81. agram Protocol UDP Internet Protocol IP operates at the Network Layer one step below TCP defines how data is addressed source destination HC900 Hybrid Controller Installation and User Guide 33 Components and Architecture Networking Basics Reference Telnet Application that provides a Telnet defines a protocol that allows a remote terminal interface between terminal session to be established with an Internet hosts using TCP IP host so that a remote user has can use the remote host as though he was sitting at a terminal connected directly to the Host Throughput Data volume transmitted per Example 10 Mbps unit of time Token Ring A network topology in The token is a special code that is passed from which the nodes are node to node in the same fixed sequence Each addressed and can transmit node can hold the token for a limited time and can in a fixed sequence transmit only as long as it holds the token Topology The configuration scheme Types of network topology include Ring Bus Star for a network and Tree UDP User Datagram Protocol Similar to Transport Control Protocol TCP but less complex regarding reliability features and hence faster than TCP Uplink Port Ethernet Port that enables Some Hubs and some Switches include an inter connection of additional port that enables connection form hub to networking devices hub hub to switch etc Typically the Uplink Port is a cross over conne
82. ake 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 You may choose 9600 Baud controller default 19 2KB or 38 4 KB Refer to the HC900 Hybrid Control Designer User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Utilities Worksheet Set Controller Serial Port for details on this step Current PC to Controller Connection Settings Pot E f tiimi Leno Fam Pretacat Honeywall ine ELN poud ops F400 PC Port Setup On the PC use the Utilities Worksheet in the HC Designer software to select the Com port as the current port Revision 5 HC900 Hybrid Controller Installation and User Guide 89 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software RS 232 Direct Link to PC Configuration Tool The Controller can be connected directly to the PC in which case a Null Modem Cable is required The Null Modem cable is available from Honeywell Part 51404755 501 or from third party suppliers or can be fabricated by the user The Null Modem construction is shown in Figure 50 Null Modem Cable Construction Cable Pinouts are shown in Table 17 PC Cable Pinouts Table 17 PC Cable Pinouts Configuration Connector Pinouts For Null Modem Cabl
83. all be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Contents NFOGIAGC HO Nise tac erate sa zccne tei eece tec ctoce fos Scat hos Seat tel ecccetal Aca tieidavneeaaacnaniacauadad 1 PUDO E eter en eee aes tO ina ANE Rr at RR ONT ene 1 PUNCONAl DOSGRDOUOM aieiaa eae ae a hei ales ME bs cee ea ak 2 FUMIC OMIM CSCO Ole st tiaras toes trees aaa hese ke negation cane ees O aoccese 2 PALS SUMMARY ssaa A a das 3 Components and Architecture cccccccecceeeceeeceeeceeeeeeseeeceeeseeesaeeseeees 5 N RW oaa a mrad ony eee a A 5 COMPONEN 2 2osisieee eee atcha a R ic edb idea ia tans oc eee oes tpauateen aden 5 HardWare COmMDONEM S eroaa ne reenter Pema ae ene ee net ieee ne eee rie re eee eee 8 Ethernet Devices Considerations ccccceeccceececeeeeeceneeeceuceeseeeessaeeesaeeessaeeesaaeesseas 13 Seral Pons R9232 ANG IRSAG 5 sevice cst Ses cca sceescsnncndenciis Sue camchdoe seta esta suwmacmn tanned 19 Networking Basics Reference ccccccssseeecceeseeecceseeceeseeeceaseeecseseeessageeessageeesseass 22 Prenstalaton Plannin Oen enere E EE E 36 OVC IVICW or E E N T adden erid
84. allation and User Guide 149 9 03 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing an I O Module A CAUTION Read and understand all of the following information regarding RIUP before attempting to remove and or replace any I O module particularly in a system that is actively controlling a process All of the I O Module types in the HC900 Controller System include the Removal and Insertion Under Power RIUP feature That is while the rack is powered any of the I O Modules can be removed or inserted e With no physical damage to the module to 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 34 provides some general guidelines for establishing appropriate procedures at a given installation Table 34 RIUP Potential H
85. alue LED Strobes N A RAM failed on power Executes an infinite loop Cycle power that toggles the LED Replace CPU Communications and control are disabled Replace rack ROM failed on power Executes an infinite loop 1 Cycle power that toggles the LED 2 Replace CPU Communications and control are disabled Replace rack SYSTEM FORCED A block has an output Remove force on OUTPUT that is forced block output Revision 5 HC900 Hybrid Controller Installation and User Guide 121 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Number of LED Strobes UNDEFINE ERROR Ol Screen Item Value Ol Screen Item INVALID CONFIG SWITCH FAULT NO MASTER PORT SYSTEM CPU GOOD WATCHDOG PREFETCH ABORT ADDRESS ERROR 122 Possible Cause A configuration that exceeds the loop capacity of the controller was downloaded or an invalid configuration exists A failure is detected in the switch reading There are slave blocks in the configuration and no communication port configured as a Modbus master Hooo reset resulting from software failure CPU failed when attempting to fetch an instruction from the prefetch register The reserved exception occurred for an unknown reason Control File Action An empty database is created 1 2 All control blocks stop running All I O scanning ceases This forces the modules i
86. and for I O Wiring Crimper For Terminal Lugs on Power Supply wiring and on I O wiring shields Screwdrivers Small flat tip Small medium flat tip or Phillips Large long blade Electric drill with drill bits for 10 or M4 screws and with drill bit extender Vacuum cleaner brush Pen ball point or felt tip for entering data on labels for I O modules Multi Meter Volt Ohms Amps Soldering pencil or gun for attaching filter capacitors to I O wiring shields Special tools Precision meters For Euro style Terminal Blocks For Barrier style Terminal blocks also for captured screws in Terminal Blocks For use as I O Module extractor For rack mounting For use during and after drilling operations For entering data on labels for I O modules For safety checks and for equipment test For attaching filter capacitors on I O wiring shields If required for testing Analog calibration refer to Analog Calibration in this manual HC900 Hybrid Controller Installation and User Guide 49 Installation Guide Overview 50 Table 10 Site and Equipment Preparation Referring to Site Planning Documentation ensure that sufficient numbers of the following items are on hand Racks 4 8 and 12 slot Power Supplies 1 per rack Controller Module or Scanner 1 per rack I O Modules correct type for each configured slot Terminal Blocks Barrier or Euro style 1 for each I O Module Jumpers
87. artbeat Straight Cable Subnet Mask TEE See DSI DS3 E TCP IP Revision 5 9 03 Ethernet cable that enables In a straight cable the Transmit wiring pair at connection of DCE to DTE one end is wired directly to Transmit wiring pair equipment connections at the other end and the Receive pair at one end is wired to the Receive pair at the other end Defines the netid Network The netid uniquely identifies a network and the ID and the hostid Host ID hostid uniquely defines a computer on the network parts of an IP address The Subnet Mask can be used to partition the network into sub networks using parts of the hostid to define new netids or more correctly subnetids Portioning a network in this way enables switches and routers to use the subnetids to reduce collision domains and to promote security Multi port device that A Switch uses MAC source and destination connects several network addresses in each packet to establish the segments on an address appropriate channel from the sending node to the selective basis receiving node The Switch looks very much like a Hub but differs in that ports are isolated from each other eliminating the multi segment collision domain that is characteristic of a Hub Transport Control a Protocol Internet Protocol Transmission Control Protocol TCP operates at the Transport Layer of the OSI Model manages connections between computers Also see User Dat
88. as 36 Power Supply Selection cccccccceeccceeseeceseecaeeeseeeeeseeessegeeesaeeessueessaeeesegeeeseeessaes 37 EVAN POMOC NE tit ee cece Gee a a a a E aaa a e a a ea 38 Orientation of Rack MOUREAG issuri ecevedeaule dice etecetemenda nia ws eae aiale 39 PICA RSO DETIN ac aenece ss yeactcaae a canes Medatuanere hae arsms uaa icceteanues toate 39 Equipment Placement Considerations cccccccccceeceeceeeseeeceseeeceseeceeaeeeseeeeseeeeeas 41 Electrical COnSIASFatiOnS css ac caaconsectseueatsaesebial aeenteedateusnadleentads Ruatsebdeienchenduneecdeel 42 IIS FAN ATION Guldens R 49 OV CIVIC oesi erates tad cee Sain Detonator el sree Ath coedia cies Shanna es ue da et als 49 I O Module Installation and Wiring ccccccecceeeceeeceeeseeeeeeeeeeeeeeeeeees 57 COV CIVIC W veprat a E E T TE doa 57 Mod le Placement in TRACKS sescenss tisine a a a aa 57 Remote Termination Panel RIP ccccssccccssseecccesseecceeseeeseeseeecsaseeseseeessaneeessaaes 59 Terminal Block to Field Signal WIriNG ccccssececeeseeeeeeeeeeeeeseeeeeeeeeeeesaeeeeeeseeeeeeeas 59 Removal and Insertion Under Power RIUP snsnnnnnnnnnnnnnnsnnnnsnnnnnsnnnnsnnnnesnrnesenenne 62 I O Installation Procedures ses cesessccces enecocesete test zeteas she satecesebesees sax tcocsccsencersiete met eases 63 I O Terminal Block Wiring Diagrams cccccseecceesseeceeeeeeeeeeeeeeeeeeaaeeeesaeeeeeaeeeeesaees 68 Revision 5 HC900 Hy
89. ation bring it to a safe and orderly shutdown Using an external user supplied switch disconnect the power supply in the Controller rack from the site AC power source Observe where communications cables are plugged into the Controller Module and if necessary tag them to identify their functions Unplug all communications cables 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 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 Re install communications cables Using the user supplied switch re connect site AC power to the rack If using the Ethernet port for configuration use the Hybrid Control Designer software to set the proper network address Download the configuration Set the Real Time Clock If all status indications are green power may be restored to the I O modules per the application s procedures HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 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 CPU only requires that the source of AC power is removed from the rack Removing power from the Expansion rack has the
90. ations PLAN AHEAD sel Ensure power can be applied safely and use the external user supplied switch to re connect power to the power supply Using a meter and the test points on the face of the power supply ensure that voltages measured on the backplane are within specifications Revision 5 HC900 Hybrid Controller Installation and User Guide 147 9 03 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing the Controller Module 148 Removing and replacing the Controller Module requires that that the source of AC power is removed from the rack Removing power from the Controller rack has the following consequences e All control action stops e All power to all I O modules in the rack is lost hence all control outputs to the process are lost Because external power connected to terminal boards from or to field devices will still be present it 1s essential that field devices are maintained in a safe condition during replacement procedures e Control to all I O expansion racks C50 CPU only is lost If power is available to the expansion racks outputs go to configured Failsafe values Before replacement e If possible upload and SAVE a copy of the configuration or ensure that a previously SAVEd copy of the current configuration is available e If possible bring the process to a safe and orderly shutdown Table 32 Controller Module Replacement If a process is currently in oper
91. ator Templates Configurator templates are provided following Figure 59 for convenience in collecting and organizing configuration data These templates include e HC900 Controller Configurator e I O Module Configurator e I O Module Channel Assignment Configurator e Peer Network Configurator It is recommended that these configurator sheets be copied and completed for each controller for each rack and each I O module in each controller and for each peer network to be installed at the user s site The data collected on these sheets will be very useful in performing and coordinating installation and software configuration tasks Revision 5 HC900 Hybrid Controller Installation and User Guide 176 9 03 Appendix A Site Planning Documentation Aids Overview Blending e 1 NoAN Reacting Packaging Utilities Controller Enclosure details Network Closet details E 1 2i Nc 1 Nc 2 For Legend refer to network diagram for legend Figure 58 Example Site Map Equipment Placement Revision 5 HC900 Hybrid Controller Installation and User Guide 177 9 03 Appendix A Site Planning Documentation Aids Overview Internet Firewall PPn 1 C 1 L 1a je soeelH 1 C2 L 1b r1 r2 For details of I O expansion networks refer to C 1 C 2 Controller diagrams s va Legend C n Controller ID number rn rack ID number Sw n Switch ID number Rn Router ID number HMI n Human Machine Inter
92. azards and Recommended Actions A CAUTION Each signal at each of the Either L confrol f terminals for an I O module has a l i OSS OF CONIFO OF view ota specific function Any or all ofthe Using trained personnel and running process Can Cause signals may be vital for safely appropriate control mechanisms damage to equipment trolli transfer to manual control of each controlling a process l ae and or to process product signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING Potentially lethal voltages on Disconnect all signals at terminal SORE 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 150 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Table 35 I O Module Replacement Revision 5 9 03 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 rota
93. brid Controller Installation and User Guide 9 03 Communications Installation cccccecccceccecccceccececcacececceaesueaceueacs 85 OY 2 gd ar ae ee E A ee ee ee epee ede ee eee ee nen eee eee 85 Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software88 RS 485 Link to Operator Interface ec ceccceeececeeeeecee cesses eeeeeesesseeeeseeeeseeeeeseeeeeas 100 Connecting the HC900 Controller to Modbus deViCe S cccccceesseeeeeeaeeeeeneeeees 105 Operating Characteristics ccccccccsecceccceeeeeeseeeseeeceeeceeeseesaeesseeseeees 107 WALFOOU CUIOM siens nenea iE E acuta dinten Masiieat teak cateadehes Moen AA 107 OV CI VIG W oosist A a Sash feet Gevtute aa a aeaa aa 107 Power Down Power Up sic ccc heccctolen se oheecs alec eece ited boa iascia te aecdie icc catabdanetoeeles 107 Controller ModS saiman shies ete eaten aeecns deen A Gene eee 110 Software Download Upload Functions ccccccccccceecceceeceeseeeeeeeeeesaecesaeeesaeeesenes 114 Diagnostics and Troubleshooting cccceccecceecseeceeeeeeeeeeeeeseeeeeeaeees 117 OV CI VIS WY snaa neds yack e eaa o aa ae cemae teense 117 External Indications of Diagnostic Information cccecceceeeeeeeeeeeeeeeeaeeeeeaeeeeeeeaees 117 User INTC ACG arusi ieee Bes a cee Oe ieee es 121 Analog Calibra ON arsine aa e a 140 OVETVIEW Jeips aa ea a a a a Mees 140 Removal and Replacement Procedulres cccccec
94. bus master 3 pin controller is Phoenix slave 1840379 or equivalent Belden 9271 or equivalent Refer to device s port instructions Page 20 Figure 16 amp Figure 17 3 8 9 RS 485 Modbus slave 3 pin network Phoenix controller is 1840379 or master equivalent Belden 9271 or equivalent Refer to device s port instructions Page 20 Figure 16 amp Figure 17 7 10 Shielded CAT5E cable up to 100 meters A crossover cable is required for PC to Controller 10Base T RJ45 connector on Host Peer or Internet Device Host Peer and Internet RJ45 Devices connection otherwise straight cable Revision 5 9 03 86 HC900 Hybrid Controller Installation and User Guide Communications Installation Overview Controller Link Type Cable Type To Device Port Reference Data Port Controller to Connector Type 10Base T I O expansion Shielded CAT5E Either link C50 CPU crossover cable up to RJ45 Connector Scanner RJ45 only 100 meters between module of Rack 2 no Controller and hub other racks on I O and hub to hub Expander Link Or Shielded CATSE RJ45 connector on Hub straight cable between controller and expansion rack and hub to expansion racks Revision 5 HC900 Hybrid Controller Installation and User Guide 87 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Connecting the HC900 Controller to a PC
95. cable segment can be up to 100 meters 328 feet long Note that in configuration 3 a second Hub is used in line with the I O expansion rack shown on the bottom of the illustration so as to extend the distance up to an additional 100 meters to the remote rack The total number of hubs allowed is limited to two in series between the controller and scanners One combination of two in series is illustrated Revision 5 HC900 Hybrid Controller Installation and User Guide 13 9 03 Components and Architecture Ethernet Devices Considerations The Ethernet Hubs used in the I O expansion network C50 CPU only are available from Honeywell I O implementation requirements include e Constructing a configuration file and loading it into the Controller Module This file includes I O numbering assignments for each I O Function Block regarding Rack Number Module Number slot number or position in the rack starting from the left and Channel Number e Physically assigning Rack Numbers by positioning jumpers 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 exam
96. cal Area Network 15 22 M MAC 22 Master Control Relay 45 Media Access Control 22 Modbus mapping structure 16 Mode switch 10 MODE switch 112 Mode Transitions 112 Modem 92 93 94 95 Module Placement 57 Module Wiring 68 N Network diagrams 176 networking concepts 22 Networking Device Types 26 Networking Protocols 22 Networking Terms 24 Node Addressing 22 nodes 22 Null Modem Cable 90 0 OFFLINE Mode 110 OHMs Inputs 68 OPC 16 Operating Modes 107 Orientation of Rack Mounting 39 OSI Model 22 pP Parallel processing 3 PC hosts 14 PC Hosts 15 PC Modem Cable 91 PDE 15 Peer Data Exchange 15 Peer to peer communication 14 Personal Computer 12 PlantScape SCADA or Vista Software 17 Power DOWN 107 Power Down Power Up 107 Power Supply 9 53 54 Power Supply De rating 40 Power transitions 107 Power UP 107 PROGRAM Mode 110 protocols 22 PV Input Types and Ranges 171 R Rack Dimensions 47 rack mounting 52 Rack Options 9 RAM 107 Relay Output Module Wiring 82 Removal and Insertion Under Power 62 Removal and Replacement Procedures 145 Repeater 26 Replacing an I O Module 150 Replacing the Controller Module 148 Replacing the Power Supply 146 Replacing the Scanner Module 149 RIUP 62 145 150 Router 15 17 18 26 RS 232 89 90 RS 232 Modem 12 RS 232 Port 10 RS 485 10 100 RTD Input Wiring 69 RTD Inputs
97. chitecture Networking Basics Reference operates in Layer 3 IP operates at Layer 2 and Ethernet itself includes protocols that operate at Layers 1 and 2 Revision 5 HC900 Hybrid Controller Installation and User Guide 23 9 03 Components and Architecture Networking Basics Reference Characteristics of Networking Devices Table 2 summarizes the characteristics of a set of generic networking devices The information in this table is intended to provide a basic overview of each type of device Many devices that are currently available are hybrids that combine features of more than one device type included in the table Glossary of Networking Terms A glossary of networking terms is given in Table 5 Each term entry and description in this table is included as an element of a language bridge between users of an HC900 Controller network and personnel who are employed to implement the construction of the network This glossary is not represented as complete and sufficient for implementing a network Rather it is intended as a starter and as a pointer to other more complete and authoritative works that are available commercially and in formal study programs 24 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Networking Basics Reference Table 3 Open System Interconnection Model Layer Components Protocols Network reside in components Number Name examples affected examples
98. cks 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 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 Module and keep higher power modules AC Output AC Input etc away from the Controller Module For power consumption of each module refer to Table 7 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 18 3 Limit the number of Analog Output modules to a maximum of 10 per rack See Figure 19 Table 7 Power Applied by Module Type esr aor a Power Watts Watts Watts controter 28 S e anatog input ff anog Output 43 da o Contactinput 20 OO Relay Output 24 oo o oo a 36 ot 35 29 Ca 0 Revision 5 HC900 Hybrid Controller Installation and User Guide 39 9 03 Pre Installation Planning Heat Rise De rating 2aU VAG srpa 264 Vac Number of ON Points 0 5 10 15 20 25 30 35 40 45 50 55 60 Temperature C gt Figure 18 AC Input Module de Rating NO Number of AO per Rack gt
99. 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 2 the HC900 Controller includes provisions for communication via Ethernet with host systems such as the Honeywell PlantScape HMI and other HMI software that supports Ethernet Modbus TCP protocol Also the communication structure of the HC900 Controller enables remote placement of input output components allowing significant economies in cabling and wiring Feature Summary Hardware e Modular rack structure components are ordered individually as needed e CPU embodies Ethernet connectivity e Easy to assemble modify and expand e Local C30 C50 and Remote input output racks C50 only private Ethernet linked in sub network e Parallel processing a CPU in each I O module performs signal processing to preserve update rates Communications e RS 232 Link to PC configuration tool up to 50 feet or 12 7 meters or modem Port configurable as Modbus RTU TCP master or slave e RS 485 2 wire link to the Operator Interface up to 2000 feet or 601meters Port configurable as Modbus RTU TCP master or slave e Ethernet 10BaseT connection to up to 5 PC hosts via Modbus TCP protocol Peer to Peer communication with other HC900 Controllers and the Internet e Private Ethernet 10BaseT connection to I O expansion racks C50
100. controller or by exiting the Program mode at an operator interface e When initiated by the user after download with Cold Start selected or any transition from PROGAM Mode to RUN Mode 108 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Operating Characteristics Power Down Power Up COLD START Y Copy RAM to Flash Flash DB Good Build empty database O invalid database l Initialize Process Values RUN t PROG Locked Locked Mode Switch position Operate in PROGRAM Mode w all outputs off Operate in RUN Mode w initialized process values Figure 53 Cold Start Operation Revision 5 HC900 Hybrid Controller Installation and User Guide 109 9 03 Operating Characteristics Controller Modes 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 19 The functions of the Mode Switch are described in Table 20 and the procedures that the controller performs in transitions between modes are described in Table 21 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 c
101. ctor on some devices the Uplink Port can be configured or selected as either cross over or straight VLAN Virtual Local Area Network Provides access to multiple IP subnets at a physical location Virtual Private Network Remote access via a secure encrypted tunnel though the Internet WAN Wide Area Network Typically a network that includes several LANs at different geographical locations interconnected using common carrier transmission services WINS Windows Internet Name Service 34 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Networking Basics Reference Revision 5 HC900 Hybrid Controller Installation and User Guide 35 9 03 Pre Installation Planning Overview Pre Installation Planning Overview 36 Methodical pre planning of an installation will preclude false starts and errors that can cause costly hardware re configuration and or poor system performance Some considerations in pre installation planning should include Power Supply Budgeting Environmental conditions such as temperature humidity and other characteristics of the physical plant site Equipment placement particularly if the locations of field devices warrant the use of separate and or remote IO hardware Selection and placement of ancillary equipment such as equipment enclosures conduits and raceways for wiring and cabling HC900 Hybrid Controller Installation and User Guide R
102. de gt 60dB Common mode gt 130 dB at 120 Vac T C mV V except for following ranges are configurable for Upscale Downscale Defined Value or None Volt 500 mV to 500 mV 1 V to 1 V 2 V to 2 V 5 V to 5 V O V to 10 V 10 V to 10 V inherent to zero volt RTD Inherent Upscale MA Inherent Downscale T C Break Detection Via current pulse Faulty thermocouple detection If greater than 100 ohms a warning status is provided as an output for the Al block Accuracy Factory configured accuracy 0 1 of range Cold Junction accuracy 0 5 of range Field calibration accuracy 0 05 of range Reference conditions Temperature 25 C 3 C 77 F 5 F Humidity 45 to 55 RH non condensing Line voltage Nominal 1 Source resistance ohm Series mode and common mode 0 V Frequency Nominal 1 Temp effect on Accuracy 0 01 of full scale C Revision5 HC900 Hybrid Controller Installation and User Guide ati iti s C C 161 Hybrid Controller Installation and User Guide 161 9 03 Specifications Analog Input Module Long Term stability 0 1 per year Channel Configuration Data Stored in non volatile memory Calibration Data Data is stored in non volatile memory Redundant Factory Calibration Individual Channel Field Calibration Diagnostics Monitoring of Factory Calibration Field Calibration 24 Vdc supply and configuration Channel Configuration Data Stored in non volati
103. dem 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 Configure the port to these settings baud rate 9600 19200 or 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key In the program s terminal window key in the following command string AT El QO Then press the ENTER key The Modem should respond with OK Key in the following command string AT amp YO amp CO amp DO amp R1 amp SO amp KO SO 1 Then press the ENTER key The Modem should respond with OK Key in the following command string AT EO Q1 amp WO Then press the ENTER key The Modem will not respond Power down the modem and disconnect it from the PC Connect the modem to the RS 232 port of the HC900 Controller using a DB 25 male to DB 9 male RS 232 cable Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Hybrid Control Designer software Set up the PC software to dial the HC900 Controller Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller HC900 Hybrid Controller Installation and User G
104. diagram of each key tab pattern use the I O Modules and or the diagram shown below Example ae E Tabs Removed KA for AC Output Module 4 1 0000080880088 0808 amp y x TIIR 64 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Installation Procedures Step Procedure Comments Reference 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 120 240 120 240 24Vdc Relay ai Vdc A Analog Vac IN Vac OUT OUT OUT OUT Revision 5 HC900 Hybrid Controller Installation and User Guide 65 9 03 I O Module Installation and Wiring I O Installation Procedures Procedure Comments Reference Using the following Barrier Terminal Block reference items e Hybrid Control Designer data Documentation Aids from Appendix A Labels in I O Terminal Block assemblies Wiring diagrams given in this Section for each type of I O module connect I O wiring to the Euro Terminal Block terminal blocks for each IO module Route wires through the channel at left of the terminal block to
105. domains Collision An indication to the Data Collision Detection causes both nodes to abort Detection Link Layer that node transmission set a random delay and attempt re contention simultaneous transmission If contention recurs each device transmission is present at doubles delay time before re transmission the Physical Layer successive redoubling is called exponential back off Crosstalk Electrical noise coupled between media elements Cross over Cable Ethernet cable that enables In a cross over cable wiring crosses over from connection of DCE to DCE the Transmit connection pair at one end to Receive equipment or DTE to DTE connection pair at the other end equipment CSMA CD Carrier Sense Multiple All nodes on the same network are free to initiate Access w Collision message transmission If two nodes transmit Detection simultaneously the collision is detected and both nodes abort transmission and attempt to re transmit after a pause CSU DSU Channel Service Unit Data Converts data from format used by telephone Service Unit company to format usable on LAN Cut Through Method used by switches Enhances transmission speed but reduces for filtering messages based transmission security and or reliability on the first few bytes Data Link A logical connection between two nodes on a network Data Link Layer Layer 2 of the OSI Model Defines protocols for data packets and how they that is media independent are tran
106. dural guidelines for planning an installation Installation Guide Procedures for installing the major components of the system controller rack I O expansion racks C50 CPU only and communication interconnections Input Output Installation Procedures for installing I O modules in the controller rack and I O expansion and Wiring racks C50 CPU only and for wiring field devices to the terminal block associated with each I O module Communications Provides guidelines for installing RS 232 RS 485 and Ethernet cabling and Installation associated components Controller Operating Characteristics of the HC900 Hybrid Controller as they relate to configuration of a Characteristics control strategy and to operation of an installed and running system Diagnostics and Descriptions of the mechanisms that detect and react to faults in the operation of Troubleshooting HC900 Hybrid Controller hardware and or software components Analog Calibration Describes hardware configuration required for calibrating AI and AI modules from the configuration software Removal and Provides guidelines for replacing system components includes Cautions and Replacement Procedures Warnings as applicable Specifications Tables that provide details of HC900 Hybrid Controller design and functioning Index Alphabetical listing with page references of terms components and topics included in this manual Revision 5 HC900 Hybrid Controller Installation and User Guid
107. e ox o o ose R o PC o O oO PC Connector Connector 9 Pin D 9 Pin D Female Male Figure 50 Null Modem Cable Construction 90 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software RS 232 Remote Connection to PC Configuration Tool The Controller can also be connected remotely by a set of modems which are available from third party suppliers In this case PC Modem Cable is used between the Controller and the modem at one end and between the PC and the internal or external modem at the other end as shown in Figure 51 Remote controller access via dial up modem 1s available via the communication setup in the PC configuration tool All functions of the Hybrid Control Designer configuration tool can be performed over this link Remote access functions include on line monitoring configuration upload and download and firmware upgrade PC Configuration Tool Controller PC Modem Cable Modem Telephone PA Cable Telephone Cable Figure 51 RS 232 Remote Access via Modems Revision 5 HC900 Hybrid Controller Installation and User Guide 91 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software B Modem Connection Modem RS 232 Configuratio
108. e Noise Rejection wire grounding bar optional at the top or bottom of each rack as indicated in Figure 27 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 ii from that at the controller a DC isolation capacitor should eis Rejection be used between the shield and the grounding bar on the rack DC isolation Capacitor Shield wire Figure 27 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 28 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 7 module and is the preferred method amp a 8 A for a limited number of wires Yes o fo 9 ea 1 19 1 a 1 For a larger number of wires or for eae wires of a heavier gauge it 1s advisable to route some wires through the top of ETETE the terminal block and some through 2 he o Ana the bott
109. e Serial Ports RS232 and RS485 Modbus Slave and Modbus Master Modbus Master and Modbus Slave 3rd Party HMI Modbus Slaves Modbus Master RS232 to RS485 Converter Modbus Slave Protocol Modbus Master RS 232 gt Protocol 2000 Ft RS 485 gt 2000 Ft lt Modbus Master Protocol Modbus Slave Protocol 3rd Party HMI Modbus Slaves Modbus Master ELN and Modbus Master Modbus Slave and Modbus Slave 3rd Party HMI Modbus Master ESOS E A ar a AE AE E EL LLL re see mete a a a i220 Modbus Slave Protocol 2000 Ft lt Modbus Master Modbus Slave Protocol Protocol Modbus Slaves PC Application for Dial Out Function Modbus Slave SixNet Modem ELN UYYY AT aT a f as LL LLL TOT ay rman rane eee Re LI EA ae Modem ELN Slave or Modbus Slave Protocol 2000 Ft lt ELN protocol Figure 17 Serial Port Configurations 7 11 Revision 5 HC900 Hybrid Controller Installation and User Guide 21 9 03 Components and Architecture Networking Basics Reference See also Refer to Communications Installation on page 85 for details on communications Networking Basics Reference The following information provides a basic reference for identifying and applying networking concepts components and methods It is intended primarily as a language bridge between users who have a limited knowledge of networking but who need to incorporate networking mechanisms in process control s
110. e 9 03 Introduction Functional Description Functional Description The Honeywell HC900 Hybrid Controller is an integrated loop and logic controller that 1s designed specifically for small and medium scale unit operations Saws Ld It comprises a set of hardware and software modules that M SS can be assembled to satisfy any of a broad range of 7 process control applications The HC900 Hybrid Controller can consist of a single rack as indicated in Figure 1 or can be can be networked with other controllers via Ethernet links to expand the dimensions of control over a wider range of unit processes as indicated in Figure 2 a A Figure 2 Expanded HC900 Controller Configuration C50 CPU only 2 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Introduction Feature Summary 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
111. e 17 7 Controller is Modbus slave Controller is Modbus master to multiple slaves Figure 17 8 Controller is Modbus master to multiple Controller is Modbus slave slaves Figure 17 9 Controller is Modbus slave Controller is Modbus slave Figure 17 10 ELN device Controller is Modbus master to multiple slaves Figure 17 11 Controller is Modbus slave via modem ELN device Such as Honeywell HCDesigner configuration software running on a PC or Honeywell 1040 559 Operator Interface Requires RS232 RS485 converter Revision 5 HC900 Hybrid Controller Installation and User Guide 19 9 03 Components and Architecture Serial Ports RS232 and RS485 ELN and ELN ACULI ELL LI ae ae SE AE wae we 2000 Ft I L cy ay a Ee wwe mee LLL LA Aaa ELN Protocol 2000 Ft Modbus Slave Protocol 3rd Party HMI Modbus Master Modbus Master and ELN RS 232 Modbus Master Protocol 2000 Ft Modbus Slave and ELN 3rd Party HMI Modbus Master Modbus Slave Protocol 2000 Ft lt ELN protocol 4 Modbus Master and ELN Modbus Slaves RS232 to RS485 Converter Modbus Master Protocol 2000 Ft ELN protocol Modbus Slave and ELN 3rd Party HMI Modbus Master RS 232 to RS485 Converter Modbus Slave Protocol 2000 Ft ELN protocol Figure 16 Serial Port Configurations 1 6 20 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architectur
112. e er ee ee re Oe ec oe Rene 167 AC OUTOUE MOG UIC osasten iae tected Sonat atiat nade Nouuaauswnn tesatee ented aentusatouesud 168 Relay Out Ut MOQUE Saria ise cecs eek a a ieaadintdu de nietedd Deadetictae tae 169 Environmental and Operating COnditions ccccecccceseeeeeeeeeeeeesaeeeeesseeeeeseeeeeesaees 170 Appendix A Site Planning Documentation AlIdsS ccsecseeeeeeeeees 176 OVET VIEW arrasan attache esa arei E E Maseatee eae teaacouata st 176 VO Mod le CON QUEALON sesuo veh asian sbanaaensed a a 180 I O Module Channel Assignment Configurator ccccccececeeneeeeeeaeeeeeseeeeeesaeeeeeeas 181 Peer Network Contiguralofacwsccusu cu eeecieeu ean uetu einen Sis 182 Appendix B Installation of Remote Termination Panels RTPs 183 OV CI VIG Wie aa select ch teetadecesannconesehiduch ea a 183 PTV OGIO UE eann 184 FREI AY CUROUNG sa 2c aie ct dul darsek a a a a cba lanudideceeaneats 191 Digital Input Digital Output Analog OUtPUL cece ceceeeeeeeeeeeeeeeeeeeeesaeeeesaeeeeeenaaes 194 RTP Cable wire positions ANd colors cccccccecccceeececeeeeeceeeeeeeeeseeecesseeeesaeeeseeeeeas 204 Latch Unlateh R EP 16 Falls soseicciaedashet a i ivel cuislalat a Nyiiol gett dicts are bes diall 205 Index Sales and Service Declaration of CE Conformity Revision 5 HC900 Hybrid Controller Installation and User Guide 9 03 yii Tables Table 1 Descriptions of Major Components Figure 3
113. e harmonization of the laws of the Member States relating to the safety of equipment designed for use within certain voitage limits The models covered by this Declaration are listed in and evidence of conformity is provided by Technical Files 541452404 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 International Inc 525 East Market Street York PA 17405 USA Honeywell International Inc 1100 Virginia Drive Sam Arcara Fort Washington PA 19034 Director Control Products Engineering Issue Date F ZE 20 OZ 51452403 doc Honeywell 51452401 Revision A DECLARATION OF CONFORMITY Ea We declare that the following product HC900 Modules Models 900A01 900B01 900C51 900C52 900C53 900G01 900G02 900603 900H01 900H02 900H03 900P01 is in conformity with the protection requirements of Council Directives 89 336 EEC as amended by 92 31 EEC and 93 68 EEC on the harmonization of the laws of the Member States relating to Electromagnetic Compatibility and 73 23 EEC as amended by 93 68 EEC on the harmonization of the laws
114. e page 205 e Connect cable to RTP 3 Set verify jumper positions as shown for the 16 point digital input module C C C Com EEE Jumper open BEE 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 62 for more details See page 203 for RTP internal schematic Revision 5 HC900 Hybrid Controller Installation and User Guide 197 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point DC Digital Input sel 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 DC Supply 16 Point AC Digital Input reel ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to 16 point AC DI 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 AC DI module label into module connector cover Connect shield drain wire to the groundin
115. e 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 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 Revision 5 HC900 Hybrid Controller Installation and User Guide 15 9 03 Components and Architecture Ethernet Devices Considerations Note PDE communications discussed previously do not use the PC host connection sockets PDE communications are separate from and are transmitted concurrent with PC host to controller communications The PC host can include software that closely relates to and supports controller functioning and can also include other software that is related remotely or not at all Closely related software can include Either Hybrid Control Designer for generating and managing configuration files Or HMI Supervisory Data Acquisition Software or Operator Panel with Modbus TCP driver Or Both configuration and HMI software and or panel All communications between a controller and a PC host use Open Modbus TCP protocol whose widespread use is making it an industry standard Modbus TCP 1
116. e the burden of documenting an HC900 Controller installation several data collection aids are given in Appendix A of this manual These include e sample diagrams maps of site facilities and of networking systems e fill in templates that aid in collection and organization of installation data Use of these documentation aids will ease the task of coordinating hardware installation tasks with software configuration tasks for example placement and wiring of I O modules and configuring Rack Module and Channel data in the configuration file 48 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Installation Guide Overview Installation Guide Overview This section contains procedures for installing one or more HC900 Controllers It is recommended that the Site Plan Documentation completed as a part of Pre Installation Planning is used as a primary data source and checklist while performing these procedures It is also recommended that the Site Plan Documentation and the information in this section be reviewed together 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 9 Equipment Preparation A checklist for site preparation is given in Table 10 Table 9 Installation Tools C omen Common tools Wire strippers For Power Supply
117. e their diagnostic set to MOD_NOCOMM their rack monitor module fail pin is turned on and the rack monitor block s RACK OK pin is turned off ASYS block s HW OK pin is turned off The statuses for the AO Al DI and DO channels that are affected are set to BAD CHANNEL HC900 Hybrid Controller Installation and User Guide 129 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action User Action Item Item Value LED Strobes DATA LINK A large number of 1 Rack 1 monitor block s 1 Check baud rate FAILURE messages are COMPORT DIAG is set resulting in data link to FAILED Ey QOSOR Connectors SI Rack 1 monitor block s er ESCAG pO RACK OK pin is turned 4 Isolate cabling from off electrical ASYS block s HW OK nietielence pin is turned off 5 If RS232 to RS485 converter is used If configured as a check its power Modbus master switch jumper 1 ASYS and FSYS settings and polarity S EEE rae 6 If configured as a p i Modbus master use Slave and read blocks the slave status associated with the screens to determine slaves experiencing the which slaves are failure have their read experiencing the pins frozen to the last problem For those value read slaves check Slave blocks associated S POWET with the slaves e connections experiencing the failure e address have their BAD COMM e baud rate and NO
118. each I O module 40 pin connectors for Controller Module or Scanner Module Mounting dimensions Mounting holes are in standardized patterns as shown in the diagram below Reference Center 12 slot ar only Cc D 4 6 04 76 76 6 04 p 153 153 Revision 5 HC900 Hybrid Controller Installation and User Guide 159 9 03 Specifications Input Output System Common Features Input Output System Common Features Slot locations Any I O slot in any rack Controller or I O expansion can accommodate any module type available for use in the HC900 system Also racks can accommodate any mix of modules within constraints regarding power availability Rack Complement Power supplies are identical for all racks Scanner modules are identical for IO Expander racks C50 CPU only I O Module Pin Output Every module has the same 20 pin inline connector on the printed wiring to terminal block board that mates with either style of wiring terminal board available for the HC900 Terminal Block Types Two types are available 20 connector barrier strip or 20 connector Euro style Both styles fit any type of I O module available for the HC900 System Blocks have color code red block with tin plating on terminals for higher voltages and black with gold plating for lower voltages Coding system applies to both block types Hardware keying Key matches module to connector ensuring correct board replacement Color coded Lab
119. 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 49 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common 82 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams A WARNING AN 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 Out 1 No Out 1 COM LOAD 1 N C Out 1 Nc Out 1 Nc Out 2 No Out 2 No OVO ig OWA COM arrenar E Out 2 Nc Out 2 Nc rom ee ut L2 N Out 3 No Out 3 No o o n Out 3 COM Out 3 COM een Form A Out 4 No sessssseed w No Out 4 COM Form A Out 4 COM Out 5 No sss Out 5 No p et Out 5 COM Out 5 COM Form Aj p E Out 6 No Out 6 No 0o H 30 vacs HK Out 6 COM Out 6 COM Out 7 No eee CCC CCCCCOCOCOCC OT Out 7 No Form C Out 7 Com te Out 7 Com OUZ Ne srrusunusununenuu Form C Out 7 Nc LOAD 8 Out 8 No Out 8 No om Com Out 8 Com Out 8 Nc Out 8 Nc Hava Legend aor External Disconnect User Supplied Safety Devices Figure 48 Relay Output Module Wiring Diagram Revision 5 HC900
120. eans 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 Connect the modem to a PC Le Power up the modem 3 Start up a PC terminal program such as Hyperterminal Configure the PC COM Port for 9600 19200 or 38400 baud must match baud rate configured in the HC900 Controller no parity 1 stop bit and 8 data bits AT E1 Q0 command and seeing if the modem responds with OK Once you establish communication to the modem its port settings are configured Establish communications with the modem A common way of doing this is simply entering the Save the port settings to the profile that gets loaded on power up HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem configuration examples Below are procedures for setting up the following commercially available modems 3Com US Robotics 56K Data Fax External Modem Zoom 56K Dualmode External Modem Best Data 56S X Data Fax External Modem SixNet VT MODEM Industrial External Modem 3Com US Robotics 56K Data Fax External Modem Revision 5 9 03 Step 1 O a A O Action Ensure that the switches are set to the factory settings Switch Setting Position Function E uP Normal OTR opsaions a a Verbal word
121. eatts 8 Figure 5 I O Expander Rack Components C50 CPU MOnTY gocicascce cand aie cca aetaadidctandancecaecend stat cnscateataddvenseareeoeeuaddvenens 8 ica 6 Rack ODIOS a iar tics dicn ca tcseten aati suniiadssat don edes eae titntdanesuasdasp smal ste lnnshiuids cnsauaraembaant deal cea tuesiaiiel dasa waesh sentence 9 LUE SP iP Oy SE UP LY hana och ee 9 Foure ss eye ins Ves om s Ca Gib cee mmm meer Onno rete Nee Cun TMC mI Teer Ten tT en a n nen Cnn Cnn neerret erm wee nes 10 eybegul gems wer wi 0 s1oLe aglhy 016 181 operate mre Cee ennh e rere ne Conn mm Neer Ten tT etn Neyr enter mt me Meer Cen eMC nr eect wine neerret en aren wee ees 10 Ficure 10 O Module Terminal ROCKS eins ieass aac nciicaatseu debaniiuisaliueatsber a ddan Sakae nei eaalieh sesaa abel oatebnan nudes 11 Foure SRS Modeni TD CV CCS acre a A od gata S 12 Figure 12 HC900 Controller Configurations cccccccccccccccsssssssnnnseeeeceeceeceessssesesnsnnnaseeeeeeeceeeeessesessessanansaeeeeeseeeeess 13 Figure 13 2 Modular Network SOl oen a a a a a a 15 Picure 142 Modbus TCP F ramiho e a r a a N 16 Figure 15 Typical installation using a Cable Modem ccccccssssssccceeeeeeeeeeeseeeeessnnnneaeeeeeeeeeeeeeseseeeeesaaaaaaeeeeeeeeeeeees 18 Figure T6 Senal Port Come urat ons Ta Oraner r N Na 20 Figure 17 SerialPort Comiieurations m i ee chasse coped Duets oligos a aa 21 Foure 18 AC Input Wiodulesde Raune 5 5 cc 2 tien eaetes EEN EEN E aeae oleae 40 Foure
122. ecommended This may help minimize electrical noise and transients that may adversely affect the system Separate external wiring group connecting wires into bundles see Table 8 and route the individual bundles through separate conduits or metal trays Use shielded twisted pair cables for all Analog I O Process Variable RTD Thermocouple de millivolt low level signal 4 20 mA Digital I O and computer interface circuits Ground shields as described in the section Input Output Installation and Wiring 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 44 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 8 provides suggested guidelines for grouping wires Table 8 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 si
123. eeeeeeeeeeeeeeeeeeaeees 145 Cy CI io seen Peer ca eI cena bee etree eal ite ener e aie rse tere aren ce 145 Safety Considerations PLAN AHEAD sec sctececssievedesnses a a a aaa 145 Controller Components and MOdUIES ccccccceecceeeseeeaeeeeeeeeeeseeees 155 SDECIIIC AU OMS aeres a E E a gant nascent 156 HC900 Hybrid Controller Design ccccccccseseecceeseeeceeseeeceeueesseaseeessaseeessenseesseaes 156 Controller Module Desig isis seceiaaseue vee heutone sande see e aaa select aaa 157 Scanner Module Desigh scine a a a a a a dees 158 Rack DESIG eec une Ootacea ane iy ae ed eee enn ota 159 Input Output System COMMON FeEatUIeS cece cee cccceeceeaeeeeeaeeeeceeeeeseeeeseeeeesaeees 160 Analog Input Analog Output Modules Common Features cccccecceeeeeeeeeeeees 161 PAT AO GIDE IOC UN sha want Sdn ea dla austen ea Rea etwas eulea etemeentaaiees 161 Analog Output MOGUICS ss acteurs esheets ator iva ioctl tials aera adadiall se 163 Digital Input Modules COMMON Features cc ccecccecseeeeeeeeeeeeeeeeeeeeeaeeeesaeeeeeeseees 164 Contact NUE Mod le serasa a A taste secedens tod deta E a 164 vi HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 DG IM Ut MOU Gonna aa a a aE AA A 165 ACIMPUCMOOUG iaa a tee Nair Mie ere 166 Features Common to all Output MOdUIES cc cecccceeccceeeeeeeeeeeaeeeeseeeeeseeeseeeeeas 166 DC 1 0 6 al 0 ene ee ee teen re rer
124. eeeeeeeeeeeeeeeeeeeeeeees 62 Tablets Connect Input Output Wine 235 scat toss sat sisaccatancasacGhaawatciatataalassacaddanaadead saaald anand ates eerasuehousrersoaeeadduuendiaa 63 Table 15 Connect Communications Wiring and Cabling cccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesseeeeseeeeeeeeeeeeeeees 85 Table 16 Links t6 Controller Communication Ports seid oicc5 ct asyadtiinaeGi a E A A AR 86 Table 7 PC Cable Pinus onera a N cieaeeaddaneateidae 90 Tableless Parts needed tor RS 465 Cabin eara E E E A 100 Table T9 Controler Opsratna Modes aeria Arar aE EA patna NETE AE REEE E E A E i 111 Table 20s Mode Switch FUNCIONS irn e EE A O E E O A Me 112 Table 21 Controller Behavior in Mode Franisit On ceccisicsriicirneieink iaeia na aa aaia 113 Table 22 Conmeuratiom fle downloa na eiir a A EEE AR ERE O EA O AE iE 115 Table 23s LED ITndicitons on Main C PU iceren ER E AEE EAR EEA E EAN AA ea 119 Table 24 LED Indications Om Scanner Module esien E AEE EE NAKER E SAES ER eA EEEE 120 Table 25 LED Indications om TO Modul ainiai aaa a a a a ES 120 Table 26 LED Indications on Ethernet HuDenens issii E EE ee 121 Table27 Controller Module DiaenOsucs nesunkiai a a a E cael eds 121 Table 25 Bad Mod le 1g OnOSiCS 32133 aie the nia a S a E a ears 133 Table 292e Bad C hance Dueno ie anao A N A N A 134 Table 30 2 Scaner Daon OSIICS a a shia sce O T E SN A EA 135 Table 31 gt Power Supply Replacement srsrscirericriresiinridiserisirrrtti tdn
125. eeeeeeeeeeeeeess 7A Figure 36 Analog Input Wiring Slidewire Position Proportion Block cccsssssccccceeeeceeceeesesssnnneeeeeeeeeeeeeeeeees 71 Figure 37 Analog Output Wiring Diagram ccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeess 12 Figure 38 DC Input Module Wiring Diagram 0 cc cccccceessssnneceeeeeeeeeeeeeeseeeessesaeeeeeeeeeeeeeeeseseeeesaasaaaaeeeeeeeeeeeees 73 Figure 39 D Topot Module TUMPE seca derer e a dea E a iE 74 Figure 40 AC Input Module Wiring Diagram ccceccesecessseeeccccccccecesessessssscenccnssccccccsseecssesssssscneceesssaccceeeeeenens 75 Pioute ALs AC Input Modale WND E icom en A A A A E E Cane 76 Pioure 47 Cotact loput Wine Diaeta eera a a 71 Figure 43 DC Output Mod le Wimine Diagram scata e a E E R dees A 79 Fitur 44 DC OnpUt MPE aea a a a a a a E A 79 Figure 45 AC Output Mod le W mine Diagram cecinisse a a E a S RS 81 Pigute 46 eC Ouipu Module TUMPE siare celts east a x seen Ses a Seated edna Cre rrendet et hed ost de 81 Figure 47 Schematic Example Relay Output and External Wiring ccccccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 82 Figure 48 Relay Output Module Wiring Tita Ct At co ta pace les i cena clacta c deh dele aula tuleadieaduluasursvencceses menace eee 83 Pidure 49 Relay Output Module TUMPET Sedia E A A a a Sat EA E E E 84 Picure 50 Null Modeni Cable Constr ction i sessies edeier e a a E
126. eesesesseeene 186 Figure 63 Milliamp input connections with 250 ohm shunt resistance cccceesssssnscceeeeeeeeesseeesessnnneeeeeseeeeeeeees 187 Figure 64 Volt millivolt input CONNECTIONS eessen aa EE A N EE EE EE AEE AER aaa 187 Figure 65 Three wire RTD input connections ssossseseeessssssssseerreeeeessssssssssserrrrreeeessssssssssseerrereeeessssssseerrrreeeeessss 188 Figure 66 Two wire RTD or ohm input connections sssseseeeseeeeeessssssssssserrrrreeeesssssssssssererresssssssssssserrreeeeeessss 188 Figure 67 Slidewire feedback connections for actuators cccceessssssseeceeeeeeeeeeeeeseeeeeessnnaeeeeeeeeeeeseseeeesaeeeeeeeeeeeeees 189 X HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Introduction Purpose This publication describes the Honeywell HC900 Hybrid Controller and facilitates its installation operation and maintenance This publication includes the following sections Section Title Section Content Introduction Describes the content and purpose of this manual relative to other manuals for the HC900 Hybrid Controller System Overview Functional features and physical characteristics of the system and of each major component of the HC900 Hybrid Controller This section includes background information on Ethernet networking components and methods of interconnection Pre Installation Planning Includes pre planning considerations environmental operating limits and proce
127. el Every terminal board assembly includes a hinged door that accommodates a color coded pre printed label Eight label types are available label type per I O module type Intelligent Module All I O modules include microcontrollers for handling communications with the Controller Module and for performing and reporting diagnostics Light Pipes All I O modules include an integrated set of light pipes on the back of the circuit board that convey Status of the module Tri color for digital modules activity status of each channel in green Metal cover w extractor All modules include a metal cover that protects the front of the board The metal cover includes a formed in loop at front for module extraction Remove and Insert Under Power standard Modules are automatically sensed and configured on insertion RIUP Field power shall be disconnected before removing terminal blocks 160 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Analog Input Analog Output Modules Common Features Analog Input Analog Output Modules Common Features Micro Controller Motorola 68HC11 micro controller 12k One time programmable PROM built in diagnostics Analog Input Module Input types RTD T C Ohms mV Volt mA mA w a Input Device ee Relay 400 Vdc point to point solid state switching 1k Vdc to logic RTDs are isolated in pairs Irro is common to two inputs Noise Series mo
128. el for each configured VO Module DARK BLUE WHITE TEXT RELAY Be sure to use the RED WHITE TEXT appropriate label for each ANALOG module type INPUT 8 PT WHITE DARK GREY TEXT 24 VDC NTAS CREEN WHITE TEXT OANOaRARh WN YELLOW DARK GREY TEXT Place the appropriate label supplied with the module gt tagname side out into the i i aq hinged door for each I O te i ee Bi _a Module oS a 2 TNE ages CAUTION Slotted tabs molded into Nae re 4 pi A the door at top and bottom BS pe es E H POWER BEFORE hold the label in place Sere i F nN i HT i Lees al p ms Tag Fi i fe oi i ET a Optional Install jumper a ie combs into designated DC Output Relay Output Barrier style Terminal Blocks to reduce the wiring required to supply power Two position jumper for the DC Input Module and or on the DC Output Module Ten position jumper for the AC Output Module O QQOOQDOOO OIG OO Five position jumper 10 position jumper cut in half for a Relay Output Module Refer to terminal block wiring diagrams for specific information HC900 Hybrid Controller Installation and User Guide 63 I O Module Installation and Wiring I O Installation Procedures Procedure Comments Reference For each configured and labeled I O Module break izoai off the key tabs in the Vac OUT pattern that identifies each module type For a
129. enance personnel to react appropriately when external actions are required External Indications of Diagnostic Information Two sets of diagnostic indicators are provided as standard e Light Emitting Diodes LEDs included in controller hardware Locations of LEDs are shown in Figure 55 descriptions are given in Table 23 Table 24 Table 25 and Table 26 e Screen items on The Operator Interface connected to the RS485 port A PC with Hybrid Control Designer connected to the controller module via the RS 232 port or the Ethernet 10Base T Open Connectivity port The LEDs are useful when personnel are performing troubleshooting activities solely at the controller Also they are useful for verifying indications viewed as screens items Revision 5 HC900 Hybrid Controller Installation and User Guide 117 9 03 Diagnostics and Troubleshooting External Indications of Diagnostic Information RS485 RS232 10Base T Ooo000000 Controller Status RS232 RS485 10 100base 10baseT Scanner Module Status Communication Status 10BaseT Each IO Expander Rack 118 HC900 Hybrid Controller Installation and User Guide OOO0000000 Figure 55 LED Indicators O O O O O O O O O O OO0O00000000 OOO0000000 OOO0000000 IO Module Status every Module every rack Revision 5 9 03 Diagnostics and Troubleshooting External Indications of Diagnostic Inf
130. enerated Site Map Module Slot number in rack Module Type Al Analog Input AO Analog Output DCI DC Digital Input ACI AC Digital Input Cl Contact Input DCO DC Digital Output ACO DC Digital Output RO Relay Output Jumper Comb specify none 2 position 2 or 10 position 10 4 180 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix A Site Planning Documentation Aids I O Module Channel Assignment Configurator I O Module Channel Assignment Configurator 1 Network Rackk 1 2 3 4 5 Slot 1 5 9 Slot 2 6 10 6 6 Slot 4 8 12 6 Slot 3 7 11 6 Module Type Module Type Module Type Module Type 7 7 7 7 Tagname Tagname Tagname Tagname g Optional assigned per user s convenience 2 Assigned in Peer Network configuration 3 Assigned in Peer Network configuration To specify rack encircle appropriate number This configurator is intended for four contiguous slots specify by encircling appropriate numbers e g 1 2 3 4 or 5 6 7 8 or 9 10 11 12 z Specify Module Type Al Analog Input AO Analog Output DCI DC Digital Input ACI AC Digital Input CI Contact Input DCO DC Digital Output ACO DC Digital Output RO Relay Output Ensure that Module Type specified here agrees with that entered in the I O Module Configurator a To specify rack encircle appropriate number 00 Rev
131. er 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 ATTENTION For calibration procedures refer to the Operator Interface manual or Hybrid Control Designer manual Revision 5 HC900 Hybrid Controller Installation and User Guide 9 03 140 Analog Calibration Overview Analog Input Calibration Analog input modules can accommodate five input types e RTD e Thermocouple e Ohms e Volt and milli Volt e 4 20 mA Calibration values for each channel are stored in the module as numeric values paired with A D conversion counts corresponding to those numeric values The numeric values are those identified as REFERENCE on the OI or HCD calibration displays apply these values to the input terminals during the calibration procedure For AI channels configured as thermocouple inputs the stored calibration values are compensated by the measured temperature of the terminals Because of this observe the following rules e If you plan on calibrating the 2 cold junction compensation devices perform this operation first before performing any thermocouple calibrations However because cold
132. evision 5 9 03 Pre Installation Planning Power Supply Selection Power Supply Selection To determine which power supply to use calculate power requirements below rH ATTENTION Using inadequate power supply will cause the controller to cycle power on and off Enter quantity of each module type in column A and calculate the 5V and 24V maximum current in columns D and E Sum the maximum current for all module types and determine if the 900P02 power supply is appropriate eo beo pbp E Y Controller Scanner Analog Input 8 pts MA Sub Tot sao Analog Output 4 pts AC Digital Input 16 pts DC Digital Input 16 pts Contact Input 16 pts AC Digital Output 8 pts DC Digital Output 16 pts Relay Output 8 pts Total mA Is total 5V less than 2000 Yes No Is total 24V less than 900 Yes No If the answer to 1 and 2 are YES go to 4 If the answer to 1 or 2 is NO use power supply 900P01 0001 Multiply 5V total by 5 1 Multiply 24V total by 24 5 Sum results of 4 and 5 Divide results of 6 by 1000 Is the result of 7 less than 28 Yes No If the answer to 8 is Yes use power supply 900P02 0001 10 If the answer to 8 is No use power supply 900P01 0001 Revision 5 HC900 Hybrid Controller Installation and User Guide 37 9 03 Pre Installation Planning Environment Environment Environmental Operating Limits The environmental conditions required for operating the HC9
133. exit through the top or bottom of the block 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 66 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Step Procedure Revision 5 9 03 Connect wire shield to grounding bars on top and or bottom of the Rack Refer to Signal Grounding at the beginning of this section for suggestions and recommendations Install I O modules in racks In each slot location not occupied by an I O module install a Filler Block cover Part number 900TNF 0001 I O Module Installation and Wiring I O Installation Procedures Comments Reference CN LO JElS O olole e S 2 eels Note The Filler Block Cover looks much like an I O Terminal Block assembly except that it does not include the wire terminating block screw terminals The Filler Block mounts in the same manner as a Terminal Block with captured screws at top and bottom Blank labels are provided for mounting in the hinged door HC900 Hybrid Controller Installation and User Guide 67 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
134. face ID number WS n Work Station ID number L nx LAN ID number cable segment number H n Hub ID number Figure 59 Example Network System Diagram HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix A Site Planning Documentation Aids Overview HC900 Controller Configurator HC900 Controller Configurator Controller ID Peer Network data Revision 5 9 03 Network Name Controller Name Alias Name of use Site Network Maps Suggested use of this configurator TF cross out components L Slots not included sit wae specify slots rack trace over cables that apply Rack 5 dotted to solid lines Slots 48 12 HC900 Hybrid Controller Installation and User Guide 179 Appendix A Site Planning Documentation Aids I O Module Configurator I O Module Configurator Controller 0 Process Area Rack 1 Enclosure ID lt o o lt o 3 voaa o e e mawe surpercons Rack 2 Enclosure ID SS Module Module Type 8 Jumper comb Module Module Type 5 Jumper comb 6 Module Module Type 8 Jumper comb 6 Module 4 Module Type 9 Jumper comb 6 4 Optional assigned per user s convenience Refer to user generated Site and Network Maps Optional assigned per user s convenience Refer to user generated Site Map Qe ee Optional assigned per user s convenience Refer to user g
135. fig Parameters Block Dynamic Parameters Block Inputs Digital I O Events Function blocks Loops Numeric Constants Peer connections Peer Data registers Recipes Segments per Profile Sequencers Sequences Set point Profiles Setpoint Programmers Setpoint Schedulers Setpoint Schedules Signals Softwire bytes Steps per Schedule Steps per Sequence Tag Descriptors Text bytes Total I O Variables Variables per Recipe 6 max Model C30 96 points max Model C50 128 points max Model C30 48 points max Model C50 64 points max 18 000 16 000 8 000 Model C30 192 points max Model C50 512 points max Model C30 400 max Model C50 2000 max Model C30 8 max Model C50 32 max 1024 controller oo Model C30 34 000 Model C50 168 000 Model C30 192 points Model C50 512 points HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Environmental and Operating Conditions Revision 5 HC900 Hybrid Controller Installation and User Guide 175 9 03 Appendix A Site Planning Documentation Aids Overview This appendix contains aids for installation planning these include e An example of a set of site diagrams that suggest methods of showing Placement of enclosures for controller components relative to process equipment and placement of enclosures closets for networking components Network diagrams that show methods routes c
136. g bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 60 198 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point AC Digital Input sel Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP EE Jumper open EE 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 62 for more details See page 203 for RTP internal schematic 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 Revision 5 HC900 Hybrid Controller Installation and User Guide 199 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point DC Digital Output 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION DC Digital Output is rated at 8A per module and 1A per output Limited to 4A per group of 8 Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 2 e Connect desired cable to
137. gnal wire such as lt 15 Vdc e Input signal wire thermocouple 4 mA to 20 mA etc e 4 20 mA output signal wiring e Slidewire feedback circuit wiring Communications Low voltage e Low voltage alarm relay output wiring lt 50 Vdc Vac e Low voltage wiring to solid state type control circuits HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Pre Installation Planning Electrical Considerations 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 add the following 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 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 1s 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 22 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 d
138. he power supply value configured for 4 Replace the I O Module its failsafe timeout Remove other modules and replace one at a time until the problem reoccurs Most likely the last module inserted needs to be replaced 6 Replace the rack EA ROM Failed its Replace Module checksum ECE pes Replace Module o A E fa f ___ y 5 1 Remove the module and check for a bent pin then reinsert the module 2 Replace module 3 Measure 24V at test points on Power Supply If below 21 6V replace Power Supply 4 Replace Rack FACTORY CAL CRC failure of y Replace Module primary and backup factory calibration FIELD CAL CRC failure of field y None controller will switch card to Factory Cal calibration values HARDWARE General Hardware y Replace module Failure Al convertor not working HW SW Key The software residing C eae a Replace module on the module does not match the module type This diagnostic should only result in the factory Shift Register The loopback test of y V viv v Jv 11 Replace module the shift register failed Revision 5 HC900 Hybrid Controller Installation and User Guide 133 9 03 Diagnostics and Troubleshooting User Interface Bad I O Channel Diagnostics 134 Below 1s a list of conditions that can cause a bad channel diagnostic The associated function block s I O status will indicate the nature of the diagnostic described in the failure column Burnout Failure Under range Over range
139. hen switch SW1 is open 0 202 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output Digital Input Digital Output Analog Output RTP Internal schematic HC900 Terminal Block ia LJ fai an Revision 5 HC900 Hybrid Controller Installation and User Guide 203 9 03 Appendix B Installation of Remote Termination Panels RTPs RTP Cable wire positions and colors RTP Cable wire positions and colors wooo i fe sooo i fe White Black Green Black Blue Black Yellow Black Brown Black Orange White Green Blue 204 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail Latch Unlatch RTP to rail Mounting screws must be installed at each end of the mounting rail with additional screws approx 2 every 8 203mm to prevent twisting of the rail Insert one side of DIN rail at A DIN rail Insert other side of DIN rail at B and push B over the rail to snap into place 4 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 5 HC900 Hybrid Controller Installation and User Guide 205 9 03 Appendix B Installation of Remote Termination Panels RTPs Latch Unlatch RTP to rail 206 HC90
140. iented user name Network Administrative services that Many commercial and industrial facilities have Management include configuration large networks that are managed by full time tuning performance professional IT employees Other facilities monitoring and problem contract the services of professional IT agencies diagnosis and repair For networks that are dedicated for special purposes process control for example and are uncomplicated and easy to control Network Management is sometimes assigned to local employees as a part time add on responsibility Advised judgment is recommended Network Interface Card The NIC 1s plugged into one of the PC s expansion slots It includes the hardware and software OSI Layer 1 and Layer 2 required for connecting the PC to the network Revision 5 HC900 Hybrid Controller Installation and User Guide 31 9 03 Components and Architecture Networking Basics Reference Node Any intelligent device that The node terminology is sometimes limited to includes a hardware address computing devices such as PC hosts but can also that can be recognized by include networking devices such as Switches and other network devices Routers OPC Object Linking and OPC is an open standard that defines the exchange Embedding OLE for of information between cooperating software Process Control applications OPC is based on the Distributed Common Object Model DCOM defined by Microsoft Corporat
141. il NiSil NiCroSil NiSil so 2372 N 322192F 25 NiCroSil NiSil 800 N 0 800C 22 NiCroSil NiSil ca 1472 Poo N 32 1472F 23 None Bo o BO ONiNiMo ONiNiMo NiNiMo ONiNiMo NiMo NiCo NiMo NiCo NiMo NiCo NiCroSi Nisil NiCroSi Nisil NiCroSi Nisil _NiCroSi Nisil Revision 5 HC900 Hybrid Controller Installation and User Guide 171 9 03 Specifications Environmental and Operating Conditions ee feel semscm Low UMC800 Input type and range Ro o ao CR SOOO s o aw F somras o Fwsw2s lo awo r wsws aars OOOO Paine lo iso c PLTML OTs me Paine 32 se F Pimn S2asteF 19 Pein 32 o2 e Pon oera OOOO O Puo as ee c Puo z080068 Puo 300 10 F Puoos21r2F60 O o TOTO W_ W26 20 2320 l QI eere O 1 Pt500 649 n a Pt500 1200 n a Pt1000 40 260 Pt1000 40 500 260 JIS 0 100C 72 7 oms o o o os 0700 FS 172 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Environmental and Operating Conditions i ae Low UMC800 Input type and range mo SO o vor or ivo w 05 vot 08 Pld 15 107 aie 102 dL 2 2 104 wo fo vow o ii I i O Carbon Oxygen Revision 5 HC900 Hybrid Controller Installation and User Guide 173 9 03 Specifications Environmental and Operating Conditions System Sizing Summary 174 Alarms Alternator Blocks Analog Inputs Analog Outputs Block Con
142. in the slot Figure 26 Terminal Block Styles The 20 pin inline connectors at the back of the terminal blocks are universal that is any type of I O module can be used with either the Barrier style or the Euro style terminal block A 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 Installation Procedures page 63 Terminal Block Colors and Keying 58 Both the barrier style and the Euro style are available in two colors red and black Black terminal blocks which have gold colored contacts are used for low voltage low energy signals such as contact inputs and low DC voltages Red terminal blocks which have tin colored 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 colored contacts are for use with I O modules that have black headers and gold colored pins in the 20 pin connector these include Analog Input Analog Output DC Input DC Output and Contact Input e Red terminal blocks which have white tin contacts are for use with I O modules that have red headers and white tin colored contacts in the 20 pin connector these include AC Input AC Output and Relay Output e Terminal blocks may be keyed by the installer to prevent high voltage terminal b
143. indications on all output modules OFFLINE RUN Function Block execution starts immediately Any calibration process that was in progress is immediately aborted and the results are discarded Revision 5 HC900 Hybrid Controller Installation and User Guide 113 9 03 Operating Characteristics Software Download Upload Functions Software Download Upload Functions 114 The following is a general description of software file transfers between the controller and computer devices external to the controller my 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 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 54 PC Configuration Tool Ol 1042 Operator Interface Host device w PC Configuration Tool Legend Secs Firmware Download only e Configuration Download Upload Figure 54 Pathways for Upload Download Transact
144. ines 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 Ethernet Open Connectivity Network The configuration of the Ethernet Open Connectivity Network varies with specific applications in purpose and in complexity In some applications configuration is straightforward and within the capabilities of experienced installation technicians In other applications for example those that include inter connection to other networks such as Intranet and Internet a working knowledge of networking is required The Ethernet Open Connectivity Network for a given HC900 Controller enables e Peer to peer communication with up to eight other HC900 Controllers e Connection to up to five PC hosts for example PCs that include HMI supervisory software and or Hybrid Control Designer configuration software 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 When inter connecting your HC900 controller sub net to a plant network where there may be significant network traffic not directed to the HC900 controllers or to related supervisory control or data acquisition software interfaces we highly recommend you use a router to protect the co
145. ing on inputs on inputs Contact Input Module ree on rover omron Contact Resistance ON 1000 Ohms Max OFF 150 K ohms Min Response Time OFF to ON 4ms max 2ms nominal ON to OFF 6ms max 5ms nominal 164 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications DC Input Module DC Input Module a mew Cd eS 2 groups of 8 inputs group dielectric strength between groups 42 4 Vdc 30 Vac ON voltage level 9 5 Vdc minimum OFF voltage level 3 5 Vdc maximum 2 6k ohms nominal 2 3 MA 12 Vdc m 6 9 mA 24Vdc nominal mommo fesa o mommo sa ooo o Base Power Required Base Power Required 230 mA maximum for 5 Vdc no 24 Vdc power Response Time OFF to ON 4 ms maximum 2 ms nominal ON to OFF 4 ms maximum 2 ms nominal Revision 5 HC900 Hybrid Controller Installation and User Guide 165 9 03 Specifications AC Input Module AC Input Module Description rere m O gem teen 2 groups of 8 inputs group dielectric strength between groups 500 Vdc 350 Vac morenn imo ovon OVERS mammon caron Maximum On caren Base power required 230 mA maximum for 5VDC no 24VDC power Response Time OFF to ON 34 ms maximum ON to OFF 50 ms maximum Software filtering Specific to 50 60 Hz line frequency Features Common to all Output Modules a Micro Controller Atmel 8515 RISC processor 8k Flash PROM Hardware software keying Key matches module to terminal block con
146. ion OPC server and client software runs in computers interconnected on a network and enables exchanges between process control devices and PCs configured as HMIs OSI Model Open Systems The OSI model is established by International Interconnection Reference Standards Organization ISO to enable computer Model communications using disparate media and protocols Includes seven Layers refer to OSI Reference Model for more information Packet A bit sequence that is The content of a packet varies with the protocols transmitted as an entity ona that are applied It includes the data message itself network and various routing and control information such as source and destination addresses In many cases a packet includes a set of frames for one protocol embedded or encapsulated in a set of frames for another protocol Several levels of encapsulation could be incorporated in a packet Port The physical connection on For 10BaseT networking devices ports are RJ 45 a networking device connectors Port Multiplier A concentrator e g a The Port Multiplier a k a Hub forwards a Hub is a multi port device message at any of its ports to all of its other ports that enables one device to with no isolation between the devices on these be connected to several ports Hence a Hub constitutes a collision others domain for all connected devices Point to Point Protocol Provides Router to Router and
147. ion User Action Condition of Strobes Ram Failure RAM failed on power up Executes an infinite Cycle power loop that toggles the LED Replace scanner Communications and module scanning are Replace rack disabled Rom Failure ROM failed on power up Executes an infinite Cycle power loop that toggles the LED Replace scanner Communications and module scanning are Replace rack disabled Invalid The scanner has not been Does no scanning of Verify that the jumpers on the configuration configured by the main CPU modules Modules scanner are setup for the remain in their failsafe correct rack address state If a hub is used check that all cables are properly connected to the hub proper crossover cables are used and that hub is powered Cycle power to the rack Cycle power to the hub Replace the expansion rack s C50 CPU only power supply Replace the expansion rack Replace the main CPU Replace the expansion rack s scanner board Revision 5 HC900 Hybrid Controller Installation and User Guide 135 9 03 Diagnostics and Troubleshooting User Interface Table 30 Scanner Diagnostics Diagnostic Possible Cause Scanner Action User Action Condition Communication The scanner is not receiving any Does no scanning of Verify that the jumpers on the failure to main messages from the main CPU modules Modules scanner are setup for the CPU remain in their failsafe correct rack address
148. ion and User Guide 195 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point Contact Digital Input 3 Set jumper positions as shown for the 16 point contact digital input module C C C Com EEE Jumper open EE Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 203 for RTP internal schematic Connect field wiring 196 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 16 Point DC Digital Input 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to 16 point DC DI module at controller Choose from 2 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 9OORTC LO25 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 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 60 Mount RTP to DIN rail e Latch to rail Se
149. ions HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Operating Characteristics Software Download Upload Functions Configuration Download Configuration files include the items indicated in Table 22 Downloading of some items 1s mode dependent That is downloading of some file types is not permitted in the Run mode or in the Offline mode Table 22 Configuration file downloading Downloading of Permitted When Controller isin Configuration items PROGRAM Mode RUN Mode OFFLINE Mode Controller Configuration Files Yes Yes No Note 1 Setpoint Profiles Setpoint Yes Schedule Yes Recipe Files Yes Yes Data Storage Configuration Yes Files Data Storage Non volatile 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
150. iptions and procedures for the installation operation and maintenance of the HC900 Hybrid Controller hardware References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title ID HC900 Hybrid Controller Technical Overview Specification 51 52 03 31 HC900 Hybrid Controller Operator Interface User Guide 51 52 25 108 HC900 Hybrid Control Designer User Guide 51 52 25 110 HC900 Hybrid Controller Function Block Reference Guide 51 52 25 109 HC900 Hybrid Controller Communications User Guide 51 52 25 111 Contacts World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL Corporate http www honeywell com Industrial Measurement and Control http www honeywell com imc Telephone Contact us by telephone at the numbers listed below Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 888 423 9883 Q amp A Faxback TACFAQS 1 800 525 7439 Service Revision 5 HC900 Hybrid Controller Installation and User Guide ill 9 03 Symbol Definitions The following table lists those symbols that may be used in this document and on the product to denote certain conditions Symbol A WARNING A CAUTION CAUTION A Definition This DANGER symbol indicates an imminently hazardous situation which if not avoided will
151. isconnected 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 AN 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 e Ensure that wiring design precludes over riding of the MCR by operator actions Failure to comply with these instructions could result in death or serious injury A WARNING A Class 1 Division 2 Installations e DO NOT REMOVE OR REPLACE MODULES WHILE CIRCUIT IS LIVE UNLESS THE AREA IS KNOWN NOT TO CONTAIN FLAMMABLE VAPORS Revision 5 HC900 Hybrid Controller Installation and User Guide 45 9 03 Pre Installation Planning Electrical Considerations L1 L2 Power Supply in HC900 Controller Rack Power Supply i in HC900 I O Expansion Rack e Up to4 e O Expansion Racks 1 1 1 1 L Power Supply in HC900 I O Expansion Rack 1 1 1 1 L Emergency Power ON Stop OFF O T O O Ai O O i O O O wer Input Modules O000000000 O O O G O O O O O 0000000000 OOOOOOD00D Output Modules Figure 22 Master
152. ision 5 HC900 Hybrid Controller Installation and User Guide 181 9 03 Appendix A Site Planning Documentation Aids Peer Network Configurator Peer Network Configurator Network _ Network Name I _ _ _ _ _ _ _ _ _ _ _ _ _ up to 16 ASCII char s 1 Controller Name _ _ _ _ _ _ _I_ _ _ _ _I_ _ _ _ Alias Name __ __ II III II I IP Address _ _ _ _ _I_ III _I_LI_ Subnet Mask _ _ _ IIll III LIL 2 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ Alias Name _ _ _ _ _ _I_I_I_I_I_I_I_ILI_UI IP Address _ _ _ _ _I_ LIII _LI_I_ Subnet Mask _ _ _ _I_I_ LILILI LIL 3 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ Alias Name __ __ II III IP Address _ _ _ _ _I_ III _I_I_ Subnet Mask _ _ _ II LILI LIL 4 Controller Name _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ _ Alias Name _ _ _I_I_I I II II I _I_I_I_l IP Address _ _ _ _ _I_ _ILI_I _I_I_ Subnet Mask _ _ _ II LILILI LILI 5 Controller Name _ _ _ _ _ _ _ _ _I_ _ _ _ _ _ _ Alias Name _ _ _ _ _ _ILI_I_I_I_I_I_ILI_UI IP Address _ _ _ _ _I_ LIII _LI_LI_ Subnet Mask _ _ _ II I III LIL 6 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _I_ _ _ Alias Name __ __ II III IP Address _ _ _ _ _I_ III _I_I_ Subnet Mask _ _ _ II III IIl 7 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ Alias Name _ _ _ _ _ _ILI_I_I_I_I_I_ILI_UI IP Address _ _ _ _ _I_ III _I_LI_ Subnet Ma
153. junction measurement inaccuracies will be compensated in each individual thermocouple calibration cold junction calibration may be skipped e After connecting the thermocouple extension wire to the terminals you must wait for the terminal temperature to stabilize e If using a compensated calibrator input the equivalent simulated temperature values corresponding to the REFERENCE mV values These will be the hi and low range values for the particular thermocouple configured Figure 56 is an adaptation of the wiring diagram given in the installation section of this manual This figure indicates how an calibration device can be connected to the appropriate terminals of an analog input module The calibration device s must have the following precision characteristics e TC mVolts Volts inputs 1 microvolt resolution e Ohms RTD inputs 01 ohm resolution e 4 20mA inputs 4 microamp resolution Revision 5 HC900 Hybrid Controller Installation and User Guide 141 9 03 Analog Calibration Overview 142 RTD Input Resistor Decade Box 2 IN 1 IN 1 Thermocouple let 1 amp 2 Input Compensated a i Calibrator z a Ohms i n Input Resistor ee Po Decade Box ne mV V Bits Input Millivolt Volt ba IN7 Source fb eeesnensens an 7 amp 8 IN 4 20 mA ELLLLEE ECECETI Input Milliamp O 3 Source peeeeeees eg K EE E E PERELE Or Copper wire T C extension wire Thermocoup
154. kplane connector and support components on a single wiring board CPU 33 MHz RISC Based Processor Includes embedded MAC for Ethernet support 6 DMA channels including 2 dedicated for MAC support RAM 8 Megs SDRAM Flash PROM 2 Megs Dual Backed Flash Memory 16 Bit Address and Data Bus PROM and RAM Communications Ethernet 10Base T Port RJ45 connector on CAT 5 cable connects I O on Scanner Module to Controller Module or to third party Hub Status Indicators Scanner Status Bi Colored LED Input Output Backplane 40 pin Samtec connector Receives power 5 Vdc and 24 Vdc from power supply Serial Peripheral Interface SPI for I O Modules in Local Rack diagnostic sensing for I O slots in this rack 158 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Rack Design Rack Design Remote I O Enables placement of I O Modules near field devices configuration Variable capacity Available in three sizes I O module capacity 4 slot 8 slot and 12 slot Multi purpose Racks are made in one basic design and any 4 slot 8 slot or 12 slot rack can be applicability used either as a Controller local rack or as an I O expansion remote Rack C50 CPU only Power Supplies Power Supplies shipped separately are identical for controller and I O expansion racks C50 CPU only and are located identically at left of rack Input Output Backplane connectors 20 pin connectors for
155. lation section in this manual e External disconnect switches e Fuses at the power source associated with input sensor or output devices for I O modules Arrange and organize items to be installed at or near enclosures and use the Site Plan Documentation as a checklist to verify readiness for installation HC900 Hybrid Controller Installation and User Guide 51 Installation Guide Overview 52 Table 11 Install HC900 Controller Components Step Procedure Comments References 1 Mount the Controller Rack For dimensions of the pattern for drilling holes refer to the diagram below in the enclosure as follows Using the diagram below as a guide mark the locations for rack mounting in the enclosure for the top holes in the rack See CAUTION and Note at right Drill and tap for 10 or M4 screws Start the mounting screws supplied by the user in the drilled holes Hang the Rack on the screws at the top Mark the locations for the bottom screws See CAUTION at right Drill and tap for 10 or M4 screws Remove the rack from the enclosure racks R e 6 04 153 CAUTION When drilling holes prevent metal flakes from falling into the rack or onto any surface within the electrical cabinet 8 slot racks only All racks 3 02 76 e Eo gt cs gt _ _
156. laves is frozen 7 All slaves in the function block diagram are scanned at the background scan rate See RS 232 C See RS 232 See RS 232 See RS 232 NETWORK Controller network 1 Rack 1 monitor block s Correct the setup SETUP names determined on COMPORT DIAG is set problem ERROR network are illegal to FAILED 2 Rack 1 monitor block s RACK OK pin is turned off 3 ASYS block s HW OK pin is turned off NO IP DHCP and IP address SEE NETWORK SETUP Enter an IP address ADDRESS are not configured ERROR HARDWARE Ethernet port tests Replace CPU module FAILURE failed during power up Revision 5 HC900 Hybrid Controller Installation and User Guide 131 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Ol Screen Ol Screen Number of Possible Cause Control File Action Item Item Value LED Strobes RACK 1 VIRTUAL CONNECT 1 5 APPLICATION ERROR 1 Rack 1 monitor block s COMPORT DIAG is set to WARNING 2 Rack 1 monitor block s RACK OK pin is turned off 3 ASYS block s HW OK is turned off At least 1 response to a host resulted in an exception code User Action At host determine which message is causing the exception code and fix APPLICATION ERROR 1 Rack 1 monitor block s COMPORT DIAG is set to WARNING Rack 1 monitor block s RACK OK pin is turned off 3 ASYS block s HW OK pin is turned off One of the peer
157. le Input r oe ee Millivolt Ice Point an Source Reference a a al IN 3 IN 3 Copper wire T C extension wire Figure 56 Terminal Board Connections for Al Calibration HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Analog Calibration Overview Analog Output Calibration Analog output modules have essentially one output type A diagram of a precision ammeter connected to the terminals of an Analog Output module is given in Figure 57 The specifications of the meter must be consistent with calibration requirements Milliameter OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 57 Terminal board Connections for AO Calibration Revision 5 HC900 Hybrid Controller Installation and User Guide 143 9 03 Overview 144 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Removal and Replacement Procedures Overview Removal and Replacement Procedures Overview This section contains procedures for removing and replacing the active components of an HC900 Hybrid Controller It also includes recommendations suggestions and hints as they apply to the circumstances under which the procedures are used Safety Considerations PLAN AHEAD When using the procedures in this section plan the sequence of procedural actions so as to ensure e The safety of personnel e The protection of property e The integrity of operating processes The first consideration is
158. le memory 162 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications Analog Output Modules Analog Output Modules p Feature scription O 500 Vdc Channel Channel 600 Vdc from logic 0 1 of full scale at reference conditions D A Resolution 12 bits Output Current O to 21 8mA into 0 to 750 Ohms range selectable Calibration Data Data is stored in non volatile memory Redundant Factory Calibration with automatic rejection of Bad version Individual Channel Field Calibration Failsafe Outputs Timeout causes outputs to be forced to configured values Diagnostics Monitoring of Factory Calibration Field Calibration Configuration and 24 Vdc power supply Output Verification Feedback to CPU that indicates output current flowing Revision 5 HC900 Hybrid Controller Installation and User Guide 163 9 03 Specifications Digital Input Modules Common Features Digital Input Modules Common Features a OO Description O O S Micro controller Atmel 8515 RISC architecture 8k Flash PROM Hardware software keying Key matches module to terminal block connector ensuring correct board replacement Status indicator Tri color LED Green Good Yellow at least one input is Forced Red Fault LED status indicators Via light pipes at front of card for each digital I O point green indicates On aie l side Hardware and Hardware and software filtering on inputs Hardware and software filter
159. lock Wiring Rules and Recommendations In general stranded copper wire should be used for non thermocouple electrical connections Twisted pair wiring with shielded cable will improve noise immunity if wire routing is suspect Wire Gage Observe all local codes when making power connections Unless local electrical codes dictate otherwise the recommended minimum wire size for connections is given in Table 12 Table 12 Minimum Recommended Wire Sizes Wire Wire Application Gauge 14 Earth ground to common power supply 14to 16 AC to power supply 10to 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 Refer to Installation Planning Environmental Considerations in this manual Also all wires must be securely terminated using appropriate wiring practices Revision 5 HC900 Hybrid Controller Installation and User Guide 59 9 03 I O Module Installation and Wiring Terminal Block to Field Signal Wiring Signal Grounding 60 The shield for each input should be grounded at the Low Frequency Be
160. locks from being installed on low voltage modules See Table 14 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 Use of documentation aids in Appendix A will facilitate correct use of labels HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 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 B Installation of Remote Termination Panels RTPs for details Terminal Block to Field Signal Wiring Although both of the two available terminal block styles can be used on all I O module types wiring methods vary with the module type and with the type of field devices connected to the terminal block The descriptions that follow provide details Wiring can be routed through the terminal block at the top at the bottom or both Wiring should be fixed in place using wire ties at the slotted tabs that are molded in at top and bottom of each terminal b
161. log Input 8 channel r Full Document set on CD 900ME 1 0001 Full document set hard copy Engish 900ME2 0001 HC Designer Config Software CD 900W01 0001 Revision 5 HC900 Hybrid Controller Installation and User Guide 9 03 155 Specifications HC900 Hybrid Controller Design Specifications HC900 Hybrid Controller Design Controller Module Description Feature CE Conformity Europe 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 Installation Category Category Il Energy consuming equipment supplied from the fixed installation Over voltage Category Multi loop Process Controller Local level appliances and Industrial Control Equipment EN 61010 1 Pollution Degree Pollution Degree 2 Normally non conductive pollution with occasional conductivity caused by condensation ref IEC 664 1 EMC Classification Group 1 Class A ISM Equipment Product Classification Class Fixed Permanently Connected Industrial Process Control Equipment with protective earthing grounding EN 61010 1 Power per rack Voltage Universal power 90 to 264 Vac 47 to 63Hz Controller Rack Rating 130VA 264VAC typical 110VA
162. meters long ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F Install relay output module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 60 Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP 3 Set switch positions SW1 through SW8 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 62 for more details See page 193 for RTP internal schematic Revision 5 HC900 Hybrid Controller Installation and User Guide 191 9 03 Appendix B Installation of Remote Termination Panels RTPs Relay Output Relay Output reef Connect field wiring O Z Q lt O mr DO 5 0O 0 0000 OGO OOOO gW ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F 192 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Relay Output Relay Output RTP Internal schematic HC900 Terminal Block J1 TB1
163. n also be used to download upload configuration files to from the controller and can be used to download program updates to firmware in the Controller Module and or Scanner Modules A PC can be connected to the controller via the RS 232 Port on the Controller module and can also be networked to the controller via the Ethernet 10BaseT Open Connectivity Network port NOTE For specific PC requirements and for specific software requirements refer to the Hybrid Control Designer Users Manual RS 232 Modem Devices PC Configuration The PC configuration tool Tool connects from the RS 232 SONORE connector on the upper part of the Controller Module to a serial port on the PC The PC PC can be located remote from etal the Controller by using Modems and telephone links Modems and suitable cabling are available from third party vendors PC Modem Cable Telephone Cable Figure 11 RS232 Modem Devices 12 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Ethernet Devices Considerations Ethernet Devices Considerations Ethernet device requirements vary with specific applications Regarding intended use however they fall into two categories e Components of the Ethernet Open Connectivity Network which links an HC900 Hybrid Controller to Peers to HMI Supervisory Stations and to other Ethernet 10Base
164. n port 9 6 38 4 KB PC Internal Modem assigned to a COM port Connect a modem to the HC900 controllers RS 232 configuration port Refer to Modem configuration examples page 95 for a list of approved modems their settings and the connection specifics On the PC check on the Utilities Worksheet in the HC Designer software to see if the PC modem is properly installed A modem icon on the associated COM port button indicates the PC modem is properly installed internal or external If the modem icon is not visible on the associated COM port button use the modem supplier s instructions to properly install the modem and verify the installation using the Windows Control Panel Modem property page to confirm proper installation Set up the phone book in the HC Designer software This list includes the phone numbers for each of the HC900 controllers that can be connected using a modem The phone book can be accessed from the Main Menu View Phone Book or from the Utilities Worksheet by selecting the modem port as the current port Refer to the HC900 Hybrid Control Designer User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Remote Access for details on this step Select the number to call Ca CAN Furnace 1 Comment Piant 3 Lecabon Frere Humba at On the PC use the Utilities Worksheet in the HC Designer software to select the modem as the current port
165. nal 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 Donot apply energized live field wiring to an input output module that is not installed in one of the racks in the HC900 Controller e Do not operate the controller without a Protective Earth connection Failure to comply with these instructions could result in death or serious injury Revision 5 HC900 Hybrid Controller Installation and User Guide 57 9 03 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 26 and the Euro style shown at right Both styles of terminal blocks have an embossed numbering key that shows the numbering pattern of the 20 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 tagnames can be written On the back visible when the door is Open are wiring patterns for the type of module located
166. nect cable to RTP 3 Set verify jumper positions as shown for use with an analog output module C C C Co EE Jumper open EE Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 203 for RTP internal schematic 194 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 4 Point Analog Output sep to Connect field wiring LOADS ARE 0 to 750 ohm 16 Point Contact Digital Input Step 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to 16 point Contact DI module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 9OORTC LO25 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 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 60 2 Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP Revision 5 HC900 Hybrid Controller Installat
167. nector ensuring correct board replacement Output Diagnostic Checks output driver ICs Status indicator Tri color LED Green Good Yellow at least one output is Forced Red Fault LED status indicators Via light pipes at front of card for each digital output point green indicates On logic side 166 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Specifications DC Output Module DC Output Module a CO ramon Cid Papercut OOOO Overload Protection Electronic high current and high temperature limiting resets after cycling field power Maximum Load Current 1 A per point 8 A max per card resistive load Maximum Leakage Current 0 15 mA 32 Vdc Maximum In rush Current 4 A for 10 ms Base Power Required 426mA 5V Response Time Off to On 10 ms On to Off 5 ms Revision 5 HC900 Hybrid Controller Installation and User Guide 167 9 03 Specifications AC Output Module AC Output Module peste scription outputs e Isolation Per output Jumper comb is available for connecting L1 terminals Protection ON Voltage drop lt 1 5 Vac gt 0 1 A lt 3 0 Vac lt 01 A Maximum Load Current 2 Aper point 8 A max per module resistive load Maximum Leakage Current 4 mA 240 Vac 60 Hz 1 2 mA 100 Vac 60 Hz 0 9 mA 100 Vac 50 Hz Maximum In rush Current 60 A for 10 ms Base Power Required 218 mA 5V Response Time Off to On 2 ms 1 2 cycle On to Off 2 ms 1 2 cycle Fuses Repl
168. nication port they are controlled by hardware PHY chip not by software Revision 5 HC900 Hybrid Controller Installation and User Guide 119 9 03 Diagnostics and Troubleshooting External Indications of Diagnostic Information Table 24 LED Indications on Scanner Module LED State Color Indicates Condition 120 Scanner Status 10Base T port I O Expansion C50 CPU only XMT upper LED LINK lower LED LED Module Status Channel LEDs one per input or output Off Solid Red Blinking Red Solid Green Blinking Green Green On Off Green On Off No power Failed Diagnostic Code refer to Table 30 Scanner Diagnostics Startup Mode Scan Mode On while a message is being sent from the Main CPU otherwise Off On while the Main CPU is receiving a message Remains On as long as host is present Off when the host is removed from the link NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by software Table 25 LED Indications on I O Module Off Solid Red Blinking Red Blinking Yellow Solid green Blinking Green Green On Off HC900 Hybrid Controller Installation and User Guide LED State Color Indicates Condition No power Hardware failure Diagnostic Code refer to Table 28 Bad Module Diagnostics At least one output is Forced Cold start with passing diagnostics Normal scanning For
169. 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 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 e Connect desired cable to Al module at controller Choose from 9OORTC LO10 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 9OORTC LO25 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install Al module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 60 2 Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP 184 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Action Set DIP switch positions SW1 through SW8 Set each input s DIP switch positions according to the input type Refer to Figure 61 Step 4 to determine which switch corresponds to which input If an input is not used set its DIP switch positions to OFF Fuses 80mA Time lag Wickmann part 3 740080041 UL CSA approved Volt millivolt Transmitter Milliamp SW9 is the red power switch for 2
170. nstallation and User Guide 73 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Jumper either 10 1 noms or 9 11 Connect any of 9 to 12 f i to DC l Figure 39 DC Input Module Jumper 74 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Input Module Wiring The AC Input Module has sixteen inputs An example of AC Input Module wiring is shown in Figure 40 Specifications for this module and for other modules are given in the Specifications section of this manual 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 1s 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 41 A WARNING AN 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 oO G N2 2 ms O yells a 6 IN 6 O N7 IN 8 O T 40 N48 1 a a 12 In 9 16 O 0 N9 aana a 14 IN 10 O N 11 E 16 IN
171. nto failsafe MSTRFEAIL pins on ASYS and FSYS blocks turn on All Modbus slave and Modbus read blocks freeze their output pins to the last value 3 All slave blocks have their BAD COMM pin on 4 All slave blocks have their NO SCAN pin on 5 IN SCAN STATUS is set to NO for all slaves 6 COMM STATUS is set to BAD for all slaves in the function block diagram 7 Statistical counters for i all slaves are 0 Associated rack monitor block s RACK OK pin is turned off 2 ASYS block s HW OK 1 pin is turned off Controller performs a restart 2 Associated rack monitor block s RACK OK pin is turned off 3 ASYS block s HW OK pin is turned off See PREFETCH ABORT User Action Download a valid configuration Replace CPU 1 Configure one of the ports as a master 2 Download a configuration that has no slave blocks 1 Force a cold start 2 Upgrade control file software 3 Replace CPU board 4 Contact Honeywell Personnel 1 Force a cold start Isolate system from noise and force a cold start Replace CPU board 1 Force a cold start Isolate system from noise and force a cold start 3 Replace CPU board Bad Instruction See PREFETCH See PREFETCH Detected ABORT Abort HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller
172. ntroller from this extraneous traffic Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled See Figure 59 on page 178 for an example of an installation for a typical interface to another network sub net Peer to Peer Communication Peer to peer communication enables any given HC900 Controller to exchange signal and variable data with up to eight other HC900 Controllers 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 14 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Ethernet Devices Considerations Implementing peer to peer communications involves e Interconnecting controllers with Ethernet media and networking devices cables hubs switches etc e Configuration via Hybrid Control Designer Controller configuration which includes entry of an IP address and if applicable a Subnet Mask and a Controller Name for each controller The Controller Name is used
173. o Eure USA l PE Ground Yellow Green 14 AWG 2 1 mm Copper 75 C Step Procedure Comments References Revision 5 9 03 Revision 5 9 03 Ensure that jumpers are installed in J9 on the Controller Module as shown at right A WARNING AN Ensure that AC power to the rack is disconnected Carefully place the Controller Module in the local 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 152 Legend Jumper Out F Jumper In Installation Guide Overview Step Procedure Comments References Controller Module J9 The three positions at right are don t care and are left open The four positions at left must have jumpers in place HC900 Hybrid Controller Installation and User Guide 55 Installation Guide Overview Step Procedure Comments References Scanner Module 56 For each I O expansion rack C50 CPU only set the Scanner Module jumpers to the appropriate Rack Address as shown at right Repeat steps Ithrough 5 for each I O expansion rack C50 CPU only Then for each expansion
174. o 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 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 LT Q BEIE Address HEALLARAT Loop Back Statistics Protocol Modbus R TCP Speed bps N A PC Port Setup Network COM1 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Be also sure that the PC Network Interface Card has an IP address that allows access to the controller on the subnet after changing the controller s network parameters You may change the controller s IP address and related network parameters from its default using the Utilities Worksheet in the HC Designer software This may be done using either the RS 232 serial port typically used via a null modem cable connection or the Ethernet connection from the PC to the controller If the RS 232 connection is desired make sure the proper PC serial Com port to be used has been se
175. o 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 154 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Controller Components and modules Safety Considerations PLAN AHEAD Controller Components and modules I O Slot Rack 900R04 0001 I O Slot Rack 900R08 0001 12 I O Slot Rack 900R12 0001 Power Supplies 120 240VAC 60W 900P01 0001 120 240VAC 28W 900P02 0001 CPU Assemblies Controller C50 CPU Config SW amp Docs Controller C50 CPU Controller C30 CPU Config SW amp Docs Controller C30 CPU I O Scanner for remote rack I O Card Selections Analog Output 0 to 20mA 4 channel Digital Input Contact type 16 channel Digital Input 24VDC 16 channel Digital Input 120 240 VAC 16 channel Digital Output Relays 8 channel Digital Output 24VDC 16 channel Digital Output 120 240 VAC 8 channel Terminal Boards Low VoltageTerminal Block Euro style ow VoltageTerminal Block Barrier Style High VoltageTerminal Block Euro style High Voltage Terminal Block Barrier Style Filler Block Terminal Cover Shield Terminal Strip package of 2 Terminal board jumpers 10 two pos jumpers Terminal board jumpers 10 ten pos jumpers Ana
176. odbus messages in TCP frames for transport in an Ethernet network Modem Modulator Demodulator a Modems are commonly used for transmitting device for translating data in digital data over analog telephone lines A modem differing media and or is required at each end of the link format Multicast Transmission of a message with multiple destinations Name Server Network software that See also DNS translates text format names into numeric IP addresses NetBIOS Microsoft networking Used with Microsoft LAN Manager and Windows NetBEUI protocols NT products netid Network Identifier The portion of the IP address left part that identifies the network Netware Network operating System NOS by Novell Network A system of Computing devices often include Personal interconnections in which Computers PCs but also can include other networking devices such as computer based devices such as process Hubs Bridges etc transport controllers operator interface units and graphical messages between trending devices computing devices Network Address A code that resides in a The identifying code is usually numeric but networked device and that additional text oriented Name codes can for added identifies the device user convenience in device identification uniquely on the network s Network addresses usually include a MAC address to which it is connected and an IP address and may also include Host Name for a PC or other text or
177. oftware 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 16 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Ethernet Devices Considerations HMI software available for use with the HC900 Controller includes but is not necessarily limited to the packages whose descriptions follow e available from Honeywell PlantScape SCADA or Vista Software which operates under Windows 2000 operating software provides PC based supervisory control and data acquisition This package includes a large selection of standard operating display templates which can reduce development time significantly PlantScape includes a full graphic display development environment enabling development of custom graphics that include animated responses to changing process conditions A batch reporting option is available in release 400 which includes a standard template for creating batch reports SpecView32 SpecView Corporation e Other software available from third party sources The following software which
178. om as indicated in Figure 28 a i lb o In this case it is necessary to adjust N wire length so as to ensure adequate flexibility of the twisted wires and to provide clearance sufficient to remove the I O module S l lolS lollellel e Figure 28 Wire Shield Grounding HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Revision 5 9 03 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 The ten position jumpers are used with AC output modules to inter connect L1 AC Hot of all channels The two position jumpers are used to connect Common DC negative or AC neutral for the DC input module the DC Output Module and the AC Input Module Each of these module types has groups of eight channels with the two groups isolated from each other The two position jumper connects Common terminals 10 and 12 making one group of sixteen non isolated channels The two position jumper can also be used to connect the V terminals on the DC Output Module Refer to the wiring information on each module given in this section of this manual Figure 29 Terminal Block Jumper Installation HC900 Hybrid Controller Installation and User Guide 61 I O Module Installation and Wiring Removal and Insertion Under Power R
179. ommunication with 120 ohm resistors 2 000 cable feet Maximum Or Belden 9182 or equivalent with 150 ohm 4 000 feet maximum 10 terminal connector Supplied with the Phoenix 1840379 o connector 3 pin Supplied with the equivalent controller ai module 047260 a Ferrite cable clamps Supplied with the operator interface 089037 Nylon cable ties 100 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation RS 485 Link to Operator Interface C Direct Ethernet Connection to one HC900 controller Defaults IP Address 192 168 1 254 Subnet Mask 255 255 255 0 Default Gateway 0 0 0 0 Ethernet 10 Base T Crossover eagle Host 10Base T Ethernet port RJ 45 connector Procedure Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled Connect an Ethernet 10Base T crossover cable to the HC900 controllers Open Ethernet RJ 45 port top RJ 45 port Connect the other end of the Ethernet 10Base T crossover cable to the PC s network port 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 t
180. omponents and configuration details e A set of templates that are intended to collect and to organize data required for both hardware and software configuration Site Map and Network Diagram Each Site Map is unique it shows the specific physical placement of process equipment and process control equipment in a given facilities environment Hence it isn t practical to provide a template in this manual and a custom Site Map drawing must be generated for the user s facility As a suggestion for content and style of a Site Map an example is provided in Figure 58 This example is based on the multiple controller configuration illustrated in Figure 3 of this manual and includes the networking components shown in Figure 59 below in this Appendix Each Network Map is unique it shows the connections and relationships between network components included in the hierarchy of networks at the user s site A Network Map should be generated by the IT MIS personnel who plan and install the system of networks and should be updated and maintained to reflect any changes to the networking system This is particularly important when more than one networking service agency is employed As a suggestion for content and style of a Network Map an example is provided in Figure 59 This example is based on the same multiple controller configuration illustrated in Figure 3 of this manual and corresponds to the Site Map shown in Figure 58 in this Appendix Configur
181. onfiguration that was previously downloaded Configuration download and other utility functions can be performed in this mode See the Hybrid Control Designer User Guide for precautions restrictions and procedures OFFLINE Mode The OFFLINE Mode can be entered only from the RUN Mode and is intended primarily for performing AI calibration A A CAUTION Because Function Blocks are not processed and outputs are Frozen in this mode inputs that is process values can vary from the values that existed when the OFFLINE Mode was entered Before entering the OFFLINE Mode e KNOW all potential consequences of suspending control action e PLAN for all operator actions required to preclude adverse consequences while processing is Suspended and when resuming control processing e EXECUTE prudent control actions such as placing all control loop in the Manual Mode Failure to comply with these instructions may result in product damage 110 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Operating Characteristics Controller Modes Table 19 Controller Operating Modes Functions in selected mode I O scanning Controller and Expander Racks Function block execution outputs are set according to function block algorithms Monitoring of Diagnostics controller rack and I O expander racks Detection of I O Modules Other functions permitted e Downloading of configurations e Indications of Forces at Status LEDs on I O
182. only by the Honeywell proprietary software for network access between controllers it should not be confused with a Network Domain Name or Workgroup Name Peer Data Exchange PDE function blocks which are included in the control strategy configuration file PDE function blocks include PDE Control PDE Write and PDE Read Refer to the HC900 Hybrid Controller Function Block User Guide for additional information An illustration of HC900 Controller Peer to Peer on a Local Area Network LAN is given in Figure 13 Typically a Router is used for interconnection to another network LAN WAN or other a Remote ie bw Host oo Host bw Host XAN bw oo bw NenoAInG Devic s e d Suitches etc lt PC Host PC Host 3 5 Configuration File Configuration File Function Blocks Function Blocks PDE Read PDE Write PDE Write PDE Control PDE Control HC900 Controller LAN Figure 13 Modular Network Structure Connection to PC Hosts Connection to PC hosts can be via Modbus TCP as well as serial Modbus RTU over either the RS485 or RS232 communications ports Both ports support Modbus RTU and are configurable as master or slave The 5 TCP hosts can be concurrent with Modbus hosts on one or both of the other ports Any given controller is capable of concurrent communication with up to five PC hosts The meaning of the term host varies but for this definition a PC host is any PC that is on th
183. ontroller LAN is installed under local addressing rules That is IP addressing can be assigned without approval of or conflict with world Internet governing bodies 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 Revision 5 HC900 Hybrid Controller Installation and User Guide 17 9 03 Components and Architecture Ethernet Devices Considerations E Mail Communications The HC900 Controller includes e mail software that enables communication of Alarms and Events to up to three Internet addresses Implementing this feature consists of e Using the Hybrid Control Designer to configure Alarm Groups and Event Groups Assignment of specific alarms to priority and e mail enabling E Mail address lists SMTP mail server IP address 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 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
184. ormation Table 23 LED Indications on Main CPU LED LED State Color Indicates Condition Controller Off No power Status Solid Red Failed Blinking Red Diagnostic Code refer to Table 27 Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode RS232 port PC Config n tool XMT upper LED Green On Off On when first byte is sent Off when the last byte is sent RCV lower LED Green On Off On when first byte is received Off when the last byte is received or failure is detected RS485 port Operator Interface XMT upper LED Green On Off On when first byte is sent Off when the last byte is sent RCV lower LED On when first byte is received Off when the Green On Off last byte is received or failure is detected 10Base T port LAN Internet Green On Off On while message is being sent from the Main CPU otherwise Off XMT upper LED 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 10Base T port I O Expansion C50 CPU only LAN upper LED Green On Off On when activity is present on the link LINK lower LED Green On Off On when another 10Base T PHY is present on the link NOTE These LEDs indicate activity on the commu
185. orrupted and or incessant Caused by a failed Network Interface Card or by a data transmitted onto a computer device that transmits packets whose network length violates network rules Kops Kilobits per second Kermit A program used widely for file transfer and terminal emulation LAN Local Area Network Networked devices logically isolated from other networks and devices Latency Delay in transmission caused by a Switch or Bridge in forwarding a message Layer One of the seven layers in the OSI model LLC Logical Link Control layer Layer 2 of the OSI Model Load balancing Transferring tasks from heavily loaded resources to less loaded resources veo ee Logical Link between source and destination devices C Media Access Control Ethernet Interface transceiver software to physical media MAC Address MAC coded ID Unique code burned into firmware by the device manufacturer MAU Medium Attachment Unit Also see AUI MDI MAC MDI Medium Dependent Physical connector at cable end e g RJ 45 plug Interface on Ethernet CAT 5 cable Also see AUI MAU gt 30 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Networking Basics Reference Modbus TCP IP Variant of Modbus protocol Modbus TCP IP is a derivative of related Modbus protocol used with RS 232 or RS 485 data acquisition and supervisory structures Basically Modbus TCP IP encapsulates M
186. per RTP for 240Vac applications and 8A per RTP 2A per output for 120Vac applications Mount RTP cable assembly to HC900 Controller Figure 60 e Remove appropriate key tabs from terminal block to allow mating with the module See page 64 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 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 60 Revision 5 HC900 Hybrid Controller Installation and User Guide 201 9 03 Appendix B Installation of Remote Termination Panels RTPs Digital Input Digital Output Analog Output 8 Point AC Digital Output sf Mount RTP to DIN rail e Latch to rail See page 205 e Connect cable to RTP EE Jumper open EE 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 62 for more details See page 203 for RTP internal schematic Connect field wiring Note S L1 in the wiring figure below refers to power that is disconnected from these screw terminals w
187. perating Mode switch on the Controller Module and by selecting parameters on displays operator interface Hybrid Control Designer In some cases mode transitions also restart Cold Start or Warm Start controller operation e Results of diagnostics in case of system hardware or software fault the controller automatically alters Operation as appropriate for the diagnosed conditions Power Down Power Up The HC900 Controller is designed to facilitate restoration of process operation after a power outage The active control configuration is maintained in battery backed RAM and the last configuration update performed in the program mode is also stored in Flash memory on the Controller Module When power is restored the system automatically enters a diagnostic procedure that checks the integrity of hardware software and the control database Depending on the results of the diagnostic the controller will execute either a Warm Start or a Cold Start Warm Start A Warm Start is a restart of the control strategy using dynamic data that 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 52 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
188. r e connects to PC configuration tool via Null Modem cable up to 50 or via straight cable to modems and telephone connections Baud 9600 19 3k or 38 4k configured from operator interface e connects to any Modbus slave or master device RS 422 485 Port 1 2 DUART 3 pin connector Phoenix 1840379 or equivalent e connects to the Operator Interface up to 2000 feet using Belden 9271 or equivalent e connects to any Modbus slave or master device Ethernet 10Base T Port to Open connectivity network RJ45 connector on CAT 5 cable Connects to PC HMI via crossover cable up to 100 meters or to a third party networking device using straight cable up to 100 meters Ethernet 10Base T Port to I O expansion network C50 CPU only RJ45 connector on CAT 5 cable connects I O on Controller Module to Scanner Module on one I O expansion rack or to third party networking device which can connect to up to four I O expansion racks Networking device enables use of 100 meters of additional cable a second in line networking device enables additional 100 meters of cable for 300 meters 984 feet maximum distance between controller and I O expansion rack Revision 5 HC900 Hybrid Controller Installation and User Guide 157 9 03 Specifications Scanner Module Design Scanner Module Design Controller Module Description Feature Module design Plug in module CPU memory RAM and Flash PROM communications connector bac
189. r serious injury Contac Input a t o COM COM COM COM Figure 42 Contact Input Wiring Diagram Revision 5 HC900 Hybrid Controller Installation and User Guide Tf 9 03 I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 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 43 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 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 1
190. 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 Legend Jumper Out BBEEEHE BBEEEER HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 I O Module Installation and Wiring Overview This section contains descriptions of and procedures for installing I O Modules in controller racks and in I O expansion racks C50 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 25 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 IO module At the front of each IO module a twenty pin in line plug receives the associated 20 pin 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 20 Pin connector l re to Backplane jee 20 Pin connector 4 to Terminal Block 0 0 Label le 0 LA 0 PA 0 0 0 0 0 0 0 0 jaewee ee i o eee A Figure 25 I O Module Installation WARNING Ay e Do not use an input output terminal block if the termi
191. rchitecture Networking Basics Reference Table 5 Glossary of Networking Terms In the name 10Base T the 10 refers to 10 Mbps transmission speed the Base refers to Baseband which means that no frequency multiplexing is applied and the T refers to Twisted Pair Specification for 10mbps carried over twisted pair cable 10Base Tx P Address Resolution Protocol I Bits Per Second A networking device that connects two LANs and forwards or filters data packets between them based on their destination addresses Broadband A network that uses multiple carrier frequencies to transmit multiplexed signals on a single cable Network Brouter A hybrid networking device that includes functions of a router and of a bridge Bus A LAN topology in which all nodes are connected to a single cable conductors in the cable Precedes IP communication between two stations Deduces Layer 2 MAC address information from IP address information A unit of binary data A binary bit has two values 1 or 0 Units of transmission speed Bridges operate at data link level or MAC layer of the OSI model Bridges are transparent to protocols and to higher level devices like routers Attachment Unit Interface See MAU MDI Several networks can coexist on a single cable without interference with each other A Brouter routes specific protocols such as TCP IP and bridges others A data transmission f
192. result in death or serious injury This WARNING symbol indicates a potentially hazardous situation which if not avoided could result in death or serious injury This CAUTION symbol may be present on Control Product instrumentation 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 not avoided may result in property damage WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury 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 sh
193. rom any node is received by all other nodes on the Bus Adataunitofeightbits Cat 3 Cat 5 Cat Category 3 5 Ethernet SE twisted pair cable available as Unshielded Twisted Pair UTP or Shielded Twisted Pair STP 10Base T can use Cat 3 or Cat 5 cable Cat 3 includes 4 wires 2 twisted pairs Cat 5 includes 8 wires 4 twisted pairs 100Base T can only use Cat 5 cable Note Cat 5 cabling and connectors are more reliable than those for Cat 3 Cat 5E refers to the Enhanced version of Cat 5 Both Cat 3 and Cat 5 cables are limited to 100 meters 328 feet per segment and both use RJ 45 connectors CGI Common Gateway Interface A programming standard that connects databases and web browsers Path through network devices from one node to another Coaxial Cable Revision 5 9 03 Electrical transmission medium with solid wire conductor at center insulated from and surrounded by tubular outer metal conductor Examples are Thin Ethernet RG 58 AU or RG48 CU and Thick Ethernet RG 8 with BNC connectors Coaxial cable was commonly used for earlier networks Twisted Pair is popular in current use HC900 Hybrid Controller Installation and User Guide 27 Components and Architecture Networking Basics Reference Collision Simultaneous transmission Collisions can be reduced and network capacity of two nodes on the same increased by use of Switches which partition and channel isolate collision
194. rvice 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 152 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Installation Procedures Table 36 Installing Backup Battery CPU not initialized 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 3 Open the plastic door at the top of the Controller Module Press the latch on the battery cover to the right to release the battery holder and use the molded in extension on the battery holder to extract the holder Note the orientation of the battery holder assembly 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 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
195. s Network Description Device Router A Hub 1s so called because a diagram of its connections resembles a hub of a spoked wheel Characteristics Echoes a message on any port to all other ports constitutes a collision domain for all connected devices Isolates the device s on a bad port A Switch is similar in appearance to a Hub but connects only the ports specified as Source and Destination devices in each message packet Collision domains are partitioned that is they are isolated to Source Destination devices Extends the distance over which network traffic can be transported all message packets at input port are repeated at the output port no domain partitioning Signals are amplified but are not re shaped or re timed An intelligent Repeater that connects input and output ports but only if the message specifies the device on the output port as the Destination An intelligent Bridge that is often used for wide area networks WANs Usually includes a computer with its own network address memory and network based software It can be configured to determine which data packets received will be transferred to a LAN node based on destination address such as an HC900 controller and or protocol port number A PC set up to inter connect two disparate network models at any combination of layers of the OSI Model HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and A
196. s basically an adaptation of the Modbus messaging structure that uses TCP IP for a message carrier 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 14 Transaction Protocol Length Modbus Identifier Identifier Field Frame oo oe oo oo oe s oo oo oe oe oe I Address Function Data Checksum Code Figure 14 Modbus TCP Framing The HC900 Controller uses either Modbus TCP or Modbus RTU 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 From an implementation and installation aspect the use of the Modbus protocol for HC900 Controller configuration differs from the use for Controller to HMI communications The Hybrid Control Designer configuration package which is supplied by Honeywell is ready for use as soon as it is installed This package uses a subset of Modbus function codes that provide for very efficient and secure configuration transactions Communications details are transparent to the user all communication drivers are included with the package and no mapping or other detailed setup is required HMI Supervisory SCADA s
197. s by keying in the following command string AT amp FO Then press the ENTER key In the program s terminal window key in the following command string AT El QO Then press the ENTER key The modem should give an OK response Key in the following command string AT amp YO amp CO amp DO amp R1 amp SO amp KO SO 1 The Modem should respond with OK Key in the following command string AT EO Q1 amp WO The Modem will not respond Power down the modem and disconnect it from the PC Connect the modem to the RS 232 port of the HC900 Controller using a DB 9 male to DB 9 male modem cable Connect the modem to a telephone jack Power up the modem and the HC900 Controller On a remote computer run Hybrid Control Designer software Set up the PC software to dial the HC900 Controller Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller HC900 Hybrid Controller Installation and User Guide 99 Communications Installation RS 485 Link to Operator Interface RS 485 Link to Operator Interface The RS 485 port is located below the hinged plastic cover on the top part of the Controller Module Typically the cable that interconnects this port to the Operator Interface must be fabricated during installation because it will probably be necessary to run the cable through conduit Table 18 Parts needed for RS 485 Cabling Belden 9271 or equivalent Variable E a available c
198. 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 A CAUTION All of the input output modules available for use in the HC900 Controller have a RIUP designation That is they can be Removed and Inserted Under Power where power refers to DC power at the backplane of the rack It does not refer to power for field wiring at the terminal board associated with the I O module which must be disconnected using a user supplied switch at the field device before removing or inserting the module For all other components
199. ser Action Condition Strobes Watchdog Reset 3 Watchdog reset resulting from Scanner restarts and 1 Cycle power to the scanner software failure requests configuration from the main CPU 2 Upgrade scanner software 3 Replace scanner module 4 Contact Honeywell Personnel Prefetch abort 3 CPU failed when attempting to See watchdog reset 1 Cycle power to the scanner CPU exception fetch an instruction from the prefetch register 2 Isolate system from noise and cycle power to the scanner 3 Replace scanner module Address error 3 The reserved exception See watchdog reset See Prefetch abort CPU CPU exception occurred for an unknown exception reason Undefine 3 Bad Instruction Detected See watchdog reset See Prefetch abort CPU instruction CPU exception exception Data abort CPU 3 CPU failed when attempting to See watchdog reset See Prefetch abort CPU exception access data exception Software interrupt 3 Spurious Interrupt See watchdog reset See Prefetch abort CPU exception exception Vector error 3 Interrupt vectors in RAM were Interrupt vectors were See Watchdog reset corrupted restored Flash write error 4 Flash failed to burn properly The boot code is the Do a code download only software running This software waits for a request to burn the flash It does no scanning of modules Modules remain in their failsafe state Rack backplane 6 The Scanner is unable to Does no scanning of 1 Remove modules and check failure successfully communicate
200. ses 2 and 3 Associated rack monitor block s module fail pin is turned on 1 Improve ventilation to rack 2 Replace Al module Associated rack monitor block s RACK OK pin is turned off Associated rack monitor block s HITEMP pin is turned on ASYS block s HITEMP pin is turned on ASYS block s HW OK pin is turned off Associated blocks set their fail pin on their warn pin off and their output pin to the failsafe value 1 Verify configuration 2 Replace module with the correct one 2 Associated blocks set their IO status to Channel No Comm 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 block s HW OK pin is turned off Revision 5 9 03 Diagnostics and Troubleshooting User Interface Table 27 Controller Module Diagnostics Number of Possible Cause LED Strobes MODULE NO Main CPU is unable to COMM communicate to the module for one of the following reasons e Module is not installed Backplane problem is inhibiting the CPU to properly communicate with the module Module is on an expansion rack C50 CPU only and the expansion rack communications is failing See Table 29 Bad Channel Diagnostics Ol Screen Item Value Ol Screen Item MODULE 1 through MODULE 16 BAD CHANNEL BAD MODULE Module is reporting a diagnostic condition See Table
201. signer software to configure the controller s RS 232 port as a master or slave Revision 5 HC900 Hybrid Controller Installation and User Guide 105 9 03 Operating Characteristics Connecting the HC900 Controller to Modbus device s 106 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Operating Characteristics Introduction Operating Characteristics Introduction 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 O
202. sk _ _ _ II LILI LIL 8 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _I_ _ _ Alias Name _ _ _ _ _ _ _I_I_I_I_I_I_ILI_UI IP Address _ _ _ _ _I_ III _I_LI_ Subnet Mask _ _ _ III LILILI LIL 9 Controller Name _ _ _ _ _ _ _ _ _ _ _I_ _ _ _ _ Alias Name _ _ _ _ _ _ILI_I_I_I_I_I_ILI_UI IP Address _ _ _ _ _I_ III _I_LI_ Subnet Mask _ _ _ _ III LIL 182 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Appendix B Installation of Remote Termination Panels RTPs Overview The Remote Termination Panel RTP provides an easy way to connect the HC900 controller to the field wiring The RTP integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I O modules There are three RTP types See page e Analog Input 184 e Relay Output 19 e Digital Input Digital Output Analog Output 194 HC900 Controller Cable various lm lengths available Shield drain wire RTP mounted on Terminals for field 2 Si DIN rail 111mm 4 38 Figure 60 Example installation all RTPs are dimensions shown Revision 5 HC900 Hybrid Controller Installation and User Guide 183 9 03 Appendix B Installation of Remote Termination Panels RTPs Analog Input Analog Input 8 Point Analog Input Step 1 ATTENTION RTP is
203. smitted between networking devices and functions above Layer 1 Includes two sublayers Media Access Control Physical Layer MAC and Logical Link Control LLC Datagram A series of bits in an Datagrams are commonly referred to as Packets ordered intelligible because they are data entities although Packets sequence apply only the top layer Application Layer of the OSI Model DCE Data Communications Devices that transport data between DTE devices Equipment DHCP Dynamic Host Runs in a DHCP server which assigns an IP Configuration Protocol address to each node that connects to the network Can not be used in a an HC900 LAN DNS Domain Name System An Internet system resident in a Web Browser that resolves domain names to IP addresses For example Http www yahoo com resolves to Http 204 71 202 160 Domain On the Internet a named User Names Passwords and related data on a network network In MS Windows an elemental administrative security oriented unit 28 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Networking Basics Reference the Host name DS1 T 1 carries 1 544 Mbps DS3 T 3 carries lines 44 736 Mbps communicate via networking devices Ethernet IEEE networking standard 10 or 100 Mbps Baseband network that uses 802 3 which defines various media thick coax thin coax twisted pair configuration rules for an or fiber optic c
204. t up See Direct Serial RS 232 Connection above Revision 5 HC900 Hybrid Controller Installation and User Guide 101 9 03 Communications Installation RS 485 Link to Operator Interface Select the Set Controllers Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controllers 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 Hybrid Control Designer User s Guide or its respective on line 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 102 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation RS 485 Link to Operator Interface D Network Access to one or more controllers Revision 5 9 03 Ethernet 10Base T LAN LTO Hub Switch 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 yo
205. te the screwdriver handle toward the back using the top edge of the rack as a fulcrum A CAUTION Removal or Insertion Under Power of an I O module is an option but if operating circumstances permit disconnecting power from the rack is the preferred option Plan and develop an action sequence before beginning the replacement procedure Primary considerations include When replacing I O module the voltages to the modules must be disconnected at the field device before removing the terminal block from the module Loss of control monitoring in a running process Each signal at each of the terminals for an I O module has a specific function Any or all of the signals may be vital for safely controlling a process Determine the functions of all signals to the modules and know the potential consequences of losing each If possible transfer control to alternate mechanisms otherwise bring the process to a safe and controlled shutdown A WARNING Disconnect all signals from power sources using user supplied switches at field devices Use a meter to ensure that all voltages are disconnected If a power down replacement procedure is opted also disconnect power from the rack using the user supplied switch in the site AC power source Loosen the captive screws at top and bottom of the module loosening the screws will cause the terminal block to be partly extracted from the module connector Remove the terminal block from the module
206. this extraneous traffic Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled See Figure 59 on page 178 for an example of an installation for a typical interface to another network sub net Revision 5 HC900 Hybrid Controller Installation and User Guide 5 9 03 Components and Architecture Components m m m m m O 0 m Figure 3 Configuration with Multiple Controllers 9 03 Revision 5 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Components and Architecture Components Table 1 Descriptions of Major Components Figure 3 Key No Component Name 1 Controller Local Rack Operator Interface PC Configuration Tool HMI Human Machine Interface Ethernet 10BaseT Hub Ethernet 10BaseT Switch or Router Ethernet CAT5E Ethernet CAT5E 10 RS 232 cable I O Expansion Rack C50 CPU only shielded cable shielded cable Includes Rack Power Supply Controller Module and I O modules Optional Includes Rack Power Supply Scanner Module and I O modules Optional link to RS 485 port on a Controller Module provides operating and utilities displays Includes buttons and optional AT keyboard interface Optional PC laptop or desktop connects to R
207. tional Default Gateway IP Address optional e Network Name optionally used in Peer Data Exchange e Local Name optional user identifier for controller e E mail Server IP Address required if e mail alarms are configured 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 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Communications Installation Connecting the HC900 Controller to Modbus device s Connecting the HC900 Controller to Modbus device s RS 485 Modbus connections Using the master and slave s RS 485 ports of the controller and other device s connect as shown Master Slave 1 Slave2 Slaven Shield Qs N S C S S u Shield TX RX X TX RX 120 ohm 120 ohm TX RX ao k TX RX 120 ohm termination resistors required at master and last slave on the link Use HC Designer software to configure the controller s RS 485 port as a master or slave RS 232 Modbus Connections Connect to the RX TX and ground pins of the controller s 9 pin RS 232 port Table 17 page 90 identifies the pins For connections on other device refer to its product manual For multiple devices on RS 232 use an approved RS232 to RS485 converter Use HC De
208. to modules Modules for bent pins on connectors any modules that are in its SPI remain in their failsafe backplane state 2 Reinsert modules one at a time and note which module the diagnostic reoccurs and replace that module Cycle power to the rack Replace the power supply Replace the rack O aA A O Replace the scanner module Revision 5 HC900 Hybrid Controller Installation and User Guide 137 9 03 Diagnostics and Troubleshooting User Interface Table 30 Scanner Diagnostics Diagnostic Possible Cause Scanner Action Condition High CJ Possible reasons for this No action is taken temperature diagnostic are 1 One of the two CJs on the module is indicating a temperature reading greater than 70 degrees C Both cold junction sensors are failing to convert The CJs are converting properly but their differential is greater than 10 degrees C will be confirmed through experimentation Wrong module The module does not agree with No action is taken the module required for the control scenario No communication The scanner is unable to No action is taken to the module communicate to the module for one of the following reasons Module is not installed Backplane problem is inhibiting the scanner to properly communicate with the module Bad channel See Table 29 Bad Channel No action is taken Diagnostics Bad module Module is reporting a diagnostic No action is taken condition
209. to the controller If your modem requires command string configuration you will need an interface cable to connect the modem to your PC Refer to your modem and computer documentation to determine this cable s requirements Revision 5 HC900 Hybrid Controller Installation and User Guide 93 9 03 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software Modem configuration Before connecting a modem to the controller s RS 232 port marked CONFIGURATION the modem must be configured with the following settings 94 Baud Rate 9600 19200 or 38400 Must match Baud Rate configured in HC900 Controller Parity None 1 stop bit 8 data bits No handshaking Ignore DTR Suppress result codes Suppress echo Auto answer Disable command recognition only necessary if the modem has this capability Some of these settings may be settable via switches Others may require command strings to be written to the modem using a PC terminal program such as Hyperterminal You will need to refer to your modem s documentation to make this determination Those settings that are configured using command strings must be 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 m
210. tput same current as previous last active current level Revision 5 HC900 Hybrid Controller Installation and User Guide 111 9 03 Operating Characteristics Controller Modes Controller Mode Transitions Mode changes are controlled primarily by positioning of the MODE switch on the controller module 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 20 The effects on controller operation for each mode transition are described in Table 21 Table 20 Mode Switch Functions Mode Name Position of Mode Mode Selections at Switch Operator Interface RUN None locked in In this position the Controller is locked in the RUN Locked RUN mode of operation Run mode configuration changes are disabled and mode can not be changed at any operator interface RUN PROG Middle PROGRAM In this position the mode can be changed at any operator interface using screen selections RUN PROGRAM RUN or OFFLINE OFFLINE PROG None locked in In this position the Controller is locked in the Locked Program PROGRAM mode of operation Mode can not be changed at an
211. twork 13 14 Euro style 11 58 Event Groups 18 exponential back off 22 F Field Signal Wiring 59 Filler Block 67 Flash 107 Form A relays 82 Form C relays 82 Fuses 80 Fusing 82 G Gateway 26 Glossary 24 Glossary of Networking Terms 27 ground voltage potential 60 grounding bar 60 grounding bars 53 Grounding lug 9 H HC900 Hybrid Controller 2 Heat Rise De rating 39 HMI 16 Hub 13 26 Hybrid Control Designer 12 I O channel numbers 58 I O expansion network 13 I O expansion port 10 I O Expansion Rack 8 I O implementation 14 I O Installation Procedures 63 I O Module Diagnostics 133 I O Module Installation 57 I O numbering assignments 14 I O slot 57 I O wiring shields 60 Information Technology 22 Input Output Modules 11 Installation Tools 49 HC900 Hybrid Controller Installation and User Guide 207 Index Intellution 17 Internet Protocol 22 IP22 IP address 15 Irto 68 isolation capacitor 60 IT 22 IT networking professional 13 eet nae jumper 63 Jumper Comb 73 75 78 80 82 Jumper Combs 61 jumpers 14 55 56 K Kepware 17 key tabs 64 Label 63 labels 58 LAN 15 22 Layer 25 Layer 2 23 Layer 3 23 LED Indications on Ethernet Hub 121 LED Indications on I O Module 120 LED Indications on Main CPU 119 LED Indications on Scanner Module 120 LED Indicators 118 lithium battery 10 Lo
212. uide 97 Communications Installation Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software 98 Best Data 56SX Data Fax External Modem Step 1 ao oa fF OO N 10 11 12 13 14 15 16 17 Action 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 Connect power to the modem 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 Configure the port to these settings baud rate 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key 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 Key in the following command string AT amp CO amp DO amp KO amp R1 amp SO amp YO SOQ 1 The Modem should respond with OK Key in the following command string AT EO Q1 amp WO The Modem will not respond Power down the modem and disconnect it from the PC Connect the modem s serial cable to the RS
213. ur 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 controllers new network parameters including IP address Subnet Mask and Default Gateway if required See your IT network administrator for proper entries Refer to the on line help provided with the HC Designer software Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Select the Network button at the bottom of the dialog box and Add any or all of controller IP
214. y operator interface 112 HC900 Hybrid Controller Installation and User Guide Revision 5 9 03 Operating Characteristics Controller Modes Table 21 Controller Behavior in Mode Transition Initial Mode Controller Behavior PROGRAM RUN Validate configuration database Reset all I O scanners Upon startup initiate Cold Start sequence Diagnostic Identify and configure all I O racks and modules All output modules are configured with Failsafe values Any modules not included in the configuration are configured with default values which causes outputs to be Off While in transition all output modules are Off when transition procedures are completed Function Block processing begins and output values are set to Function Block output values Any calibration process that was in progress is immediately aborted and the results are discarded PROGRAM OFFLINE Same as PROGRAM to RUN transition except that Function Blocks are not processed and outputs remain Off Any calibration process that was in progress is immediately aborted and the results are discarded RUN PROGRAM Set all channels of all output modules to Off Set all output module Failsafe values to the Off state Turn off the LED indications on all output modules OFFLINE PROGRAM Same as RUN to 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
215. ystems and Information Technology IT professionals who are adept in network implementation Networking topics are many and broad To be useful the networking language bridge given here includes topics that apply to HC900 Controllers and to closely related computer and networking devices Ethernet Ethernet is a networking standard IEEE 802 3 that features e Local Area Network LAN which means that networked devices are near to each other usually in the same building e bus or star topology Bus topology means that all networked devices also called nodes connect to a common cable at different locations Star topology means that a networking device called a hub or concentrator provides interconnections for cables from network nodes e Transmission speed of 10 Mbps or 100 Mbps e CSMA CD access CSMA CD stands for Carrier Sense Multiple Access Collision Detection All devices on the LAN are free to transmit at will If two nodes that are inter connected at Hubs transmit simultaneously the collision of the multiple access is detected by the hardware devices associated with the nodes Each device will wait a random time and will attempt to re transmit If the device detects another collision it will double wait time before transmitting again Doubling the wait time 1s called exponential back off Node Addressing Every node on a network has a unique number and or name that is used by transmission protocols to identify it as

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