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Honeywell HC900 Process and Safety Controller User Manual

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1. Power P01 Voltage Universal power 90 to 264VAC 47 to 63 Hz In Rush Current 7 Amps peak to peak for 150 ms at 240VAC Input rating 130 VA Output rating 60W Fuse Internal non replaceable fuse User installed external fuse Power P02 Voltage Universal power 90 to 264VAC 47 to 63 Hz In Rush Current 7 Amps peak to peak for 120 ms at 240VAC Input rating 90 VA Output rating 28W Fuse Internal non replaceable fuse User may install external fuse Power P24 Voltage 21 to 29VDC In Rush Current 30A for 3ms 29VDC Input rating 72 5W Output rating 60W Fuse Internal non replaceable fuse User may install external fuse Normal Scan Time 500ms Each analog input card has its own A D converter providing parallel processing Fast Scan Time 25ms for up to 250 fast 10ms for up to 250 fast 10ms for up to 330 fast 25ms for up to 500 fast logic blocks logic blocks logic blocks logic blocks 35ms for up to 315 25ms for up to 500 fast 25ms for up to 660 fast 35ms for up to 780 fast fast logic blocks logic blocks logic blocks logic blocks 50ms for up to 400 35ms for up to 780 fast 35ms for up to 1040 50ms for up to 1040 fast logic blocks logic blocks fast logic blocks fast logic blocks 50ms for up to 1040 50ms for up to 1380 60ms for up to 1300 fast logic blocks fast logic blocks fast logic blocks 60ms for up to 1300 60ms for up to 1700 125ms for up to 2500 fast logic
2. Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 225 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Contact Digital Input Connect field wiring 16 Point DC Digital Input poe 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP combines the two groups of 8 inputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect desired cable to 16 point DC DI module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 9OORTC LO50 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DI module label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 2 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 226 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Inpu
3. oO oo N DOD oO A W PD oO oo N DOD oO A W PLP 10 10 a ot oOo N 0 oe U N a o a A a 0 ot a A 4 o 4 O N a N po O oO po o O Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 221 January 2014 Appendix Installation of Remote Termination Panels RTPs Relay Output RTP Cable wire positions and colors applies to 8 point Al and Relay Output Twisted Pair Number HC900 Module TB Position RTP J1 Plug Connector Color 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 9 17 Black 10 16 Blue 5 11 15 Black 12 14 Yellow 6 14 12 Black 15 11 Brown 7 16 1 Black 17 2 Orange 8 19 4 Red 20 5 White 9 3 8 Red 8 18 Green 10 13 13 Red 18 3 Blue 222 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output Analog Input Digital Input Digital Output Analog Output A single DI DO AO RTP and cable is used with the following modules See page e 4 point Analog Output 223 e 16 point Contact Digital Input 225 e 16 point DC Digital Input 226 e 16 point AC Digital Input 228 e 16 point DC Digital Output 229 e 8 point AC Digital Output 232 e 8 point Analog Output
4. 4 At the top and bottom of the module loosen the captured screws that secure the module in the rack and remove the power supply from the rack 5 Place the new power supply in the rack cont d 190 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Step Action 6 Secure the lugs for AC wiring to the terminals on the new power supply e L1 top terminal Black USA or Brown Europe e L2 N middle terminal White USA or Blue Europe e Ground bottom terminal 7 Ensure power can be applied safely and use the external user supplied switch to re connect power to the power supply 8 Using a meter and the test points on the face of the power supply ensure that voltages measured on the backplane are within specifications Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 191 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing the Controller Module Removing and replacing the Controller Module requires that that the source of AC power is removed from the rack Removing power from the Controller rack has the following consequences 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 t
5. gpecaconasces MV or s mV or V3 8 abel Source Suen n Seeccccesees See note see isan y 4 20 mA f Xmtr sees s Input POET gt 24 V ci Note The following Al types are not available for High Level Analog Input modules RTD Thermocouple Ohms mV Figure 92 Terminal Board Connections for Al Calibration Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 187 January 2014 Overview Analog Output Calibration Analog output modules have essentially one output type A diagram of a precision ammeter connected to the terminals of a 4 channel Analog Output module is given in Figure 93 The specifications of the meter must be consistent with calibration requirements See page 98 for terminal connections for 8 and 16 channel AO euecesseusssousess de Seeceee ene OUT 1 SS le Milliameter LOAD Pry Sensennsnensees OUT 2 OUT 2 OUT 3 OUT 3 OUT 4 OUT 4 Figure 93 Terminal board Connections for AO Calibration 188 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Removal and Replacement Procedures Overview Removal and Replacement Procedures Overview This section contains procedures for removing and replacing the active components of an HC900 Process Controller It also includes recommendations suggestions and hints as they apply to the circumstances under
6. wha AE ones Ou So mK A m SAE og j ja AES K a NIEZ acer a Y 6 If installing 8 or 16 channel Analog Output module set its DIP switch as follows Switch is located at edge of module marked SW1 e For internal rack power set DIP switch to ON e For external power 18 36V set DIP switch to OFF default Note 24VDC external power is required if using 6 or more 8 pt AO modules or 3 or more 16 pt AO modules A small slotted screwdriver or paperclip works well avoid using pencils 84 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 7 If installing a PFQ module set its Input 1 Input 2 and Index DIP switches to differential or single ended mode Inputs mode need not match index mode See below for switch positions Switch location on PFQ module Honeywell SW1 lt a INPUT1 4 SW2 INPUT 2 SW3 INDEX on gt see Settings using Input 1 as example Single ended factory setting ON OFF IN1 Cas DIFF _ coe LIN SINGLE fs IN 1 and 2 SINGLEGAQN 3 and 4 DIFF OFF Differential ON OFF IN1 QFF 3 and 4 DIFF ON Revision 2 1 January 2014 HC900 Process
7. One of the following remote I O conditions exist Communications between the CPU and a Scanner 2 is failing Scanner 2 is unable to communicate to a module or a wrong module is installed A module in the O rack is reporting a diagnostic C75 and Scanner 2 firmware versions are incompatible Scanner 2 O rack or power supply is defective C75 module is defective Abad channel has been detected on one of the modules 1 Associated blocks set their fail pins on their warn pins off and their output pins to the failsafe value 2 Associated blocks set their IO statuses to either Channel No Comm if the module cannot be communicated to or a message indicating the bad channel condition 3 Associated rack monitor block s module fail pin is turned on 4 Associated rack monitor block s RACK OK pinis turned off 5 ASYS and FSYS blocks HW OK pins are tumed off Locate the Scanner 2 that has a status LED indicating a diagnostic and follow the scanner 2 diagnostic section to solve the problem See the associated rack s Rack Diagnostics Overview display for details regarding the diagnostic See Rack Diagnostics dialog box Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 173 Diagnostics and Troubleshooting Controller CPU indicators Number of Red Strobes Possible Causes Lead an
8. e Screen items on The Operator Interface connected to the galvanically isolated RS 485 port See Operator Interface manual 51 52 25 108 A PC with Designer Software Process Control Utilities connected to the controller module via the RS 232 Converter or the Ethernet 10Base T Open Connectivity port See the Diagnostics section in the application s help Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 167 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Controller CPU indicators Figure 89 LED Indicators on Controller CPUs See Table 26 168 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Table 26 LED Indications on Controller CPUs CPU Figure LED LED State Color Description model 79 item All models 1 Controller Status Off No power Solid Red Failed Blinking Yellow Failed Blinking Red Diagnostic Code refer to Table 27 Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode while Flash RAM programming All models For legacy systems RS 232 RS 485 S1 port 2 For new systems RS Yellow Green Yellow when transmitting green when 485 S1 port receiving XMT RCV All models For legacy systems RS 232 RS 485 S2 port 3 For new systems RS Yellow Green Yellow when transmitting
9. Controller configuration which includes entry of an IP address and a Subnet Mask and a Controller Name for each controller The Controller Name is used only by the Honeywell proprietary software for network access between controllers it should not be confused with a Network Domain Name or Workgroup Name Peer Data Exchange PDE function blocks which are included in the control strategy configuration file PDE function blocks include PDE Control PDE Write and PDE Read Refer to the HC900 Process Controller Function Block User Guide for additional information An illustration of HC900 Controller Peer to Peer on a Local Area Network LAN is given in Figure 19 Typically a Router is used for interconnection to another network LAN WAN or other However Peer controllers must all be on the same subnet For additional details refer to the HC900 Process amp Safety Controller Safety Manual i PC Host F awe g Devices Configuration File Configuration File Function Blocks 1 Function Blocks PDE Read PDE Read PDE Write PDE Write PDE Control PDE Control Figure 19 Modular Network Structure 34 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Ethernet Open Connectivity Network Connection to PC Hosts For legacy systems connection to PC hosts for example PCs that include HMI supervisory software and or Designer So
10. Legend External F Disconnect cii User Supplied Safety Devices Figure 53 DC Input Module Wiring Diagram 100 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Jumper either 10 12 mag or 9 11 Connect any of 9 to 12 to DC Figure 54 DC Input Module Jumper Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 101 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 32 point DC Input Module Wiring The 32 point DC Digital Input module Figure 55 provides two groups of 16 inputs each with a pair of terminals for connection to common DC power applied between the common terminal and an input cause the input to turn ON A green LED on the module provides indication of an ON state Logic in the controller allows the state to be inverted when necessary Requires Low Voltage Euro style 36 terminal terminal block BOWIOMOMOIS O O O P O oS Ow he 9 BOOS Legend c2mai Figure 55 32 point DC Input Module Wiring AC Input Module Wiring The AC Input Module has sixteen inputs An example of AC Input Module wiri
11. Universal Analog Input Wiring Diagram v AO J DDS V WY Oe 90 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams suuasaummsey RTD 3 Wire Input omy k Tasu w F IN 1 D Search gta D RTD 3 Wire Ce ey len 1 amp 2 EEI ont precenene IN2 D be aa j p n 5 i EEEE No Ean s 0 OK bo 38 4 oo oa out D IN 5 2 k lew 5 amp 6 S 7 RTD 3 Wire aia IE Input aa L S wee ai ee IN7 lt mr ben 7B F ad 7 po ina 0 n g Jumper RTD 2 Wire il Input Figure 44 Examples of RTD Input Wiring Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 91 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Thermocouple Inputs 0S9 CD DOOS OG BYOSIOOD Odo Shield Ground typical s e P5 Figure 45 Analog Input Wiring Eight TCs 92 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Thermistor Inputs F W Shield Ground typical
12. Note Consult your service provider for availability of access to network local cable or DSL in your area Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 37 January 2014 Components and Architecture Ethernet Open Connectivity Network HC900 Controller LAN i Legend Ethernet 3 Router Cable Modem p gt Controller I 4 Figure 21 Typical installation using a Cable Modem sesapo 38 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems Overview SHIELD TX RX gt TX RX Figure 22 Controller Serial Ports e For Legacy systems the S1 default setting is RS 232 S2 default setting is RS 485 Each port can be set to RS 232 or RS 485 see page 40 For RS 232 cable connections see page 130 For RS 485 connections see page 148 e For new systems either of two ports S1 and S2 can be configured as RS 485 For SIL applications communication cable shield connection must be made to IO grounding bar instead of the connector shield connector e Ports configurable as ELN default or Modbus RTU e Controller can act as Modbus master or slave
13. Specification C30 C50 C70 C75 Combined Analog and Digital I O 384 points 1920 points 1920 points 1920 points Analog Inputs 142 points 960 points 960 points 960 points Analog Outputs 40 points 200 points 200 points 200 points Block inputs Quantity based on available memory Block parameters Quantity based on available memory Block values 375 000 375 000 375 000 375 000 FDB worksheets 20 20 40 40 Function blocks 400 2000 5000 5000 Local I O Yes Yes Yes No Loop blocks Quantity based on available memory Modbus registers used by slave blocks 1024 1024 1024 1024 Modbus slave blocks 32 32 32 32 Numeric constants Quantity based on available memory Page connectors 200 1000 2500 2500 Peer blocks 32 32 32 32 Peer data exchange items 2240 2240 2240 2240 Position proportional output blocks Quantity based on available memory Profiles in Pool User Configurable Ramp blocks Quantity based on available memory Recipes in Pool User Configurable Redundancy capability No No No Yes Redundant host comms No No Yes Yes Schedules in Pool User Configurable Segments per profile 50 50 50 50 Sequencer blocks Quantity based on available memory Sequences in Pool User Configurable Setpoint programmer blocks Quantity based on available memory Setpoint scheduler blocks Quantity based on available memory Signal tags Quantity based on available memory Soft Wire bytes Quantity based on available memory Stage blocks Quantity based on available memory Steps per schedule 50 50 50 5
14. ces ceeeeseccssceceseeesseeesseeeesneessaeeesaeessseeesaeeesaes 187 Figure 93 Terminal board Connections for AO Calibration ccc cceseeseeceseceseeeeseeeeseeeesaeeesaeessaeessaeessaeeesaes 188 Figure 94 Extended Distance Example 1 o ceeceescccescessseesesceeeseeeeceeesneecsaeessaeessaeecsaeecsaeecsseeseeesesaeeesaeessas 209 Figure 95 Extended Distance Example 2 0 ccessscssssecescecsseeceseecescecesaeersnecesaeessaeesseeecsaeecsseessaeeseeeeesaeeeses 210 Figure 96 Example installation not shown 2 RTP amp cable for high capacity AI DI DO csccesceseeeees 211 Figure 97 Analog input termiinal sisc0 1sc4 dec feeds renia sl eaed eecadalea Ain aE TEREE T 214 Figure 98 Two wire transmitter connections with common 24 VDC supply cesceeeseeceseeeeneeeeneeeeaeeeaes 214 Figure 99 Milliamp input connections with 250 ohm shunt resistance eceeeeeeseeeesneeeseessaeeseaeeesaeeesaeeesaes 215 Figure 100 Volt millivolt input CONMECTIONS cee eeseeeeseeesseeceseeesseeeesaeecsaecesaeeesaeeesaeecsaeecsaaesseessnaeeeeaeesnas 215 Figure 101 Three wire RTD input CONNECTIONS eee eeeeceeseeeseeeeseeceseersaeessaeessseeesseecesaecsseesseeeesaeestaeeesaes 216 Figure 102 Two wire RTD or ohm input connections ee eee eeseeeneecsneeeeeceesaeeeseeesseecesaecsaeceseeeesaesesaeeesaes 216 Figure 103 Slidewire feedback connections for aCtUatOTs eescee
15. Cable Wiring Distance Planning For all installations observe the following guidelines Maximum length of RS 232 cabling Controller to PC is 50 feet 15 2 meters Maximum length of RS 485 cabling is 2000 feet 609 6 meters For Ethernet connections cable length must be less than 100m For greater than 100m a switch is required The use of Ethernet cables in excess of 100 meters and or devices other than recommended Switches will cause transmission delays on the I O link which could have adverse affects on Controller performance You can also use fiber optic cable for connections between the controller and a remote rack Distances up to 750m 2460 ft can be accomplished with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint See page 209 With redundant CPUs when using 2 or more I O racks an Ethernet switch is required between each CPU and the I O racks Use Honeywell approved switches only see page 209 Maximum of 2 switches between each CPU s I O port and all I O racks Cable lengths specified in this manual are absolute When planning for routing of cables and wires be certain to include vertical and horizontal routing within cabinets raceways and conduits It is advantageous to minimize length of I O wiring However it is also a good idea to locate racks and wiring away from adverse environmental conditions such as sources of RFI EMI and away from are
16. Form A relays 116 Form C relays 116 Fuses 113 Fusing 116 G ground voltage potential 78 grounding bar 78 grounding bars 67 Grounding lug 24 H Hardware and wiring considerations for safety configuration 60 HC900 Process Controller 8 Heat Rise De rating 50 HMI 35 Controller Module Diagnostics 170 Hub 31 Controller Name 34 Controller Rack 20 custom graphics 36 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 251 January 2014 INDEX Analog Input Digital Input Digital Output Analog Output I TO channel numbers 76 T O Expansion Network C50 CPU only 31 TO Expansion Network C70R 32 VO expansion port 27 28 VO Expansion Rack 22 T O expansion rack assembly 72 VO implementation 32 VO Installation Procedures 81 VO Module Diagnostics 181 TVO Module Installation 1 57 65 75 T O numbering assignments 32 TO rack address 73 VO slot 75 TO Wiring 88 TO wiring shields 78 Input Output Modules 28 Installation Tools 63 Intellution 36 IP address 34 El 125 E2 125 kp 89 isolation capacitor 78 IT networking professional 30 J jumper 82 Jumper Comb 99 103 109 113 117 Jumper Combs 79 jumpers 32 K Kepware 36 key tabs 82 L Label 81 labels 76 LAN 34 LED Indications on Ethernet Hub 183 LED Indications on I O Module 180 LED Indications on Main CPU 169 LED Indications on Scanner Module 176 LED Indicators 176
17. lithium battery 26 Local Area Network 34 M Master Control Relay 58 Modbus mapping structure 36 MODE switch 157 Mode Transitions 157 Model number compatibility 7 Modem 134 135 136 Module Placement 75 Module Wiring 88 mounting racks 66 N Null Modem Cable 130 O OFFLINE Mode 155 OHMs Inputs 89 OPC 36 OPC server client software 36 Open Modbus TCP protocol 36 Operating Characteristics 151 Operating Modes 151 operator interface connect to controller 127 P Parallel processing 11 PC hosts 35 PC Hosts 35 PC Modem Cable 131 PDE 34 Peer Data Exchange 34 Peer to peer communication 34 Personal Computer 29 PlantScape Vista Software 36 Power DOWN 151 Power Down Power Up 151 Power Status Module 22 23 Power Supply 24 68 69 71 Power transitions 151 Power UP 151 PROGRAM Mode 154 PV Input Types and Ranges 205 208 210 252 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Analog Input Digital Input Digital Output Analog Output R rack address for I O 73 Rack Dimensions 46 rack installation 63 rack mounting 66 Rack Options 23 RAM 151 Redundancy Switch Module RSM 10 21 27 Redundant 2 systems w PC supervision 144 C7OR controller module 26 components 18 controller rack 21 Controller Rack components 21 default gateway 37 Ethernet connections 141 example of single process 10 failover 164 fe
18. 40 500 F Pt1000 50 752 F 121 JIS100 200 500 C JIS 200 500C 78 JIS100 328 932 F JIS 328 932 F 79 JIS100 200 260 C JIS 0 100C 72 JIS100 328 500 F JIS 32 212F 73 Cu10 20 250 C Cu10 20 250 C 84 Cu10 4 482 F Cu10 4 482F 85 YSI405 10 37 8 n a YSI405 50 100 n a Ohms 0 200 Ohms 0 200 86 Ohms 0 500 n a Ohms 0 1000 n a Ohms 0 2000 Ohms 02000 87 Ohms 0 4000 n a MA 4 20 mA 4 20 100 MA 0 20 mA 0 20 99 MV 0 10 mV 0 10 88 MV 0 50 mV 0 50 92 MV 0 100 mV 04100 95 MV 10 10 mV 10 10 89 MV 50 50 mV 50 50 93 MV 100 100 mV 100100 96 MV 500 500 mV 500 500 98 V 0 1 V 01 101 V 0 2 V 02 103 V 0 5 V 05 105 V 0 10 V 010 108 V 1 5 V 15 107 V 1 1 V 1 1 102 V 2 2 V 2 2 104 206 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications General Specifications Type Range Range High EU Reference Corresponding Low UMC800 Input type and range V 5 5 V 5 5 106 V 10 10 V 10 10 109 Carbon 0 1250 mV n a Oxygen 30 510 mV n a Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 207 Specifications System Sizing and Availability Summary System Sizing and Availability Summary Table 42 System Size and Availability Summary
19. 7 amp 3 2 ol 2 3 1 Signal Name Pin No Connection Signal Name Plug No DCD 1 None RXD 2 Connects to TXD TXD 3 Connects to RXD DTR 4 None GND 5 Connects to GND 1 DSR 6 None RTS 7 None CTS 8 None RI 9 None 130 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Rs 232 Remote Connection to PC Configuration Tool Legacy Controllers The Controller can also be connected remotely by a set of modems which are available from third party suppliers A Null Modem Cable is used between the Controller and the modem shown in Figure 76 and shown in Table 19 A second Null Modem cable is used between the PC and the internal or external modem at the other end as shown in Figure 76 This cable is Remote controller access via dial up modem is available via the communication setup in the PC configuration tool All functions of the Designer Software configuration tool can be performed over this link Remote access functions include on line monitoring configuration upload and download and firmware upgrade PC Configuration Tool Controller RS 232 Port TAE Null P Modem a p Cable Null Modem Cable ee Modem Cable _ Telephone Cable FR Figure 76 RS 232 Remote Access via Modems Revision 2 1 HC900 Process amp Safety Controller User and Installation
20. AC Input Module Wiring 102 AC Input terminal block 24 AC Output Module Wiring 112 Access See Controller access Alarm Groups 37 Alarm Event messages 37 Analog Calibration 185 Analog Input Calibration 186 Analog Output Calibration 188 Analog Output Module Wiring 96 Appendix Installation of Remote Termination Panels RTPs 211 ASCII 35 B backplane 69 75 barrier style 76 Barrier style 28 Battery Installation 70 71 196 Battery Installation Replacement 70 71 Battery Replacement 198 C C30 C50 controller rack assembly 68 C7OR controller rack assembly 71 Cabinet Wiring 54 Cable length 52 cable segment 31 Cable Type 124 Cables how to make shielded CATSE 53 captured screws 75 CE Conformity 57 Cold Start 151 COM 1 29 Communications Installation 123 Contact Input Module Wiring 107 Controller access how to access via serial port when port settings are unknown 157 Controller Modes 154 Controller Module 26 INDEX D DC Input Module Wiring 99 DC Output Module Wiring 108 Designer Software 29 Diagnostics and Troubleshooting 167 Distance planning 52 Download Upload 159 DSL 37 E E Mail 32 E Mail Communications 37 Emergency Stop switches 58 enclosure 54 equipment enclosures 49 Ethernet Devices 30 123 Ethernet Open Connectivity Network 30 32 Euro style 28 76 Event Groups 37 F Field Signal Wiring 77 Filler Block 88 Flash 151
21. CPU in the Lead CPU Diagnostics timeout When the microprocessor 1 Ensure the system is properly oe In te Tead S Aides iior completes its reset condition twill grounded display Diagnostics become an available reserve if a If the reserve s Overview dialog e Prefetch error leadis present or become aleadif 2 Ensure the system is properly status LED is box e Data abort error noleadis present isolated from extemal noise sources indicating the If the reserve s e Software interupt This diagnostic will cause the 3 Upgrade the firmware failure see CPU in status LED is HWOK pins of the AYSY and FSYS 4 Replace the CPU board the Reserve CPU indicating the e Undefined blocks to be turned off H IP Diagnostics failure see CPU instruction error 5 Contact Honeywell Personnel display Diagnostics in the Reserve Diagnostics Overview dialog box 3 One of the exception The exception vector was vectors located in RAM automatically corrected in the became corrupted controller s RAM and the controller continues to operate normally This diagnostic will cause the HWOK pins of the AYSY and FSYS blocks to be tumed off Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 171 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of
22. Communications Low voltage e Low voltage alarm relay output wiring lt 50 Vdc Vac e Low voltage wiring to solid state type control circuits Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 57 January 2014 Pre Installation Planning Electrical Considerations Master Control Relay A Master Control Relay MCR structure is a safety mechanism for shutting down the process control system in emergency conditions This mechanism which is hard wired provided and installed by the User can include several Emergency Stop switches strategically located near process equipment An example of an MCR structure is given in Figure 32 Operating any of the Emergency Stop switches opens the holding path for the MCR When the MCR de energizes the MCR contact opens disconnecting all AC power that is supplied to AC Input Modules and to AC Output Modules Notice that AC power is disconnected only from the AC input output modules Power is still available to Power Supplies at the Controller Rack and at each I O expansion rack The Controller Module and the Scanner Modules in the racks continue to execute diagnostics and other programs Ay WARNING Ay The Master Control Relay does not remove power from the Controller rack or from any of the I O expansion racks e Before performing service tasks such as installation of terminal connections or fuse replacement use the appropriate switch s to disconnec
23. Controller Module 4 Grounding bars for I O wiring optional 5 Input Output modules 6 I O Terminal Blocks Figure 6 Controller Rack Components 20 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Hardware Components HC900 Redundant Controller Rack A HC900 Redundant Controller is shown in the following figure 1 Rack 2 Redundancy Switch Module RSM Interface between Lead Reserve controllers 3 Lead Reserve controllers Two C75 CPUs designated CPU A left CPU B right 4 Two 900P02 0001 Power Supplies Figure 7 Redundant Controller Rack Components Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 21 January 2014 Components and Architecture Hardware Components I O Expansion Rack T O expansion remote racks shown in Figure 8 are available to accommodate additional input output modules and or to enable location of I O modules close to the process and remote from the controller For C75 C7SS all I O is in a rack or racks separate from the controller rack An I O expansion rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3 Scanner 1 Module S50 S50S shown or Scanner 2 Module S75 S75S 4 Grounding bars for I O wiring optional required for safety applications 5 Input Output modules 6 I O Terminal Blocks 7 Power
24. Figure 46 Analog Input Wiring Eight Resistance Inputs Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 93 January 2014 94 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Resistance Temperature Device Inputs 4 H H i H Shield Ground typical Figure 47 Analog Input Wiring Eight RTDs HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Slidewires OGOOG Cias OQ OOOO 5 s 13 Figure 48 Analog Input Wiring Slidewire Position Proportion Block Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 95 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 16 point High Level Analog Input Wiring Figure 49 Be sure to set the module DIP switches for voltage or current mode See page 84 This requires Low Voltage Euro style 36 terminal terminal block OHOOO Q000 IOO QOC 4 20 mA Input YOQ OWIGQO OG OK ooo 5 OCOOQOQOOG Figure 49 16 point High Level Analog Input Wiring 4 channel Analog Output Module Wiring An example of Analog Output Module
25. T INOTWOMK 2s seme Sens Safe hcer ace Seat aheecce Mire E E E maga naigs ge ctines canuuadisierenteenelsaeagdetes 31 Ethernet Open Connectivity Network ccececeeeeeeeee eee eeeeeeee rete eee eeecceee sete eee eecccaaeeeeeeeegeeaaaeeeeeeenenee 32 Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for MNEW SYSLOMS AATE ee eg Beat te RS Baek Mah ON cD ETA 39 Pre Installation Planning occas veysccos sex ee tencenedses see encacesecenaceyeees nce ces soe aceeguseeet ease eeeceeeiens 43 E A EEE ee ett thle tatatttets tok At seal tent tual tens otas Coast cgs rte ora mtn cua chelate oh 43 AC Power Supply Selection for racks with I O ecccceeeeeeeeeeeeeeeeeeeeeeeeeeeececceeeeeeeeeetececaeeeseeeeneeeaaaes 44 DG Power Supply 3 2 23 sawiiet a a aa a a a ete ene eee 46 Rack Orientation and MOUNTtING cccceeeeeeeeeeeeee etree eee ceeeee eee e eee ecenaeeeeeee ee eneaaeeeeeeeeeseeecaaaeeeeeeenneee 46 Remote Termination Panels c cccccecceeeeeeeneeeeeeeeeeeeeeeaeeeeeeeeeteeeaaeeeeeeeeenecaaaaeeeeeeeesgescaaaeeeeeeeenenees 48 Environments 7 23 0 2 2 PRR ARR RRS Ae a eh ee a Jae aed A 49 Heat Rise De rating xivicckes anaa a aranan eraa aa tea eens vecterdet kip morania iahon hA a Tea aaah 50 Cable Wiring Distance Planning c ccccccceeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeccaeeeeeeeeeesecaaeeeeeeeeeeeessaeeeeeees 52 Electrical Considerations aae a TEA doe aie a Saas Aaa D
26. peo meern module type ANALOG WHITE OAR GREY TEXT eure se ee YELLOW DARK GREY TEXT 2 Place the appropriate label supplied with the module tagname side out into the hinged door for each I O Module Slotted tabs molded into the door at top and i i DE EN bottom hold the label in X 7 i in MODULE RIAD place em POWER BEFORE T gt SERVICING Term No IN1 1 N1 2 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 81 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 3 Optional Install jumper we bas combs into designated RAS G ripu Barrier style Terminal Blocks to reduce the wiring required to supply pogga power IS a Two position jumper for l the DC Input Module and or on the DC Output j 2 a Module S Ten position jumper for i the AC Output Module i eee 5 I5 Five position jumper 10 E position jumper cut in half j pms for a Relay Output i Module z Refer to terminal block wiring diagrams for specific information 4 For each configured and 120 240 VAC labeled I O Module break 125 VDC IN off the key tabs in the pattern that identifies each module type For a diagram of each key tab pattern use the I O Modules and or the diagram shown next page 4 3 3
27. relay sources power Figure 35 Common Series DO connections Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 61 Pre Installation Planning System Monitor Function Blocks Internal 24VDC 24v Supply Relay Output 900H01 m AO 4 900801 AO 8 900B08 be o a i AO 16 900816 External 24v Supply Al 8 900A01 AO 8 900B08 Validation channel in or Al 16 AO 16 900B16 parallel with Load 900A16 Al 8 900A01 A A orae 900416 Use of Internal supply requires Hee of Externa ee one relay per Analog Output See ee nog see Output External Internal 24VDC 24v Relay Output B a J AO 4 900B01 900H01 AO 8 900B08 AO 16 900B16 P AO 8 900B08 d 1 ae AO 16 900816 Al 8 900A01 Validation channel in S 900A01 Al or Al 16 series with Load a ake 900A16 LOAD LOAD Figure 36 Series Relay for Analog Outputs System Monitor Function Blocks The HC900 Controller includes function blocks that enable the user to monitor the status of system functions When constructing a control configuration consider adding the following monitoring function blocks to the control strategy e ASYS System Monitor e FSYS Fast System Monitor e RK Rack Monitor e FMON Fault Monitor These function blocks are described in the HC900 Function Block Reference Gui
28. the last good known position prior to THE PROPER STATE PRIOR TO he failure INSERTION 2 TheRSMswich Melale are l position is invalid If failover occurs the new lead will 2 If the key is installed in the RSM assume the mode prior to failover remove it to make sure the switch is 3 The lead and until a good switch reading is seated properly If the key does not on a acquired pull out tum it slightly to the proper aaah If after the power is cycled to both position until it can be removed the lead and reserve and the lead is 3 Replace the RSM paar ieena eee ion wi the run program mode of operation gt Replace lead CPU This diagnostic will cause the 6 Replace rack HWOK pins of the analog and fast logic System Monitor blocks AYSY and FSYS to be turned off 170 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indication Utilities Indication Strobes 2 There are slave blocks e MSTRFAILpins on ASYS and_ 1 Use the Ol HCDesigner or in the configuration FSYS blocks turn on HCutilities to configure one of the and no cea e All Modbus slave and Modbus serial ports S1 or S2 as a master PoE configured 2S read blocks freeze their output 2 Use the Ol HCD
29. 047 0 058 0 049 16 0 051 0 230 0 137 0 117 0 276 0 071 0 073 0 092 0 078 18 0 040 0 374 0 222 0 190 0 448 0 116 0 119 0 148 0 126 20 0 032 0 586 0 357 0 298 0 707 0 185 0 190 0 235 0 200 24 0 0201 1 490 0 878 0 7526 1 78 0 464 0 478 0 594 0 560 26 0 0159 2 381 1 405 1 204 2 836 0 740 0 760 0 945 0 803 30 0 0100 5 984 3 551 3 043 7 169 1 85 1 91 2 38 2 03 Table values are shown as a reference only actual values may vary Consult manufacturer specifications Isolation This module has eight inputs which are isolated except for RTD current sources RTD Inputs RTD inputs share current sources two RTD inputs per source as shown in 88 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Figure 42 Figure 43 and Figure 44 For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 Irrp 1 amp 2 This same current source Irtp 1 amp 2 is also used for an RTD input at channel two terminals 4 and 5 Figure 42 and Figure 46 show examples of RTD input wiring 2 wire and 3 wire RTDs Four wire RTD inputs are not available iiie p RTD 3 Wire Input i i RTD 3 Wire Input a Figure 42 RTD Inputs OHMs Inputs Ohms inputs are wired similar to 2 wire RTD inputs That is they require a current source and thus mu
30. 1 T i N3 5 IN4 ay a y pe ING E z IN7 ra INB as 5 ES COM COM ae si COM COM D COM COM COM COM NG EE S IN 10 a gt H i n IN 12 D Ms IN 14 lt IN 15 wa Aye Figure 59 Contact Input Wiring Diagram DC Output Module Wiring The DC Output Module provides 16 current sinking outputs in two groups of eight points per group The two groups are isolated from each other outputs are non isolated within each group Current sinking means that a positive voltage potential is continuously applied to one side of each DC output load and the negative side of the load is switched internally in the module SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Specifications for this module and for other modules are given in the Specifications manual Examples of DC Output wiring are shown in Figure 60 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 108 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Reverse Polarity Protectio
31. 140 32 to 140 40 to 158 C 25 3 0 to 60 0 to 60 40 to 70 Ambient Relative 45 to 55 RH 10 to 90 RH 5 to 90 RH 5 to 95 RH Humidity non condensing non condensing non condensing non condensing Mechanical Acceleration 0g 1g 1g Not rated Duration 0 ms 30 ms 30 ms Vibration 0 Hz 0 Hz to 14 Hz 0 Hz to 14 Hz 0g amplitude 2 5 mm amplitude 2 5 mm peak to peak peak to peak 14 Hz to 250 Hz 14 Hz to 250 Hz acceleration 1 g acceleration 1 g Applies up to 40C 204 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications General Specifications Table 41 HC900 PV Input Types and Ranges Type Range Range High EU Reference Corresponding Low UMC800 Input type and range None n a B 18 1815 C B 40 1820 C 58 B 0 3300 F B 104 3308F 59 E 270 1000 C n a E 454 1832 F n a E 129 593 C n a E 200 1100 F n a J 18 871 C J 200 870C 4 J 0 1600 F J 328 1598 F 5 J 7 410 C J 0 400C 2 J 20 770 F J 32 752F 3 K 18 1316 C K 01200C 16 K 0 2400 F K 322192F 17 K 18 982 C K 0 800C 14 K 0 1800 F K 321472F 15 K 29 538 C K 0 400C 12 K 20 1000 F K 32 752F 13 Ni NiMo 0 1371 C NiMo 01400C 50 Ni NiMo 32 2500 F NiMo 322552F 51 Ni NiMo 0 682 C n a Ni NiMo 32 1260 F n a NiMo NiCo 0 1371
32. 4 Oul S No memes DUE No Form A Mo Ques COM em Oul 5 COM Form A k Ours No Outs No o f Cure CO ul COM Owe Na Oul 7 Cary Out Cam Out 7 Notam ma a a a a mn DEANE n AN Form Sue Ne oO O LOAD 8 Ouh No Oul 6 Ne N O om Sem om Tom Out Ne Dusa No P Form c o o Legend Exeral A Disconnect User Supplied Safety Devices Figure 66 Relay Output Module Wiring Diagram Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 117 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Relay Output Module One half rd 10 position j jumper QO AA AAN To Relay Loads via external disconnect a switches fuses 30 Vdc mana attt teen S either 1 GBADAOQODOCOO Figure 67 Relay Output Module Jumpers Pulse Frequency Quadrature Module Wiring Figure 68 through Figure 74 The 4 Channel Pulse Frequency Quadrature Module provides four different functionalities in the form of Pulse Input Frequency measurement Quadrature encoder input and Pulse Output Each of the 4 channels can be configured for any one of these four functionalities with the exception that quadrature encoder input A and B pulses can be applied to only Channels 1 and 2 respectively When configured for quadrature Channels 3 and 4 will still be ava
33. 5 Ensure that you set the S1 S2 and RS 485 terminal dip switches as applicable 6 Ensure that the new Controller Module is properly aligned with the slot guides insert the new Controller Module in the rack and secure it in place with the captured screws at top and bottom of the module 7 Re install communications cables 8 Using the user supplied switch re connect site AC power to the rack 9 If using the Ethernet port for configuration use the Designer software to set the proper network address 10 Download the configuration 11 Set the Real Time Clock 12 If all status indications are green power may be restored to the I O modules per the application s procedures 192 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Replacing the Scanner Module Removing and replacing the Scanner Module from an I O expansion rack C50 C70 C75 CPU controllers only requires that the source of AC power is removed from the rack Removing power from the Expansion rack has the following consequences e All power to all I O modules in the rack will be lost hence all control outputs from the rack to the process are lost e Redundant controllers will operate with the affected I O in failsafe state during Scanner2 module replacement e Does not impact other I O Racks in the same configuration Table 3
34. Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 9OORTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 8 point AC DO label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 2 3 Set verify jumper positions as shown EE _ Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 234 for RTP internal schematic 232 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point AC Digital Output Connect field wiring CAUTION S L1 terminals in the wiring figure below are live when switch SW1 is on 1 L1 L2 Note AC Outputs are individually fused in the module but adding a fuse here protects the wiring Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 233 Janua
35. Cover 900TNF 0101 Yes Analog Input Remote Terminal Panel 900RTA L001 No Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 5 January 2014 Introduction Model Selection Guide RTP Relay Output Remote Terminal Panel 900RTR H001 No RTP DI DO AO Remote Terminal Panel RTP 900RTS 0001 No Power Supplies 120 240 VAC 60W 900P01 0201 Yes 120 240 VAC 28 W 900P02 0201 Yes Redundant Power status module 900PSM 0101 Yes Redundant Switch module 900RSM 0101 Yes Conventions Throughout this guide where the text Legacy systems is used the following model numbers are applicable e Legacy systems Model Numbers 900C51 00XX 00 900C52 00XX 00 900C31 00XX 00 900C32 00XX 00 900C71 00XX 00 900072 00XX 00 900C71R 0000 XX 900C72R 0000 XX 900RSM 0001 900C73R 0000 XX 900C53 00XX 00 Throughout this guide where the text New systems is used the following model numbers are applicable Note Model number change 900 xx where if C designates Controller module and S designates Scanner module e New System SIL and Non SIL Model Numbers 900C30 0360 00 900C50 0360 00 900C70 0360 00 900C75 0360 00 900S75 0360 00 6 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Model Selection Guide 900S50 0
36. DC current and voltage field wiring 22 DC current and voltage wiring in control room Routing and Securing Wires Typically field wiring is routed to connections at a terminal panel near the controller and then from the terminal panel to the terminal blocks on the I O modules Whatever method of routing is used wiring must be mechanically supported along its length and must be protected from physical damage and electromagnetic noise interference See Electrical Considerations page 54 Also all wires must be securely terminated using appropriate wiring practices Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 77 January 2014 This page is intentionally left blank I O Module Installation and Wiring Terminal Block to Field Signal Wiring Signal Grounding Figure 39 Low Frequency Shield Noise Rejection wire The shield for each input should be grounded at the grounding bar optional at the top or bottom of each rack as indicated in Figure 40 For low frequency noise rejection I O wiring shields should be grounded only at the controller end For high frequency noise rejection shields should be grounded at the controller and at the field device If the ground voltage potential at the field device is different from that at the controller a DC isolation capacitor High Frequency should be used between the shield and the Noise Rejection grounding bar on
37. Identification 16 character tagname 16 character descriptor 6 character units of measure analog only 6 character on off state digital only Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 201 Specifications General Specifications Communications C30 C50 C70 C75 Network Communications Ports Number of Ethernet 1 1 2 2 10 100Base T connections Ethernet 10 100Base T RJ 45 connection Max number of concurrent Ethernet host connections Supports Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Initiator Peer to Peer and Designer Software configuration software Supports redundant Modbus TCP Protocol to PC supervisory and data acquisition software packages OPC server Modbus TCP Initiator non redundant Peer to Peer and Designer Software configuration software Up to 5 peer data exchange does not consume a host connection Up to 10 shared between two ports peer data exchange does not consume a host connection RS 232 Port Ports per controller Baud rates Modem RS 485 with Modbus RTU or Honeywell protocol 3 Plug connectors supplied 1200 2400 4800 9600 19 2K 38 4K 57 6 K 115 2K configured by Designer software or Ol For remote connection to Designer software requires external modem at controller 1200 baud to 57 6KB Galvanically Isolated R
38. Install 32 point DC DI label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 2 Mount RTPs to DIN rail e Latch to rail See page 247 e Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 16 RTP B to Inputs 17 32 You can write on the RTPs labels to distinguish them 3 C Om Cm CO See page 246 for RTP internal schematic 244 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Input Connect field wiring RTP A for inputs 1 to 16 RTP B for input 17 to 32 rene D Install jumper wires DC Supply Note SDC refers to switched positive side of the DC supply Note Terminals 9 and 11 DC are connected through the RTP cable Same for terminals 10 and 12 DC Revision 2 1 HC900 Process amp Safety Controller User and Installation Man
39. Lead and Reserve Controllers execute the function blocks in the control strategy but only the Lead Controller writes the physical outputs to the I O Racks See e Figure 88 e The Lead and Reserve controllers exchange system status to determine conditions for failover Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 163 January 2014 Redundant Operating Characteristics Failover Lead Controller Reserve Controller Get Inputs Get Inputs SYNC SYNC Control SYNC Control SYNC Execute Control Strategy Execute Control Strategy Write Outputs Diagnostic Check Diagnostic Check Communications Figure 88 Lead Controller synchronization Failover Automatic Failover e Triggered on any of the following conditions of the Lead Controller Loss of communications with I O Rack s Processor exception conditions e Error conditions that occur in the following areas will not cause a failover Loss of communications to a Host on a network Loss of communications to Modbus Slave devices Loss of communications to Operator Interface Loss of communications with a Peer controller e During the transition from the Lead to the Reserve analog and digital output status is maintained at the T O racks 164 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Redundant Operating Characteristics File Download Upload Functions Manual Failover
40. Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Overview Diagnostics and Troubleshooting Overview The HC900 system incorporates a comprehensive set of diagnostic tools that test hardware and software operation Diagnostic software elements are contained in each system component The diagnostic elements that are executed at any given time depend on operating conditions such as current operating mode and the current status of hardware and software As long as power is applied each major component of the controller will execute one or more diagnostic elements Diagnostics have two functions they e Automatically alter system operation to react appropriately to operating conditions particularly in the event of a system fault e Provide external indications that enable operating and maintenance personnel to react appropriately when external actions are required External Indications of Diagnostic Information The following diagnostic indicators are provided e Light Emitting Diodes LEDs included in controller hardware Locations of LEDs are shown in the following figures and tables The LEDs are useful when personnel are performing troubleshooting activities solely at the controller Also they are useful for verifying indications viewed as screen items LED indicators See page Controller CPU indicators 168 Scanner indicators 176 I O Module Indicators 180 Ethernet Switch indicators 183
41. O module has a i Loss of control or view of Specific function Any or all of the Using trained personnel and ar nnind process signals may be vital for safely appropriate control mechanisms gp controlling a process transfer to manual control for each signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON HAZARDOUS 80 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures I O Module Installation Procedures Table 14 Connect Input Output Wiring Step Procedure Comments Reference 1 Using Rack Slot Channel data from a Designer Software report select Label fill in the tag names on the ergs Label for each configured P I O Module Module slot tagnamen 77 position should take heat de rating into account See Heat Rise De rating page 50 120 240 VAC z INPUT 16 PT ORANGE WHITE TEXT GREEN WHITE TEXT CONTACT a eee RED WHITE TEXT CTAA O PFQ GREEN WHITE TEXT Be sure to use the a DARK BLUE WHITE TEXT appropriate label for each RELAY
42. O racks 3 Control Station 900 Control Station operator interface Honeywell communicates via Ethernet or RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Serial Controller Module to a serial port on the PC software is from Interface i Honeywell RS 485 to option e For new system The PC Configuration tool USB converter is a third connects from the galvanically isolated RS 485 party device available port of the Controller Module using an external from Honeywell Honeywell qualified RS 485 to USB converter 5 HMI Human _ Optional PC link to Ethernet network which may PC is from third party Machine include other HMls other HC900 Controllers and supplier Interface other networks including Internet HMI software is Typically includes HMI operating software available from f Honeywell Experion May also include Designer Software configuration HS or SpecView32 or tool and utility software from third party supplier 6 Ethernet Required if using 2 or more I O Expansion racks Qualified third party 100Base T Provides connection of the I O Ethernet 100Base T devices available from Switch port on a Controller Module to the Scanner Honeywell modules Switch not required for connection to a single I O rack 6a Ethernet Enables inter connection of several 10 100Base T Honeywell or third part
43. RJ 45 port 3 Connect the other end of the Ethernet 10 100 Base T crossover cable to the PC s network port 4 On the PC use the Utilities Worksheet in the Designer software to connect to the controller over Ethernet Every HC900 controller is shipped with the default IP address of 192 168 1 254 and Subnet Mask of 255 255 255 0 You can use these network parameters initially for testing or configuration use In the Current PC to Controller Connection Settings area of the dialog box click on the Network button to bring up the Network Port Properties dialog box and Add the default IP address Be sure the Ethernet Network Interface Card in the PC has a fixed IP address on the same subnet as the controller 192 168 1 x where x 2 to 253 Note 900 Control Station uses IP 192 168 1 253 as default 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network z Device Name Honeywell HC900 Controller bd Address fi 92 168 1 254 z Er Q ki Statistics Protocol Modbus R TCP Speed bps N A PC Port Setup for Controller Access Network COM1 6 Consult your IT systems administrator for allocating IP addresse
44. Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Output Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 237 for RTP internal schematic Connect field wiring LOADS ARE 0 to 750 ohm RTP A for Outputs 1 to 8 9 and 10 RTP B for Outputs 11 to 16 9 and 10 2 gt 2 7 RO OOS a EXT 24V Install 24V wires as shown 22 to 10 4V RTN EATS 22 to 12 External 24VDC supply RTN r i Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 239 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP labeled DI DO AO RTP ASSY with jumpers J2 J9 is the correct one for 16 point Al Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect terminal block end of desired cable assembly to 16
45. Status Module PSM req d if using Reserve Power Supply 8 Reserve Power Supply optional Available in 8 or 12 slot racks Figure 8 I O Expansion Rack Components 22 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Hardware Components Rack Options Racks are available in 4 slot 8 slot and 12 Slot versions Racks are interchangeable between the Controller rack and an I O expansion rack and all three versions shown in the following figure are available for either purpose 8 and 12 slot I O racks can be modified with additional slots for optional Reserve Power Supply and Power Status Module Note You can install redundant power on any 8 or 12 slot I O rack 4 VO Slots 900R04 4 1 Power Status Module i req d if using Reserve Power Supply tee Optional Reserve Power Supply C75 Power Power C75 Supply cpu RSM CPU Supply Figure 9 Rack Options Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 23 January 2014 Components and Architecture Hardware Components Power Supply The PO1 Power Supply shown in Figure 10 provides 5 Vdc and 24 Vdc to the backplane connectors in the local and remote racks Power Supply is used in each Controller Rack I O expansion racks and for all rack versions 4 slot 8 slot and 12 Slot The lower capacity P02 power sup
46. T Port using Designer Software A field calibration procedure consists of two parts e Connecting a calibration device to each channel of an AI or AO module and e Using the Control Station HC Designer or HC Utilities to select actions and enter custom calibration data values calibration into the I O module This section contains information and instructions for connecting calibration devices A WARNING Hazardous voltages exist at the Power Supply and at the terminal boards on I O Modules Only trained and authorized personnel should perform the procedures in this section Failure to comply could result in death or serious injury H ATTENTION For calibration procedures refer to the Control Station manual or Process Control Designer manual Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 185 January 2014 This page is intentionally left blank Analog Calibration Overview Analog Input Calibration Analog input modules can accommodate five input types e RTD e Thermocouple e Ohms e Volt e milliVolt e 4 20 mA Not available on high level analog input modules Calibration values for each channel are stored in the module as numeric values paired with A D conversion counts corresponding to those numeric values The numeric values are those identified as REFERENCE on the OI or HCD calibration displays apply these values to the input terminals during the calibra
47. T cable to the Ethernet switch Connect an Ethernet 10 100 Base T cable to each HC900 controller s Open Ethernet RJ 45 port top RJ 45 port Connect the other end of each Ethernet 10 100 Base T cable to the Ethernet switch 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 Setting Up the Controller Network Parameters See the Designer Software Users Guide Doc 51 52 25 110 or respective HC Designer Help Files for setting up following network parameters e IP Address Subnet Mask optional Default Gateway IP Address optional e Network Name optionally used in Peer Data Exchange e Local Name optional user identifier for controller e E mail Server IP Address required if e mail alarms are configured H ATTENTION This setup will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current conf
48. amp Safety Controller User and Installation Manual 85 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 8 Connect wire tie into the top and or bottom of the Rack Form a bend in each wire to provide strain relief and secure the wire bundle with the tie Euro Terminal Block 86 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 9 Install I O modules in racks Be sure to follow placement guidelines under Heat Rise De rating W page 50 ah zA ae ga ag ad Be oS ga P ADP amp a a pa 6 D g 9 J G ke3 E ee me st obs ox i Te eee a ae e gt 9 o e A z al 10 Install I O module install appropriate terminal block Sheet ot ast GA ga ga Bo ae gai pi Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 87 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Step Procedure Comments Reference 11 In each slot location not Note The Filler Block Cover looks much like
49. and Replacement Procedures Safety Considerations PLAN AHEAD Replacing an I O Module CAUTION Read and understand all of the following information regarding RIUP before attempting to remove and or replace any I O module particularly in a system that is actively controlling a process All of the I O Module types in the HC900 Controller System include the Removal and Insertion Under Power RIUP feature That is while the rack is powered any of the I O Modules can be removed or inserted e With no physical damage to the module to the rack or to other modules in the rack e Without disturbing the functions of other I O modules in the rack or in the system Under carefully controlled circumstances this feature enables the user to remove and insert an I O module without completely shutting down a running system However it must be recognized that removing or inserting an I O module under power is potentially hazardous to property and to personnel Circumstances that dictate prudent actions depend on conditions and specific process applications at each user facility It is the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 37 provides some general guidelines for establishing appropriate procedures at a given installation Table 37 RIUP Potential Hazards and Recommended Action
50. are shown in Figure 86 PC Configuration Tool Ol 900 Control Station Operator interface Host device w PC Configuration Tool Legend Configuration Download Upload Figure 86 Pathways for Upload Download Transactions Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 159 Operating Characteristics File Download Upload Functions Configuration Download Configuration files include the items indicated in Table 25 Downloading of some items is mode dependent That is downloading of some file types is not permitted in the Run mode or in the Offline mode Table 25 Configuration file downloading Downloading of Permitted When Controller isin Configuration items PROGRAM Mode RUN Mode OFFLINE Mode Controller Configuration Files Yes No Note 1 No Setpoint Profiles Setpoint Yes Yes Schedule Recipe Files Yes Yes Data Storage Configuration Yes Yes Yes Files Data Storage Non volatile Yes Yes Yes parameters Note 1 Controller files can be downloaded with the controller in Run Mode with the Mode switch set to Run Program but not with the switch set to Run Lock The download from the host processor is directed to an area of controller memory separate from that used for running the controller and hence has no effect on the active process The host signals the controller when the download is complete and requests a confi
51. at Status LEDs of I O modules Other function NOT permitted AO calibration Note 1 The Off state of the module outputs are defined as e Digital output low state e Time proportional Output TPO 0 duty cycle e PPO and TPSC Outputs Both Fwd and Rev are Off e Analog output 0 0 mA Note 2 The Frozen states of module outputs are defined as e Digital output same state as previous last active state e Time Proportional Output TPO Same duty cycle as in last active state e PPO and TPSC Outputs digital outputs are Off to freeze the motor position e Analog output same current as previous last active current level 156 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Operating Characteristics Controller Modes Controller Mode Transitions Mode changes are controlled primarily by positioning of the MODE switch Figure 85 on the controller module or RSM and secondarily by selection of mode names on operator interface displays That is the Mode switch takes precedence In the RUN Locked position or in the PROG Locked position selecting a mode name at the operator interface has no effect on the operational mode In the RUN PROG position the mode may be changed from any mode to any other mode The effects of the Mode switch operator interface selections are described in Table 23 The effects on controller operation for each mode transition are described in Ta
52. between each CPU CPU A and CPU B and the I O racks Ethernet Open Connectivity Network The configuration of the Ethernet Open Connectivity Network varies with specific applications in purpose and in complexity In some applications configuration is straightforward and within the capabilities of experienced installation technicians In other applications for example those that include inter connection to other networks such as Intranet and Internet a working knowledge of networking is required The Ethernet Open Connectivity Network for a given HC900 Controller enables e Redundant Networks e Peer to peer communication e Connection to other PC hosts e Inter connection to other networks such as for sending Alarm Event messages via e mail CAUTION Communications lockout is possible in high network traffic conditions Extraneous traffic is possible when sharing bandwidth with other devices We recommend putting the controller on a private network segment Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled 32 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Ethernet Open Connectivity Network Redundant Networks Honeywell Matrikon OPC Server supports redundant networks Up to 10 connections may be distributed in any combination across the controller s 2 network ports E1
53. blocks fast logic blocks fast logic blocks 125ms for up to 3300 fast logic blocks Detection Failover Time from Lead to Reserve CPU N A Up to 4 analog scan cycles Run Mode Edit Transfer Time 3 normal scan times 1 5 sec typical for all configuration edits not including I O changes Operating Modes Run No configuration download in this position Run Program Download allowed Program Outputs Off initialization on download Offline mode is available via software selection for Al calibration 200 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications General Specifications Features C30 C50 C70 C75 Maximum user 400 2000 5000 configurable Function Blocks Maximum Control Loops Quantity based on available memory System Blocks Not user configurable 100 not part of 400 2000 or 5000 for Alarm Group blocks System block Rack Monitor blocks Communications Loop Outputs Current time proportional position proportional 3 position step motor positioning dual output heat cool Control Loop Types PID A PID B Duplex A Duplex B Ratio Cascade Carbon Dewpoint Relative Humidity On Off Auto Manual Bias Auto tuning Accutune III fuzzy logic overshoot suppression applicable to all control loops Setpoint Programmers Ramp Types Ramp Rate or Ramp T
54. communications The PC host can include software that closely relates to and supports controller functioning and can also include other software that is related remotely or not at all Closely related software can include Either Designer Software for generating and managing configuration files Or HMI Supervisory Data Acquisition Software or Operator Panel with Modbus TCP driver Or Both configuration and HMI software and or panel All communications between a controller and a PC host use Open Modbus TCP protocol whose widespread use is making it an industry standard Modbus TCP is basically an adaptation of the Modbus messaging structure that uses TCP IP for a message carrier In general Modbus messaging is available in two versions ASCII in which each eight bit byte is sent as 2 ASCII characters and RTU in which each byte is sent as two four bit hexadecimal characters Each Modbus message frame is embedded into a TCP IP datagram as indicated in Figure 20 Transaction Protocol Length Modbus Identifier Identifier Field Frame J l r 1 Function vaaress Functor paia checksum Figure 20 Modbus TCP Framing Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 35 January 2014 Components and Architecture Ethernet Open Connectivity Network The HC900 Controller uses either Modbus TCP or Modbus RTU not ASCII The fixed Modbus mapping structure for the HC900
55. e Via Key Switch on the Redundancy Switch Module in the Redundant Controller Rack When doing manual failover with keyed switch turn key to Failover and hold it there until both Reserve lights are on then release the key e Via Software Command from HC Designer amp HC Utilities PC Software e Via Software Command from Modbus TCP amp Serial Modbus RTU Hosts e Via Software Command from 900 Control Station e Via input to RSTAT Function Block to initiate failover User can configure logical conditions such as loss of communication handshake between Host and Controller to initiate failover Failover Performance Failure condition detection and failover from Lead to Reserve CPU executed in 4 analog control cycles or less Redundancy Diagnostic Monitoring e From HC Designer and HC Utilities PC Software Redundant System Status current status of Lead Reserve Controller CPU s On Line Monitoring Controller Diagnostics Communications Loop Back tests Redundant Link Status status of communications between Lead and Reserve controllers Lead CPU status Reserve CPU status Scanner status File Download Upload Functions See page 159 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 165 January 2014 Redundant Operating Characteristics File Download Upload Functions This page is intentionally left blank 166 HC900 Process amp Safety Controller User and Installation
56. experiencing the problem For those the lastcharacteis e Slave blocks associated with slaves check the slaves experiencing the beanie hed failure have their BAD COMM Power PEURA A a y and NO SCAN pins turned on e Connections least 75 of the e IN SCAN STATUS is set to e address last messages NO for all slaves experiencing baudrate received have the failure ae been invalid e COMM STATUS is setto BAD eon Ifthe portis for all slaves experiencing the number of stop bits configured as a failure e for electrical interference seal sal at e The slaves with the data link e grounding eas o of the 2 last requests to a Tak Rii zero data termination resistor if at end panicular siave e The slaves experiencing the N resulted in no fail xp h 9 9 The diagnostic is cleared by response or a reply allure are moved to the clearing the port s statistics that failed the data background scan rate link protocol 2 The UART failed its See above Replace CPU module power up tests 10 Ethernet port tests 1 E1 or E2 port diagnostic is set to Replace CPU module If the lead s status If the lead s status failed during power up FAILED LED is indicating LED is indicating 2 ASYSblock s HW OK pinis the failure see the failure see turned off NETWORK Lead Port E1 PORT E1 or Network Port NETWORK Diagnostics or PORT E2inthe Lead Port E2 Lead CPU Network Port Diagnostics Diagnostics in display the Lead If the reserve s
57. for AC Output Module i 82 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 4 NOTE In the diagram below the white cut outs represent the cut outs on the modules that cont d accommodate tabs on the Terminal Block That is all key tabs that line up with the white cut outs on the diagram should be retained and all other tabs should be removed The orientation of the diagrams below corresponds to the picture of the terminal block shown in the previous picture Diagrams for I O Module Key Tabs Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 83 January 2014 120 240Vac 125 VDC IN 120 240Vac IN 120 240Vac OUT 24Vdc OUT 32 DO Relay OUT Contact IN 24 VdciIN 32DI Analog IN 16Al Analog OUT PFQ This page is intentionally left blank I O Module Installation and Wiring I O Module Installation Procedures Step Procedure Comments Reference 5 If installing High Level 16 channel Analog Input module set its SW1 and SW2 DIP switches to ON This connects an internal 250 ohm resistor A small slotted screwdriver or paperclip works well avoid using pencils 4 Honeywell e HEN AT o S ATS ve V Pa J f Z E 0 NE
58. for RTP internal schematic Connect field wiring LOADS ARE 0 to 750 ohm 224 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Contact Digital Input Ea 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect desired cable to 16 point Contact DI module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point contact DI module label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 2 3 Set jumper positions as shown for the 16 point contact digital input module Ca Os C CO Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 234 for RTP internal schematic
59. for cable assembly drawing applies to 16 Al 32 DI 32 DO Twisted Pair Number of HC900 Module TB Position RTP B J1 Plug Connector Color Cable B 1 19 6 Black 20 7 Red 2 22 9 Black 23 10 White 3 24 20 Black 25 19 Green 4 36 17 Black 35 16 Blue 5 36 15 Black 35 14 Yellow 6 28 12 Black 29 11 Brown 7 30 1 Black 31 2 Orange 8 33 4 Red 34 5 White 9 21 8 Red 26 18 Green 10 27 13 Red 32 3 Blue RTP B J2 J3 J4 J5 sw ea Tr Tr oi TT Pa Terminal v y Block Ji c1 c1 c1 c1 SW SPST TB1 19 6 1 20 7 E a1 21 8 e 22 9 T N er rel 23 10 E E EE S 25 19 36 17 A 35 16 r e aaa st i ER and Ga ees Fs ee DEn CA Ps 7 z 4 vy z 34 5 ct ct ct ct nl 27 13 28 12 n rll ep df a0 29 11 E See N 22 32 3 lt a 34 31 2 ate 30 aa e 37 EE e 3a 36 15 y a 35 14 a cons Latch U nlatch RTP to rail Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 247 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output Mounting screws must be installed at each end of the mounting rail with additional screws approx every 8 203mm to prevent twisting of the rail DIN rail To remove using slot
60. green when 485 S2 port receiving XMT RCV All models E1 port 4 Upper LED Yellow On Off On for 100Base T Off for 10Base T 5 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C70 E2 port C75 6 Upper LED Yellow On Off On for 100Base T Off for 10Base T 7 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity C50 I O port ee 8 Upper LED Yellow On Off On for 100Base T Off for 10Base T 9 Lower LED Green On Off Flash On for connection Off for no connection Flash for activity Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 169 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Controller Status LED Diagnostic indicators When the Controller Status LED Figure 89 on page 168 item 1 is flashing red consult Table 27 Ay WARNING Ay Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources e Disconnect power before servicing More than one switch may be required to disconnect all power Failure to comply with these instructions could result in death or serious injury Table 27 Controller Status LED Diagnostics Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indication Utilities Indication Strobes 1 RAM or ROM failed on Executes an inf
61. or 44 0 1202645583 Email Sales FP Sales Apps Honeywell com ort honeywell com 51 52 25 154 Rev 2 1 January 2014 AMERICA S Honeywell Process Solutions Phone TAC 1 800 423 9883 or 215 641 3610 Sales 1 800 343 0228 Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com Honeywell 2014 Honeywell International Inc
62. point Analog Input module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 16 point Analog Input label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Set verify jumper positions on each RTP as shown J Jd K C C C m J3 J5 J J9 sw C C C C Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is possible but voltage is still present on the positive side at RTP and module terminals See page 246 for RTP internal schematic Ea 2 Mount RTPs to DIN rail Latch to rail See page 247 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs 240 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Inp
63. 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 2 Loosen the captive screws at top and bottom of the module loosening the screws will cause the terminal block to be partly extracted from the module connector Remove the terminal block from the module 3 Using the extractor loop on the cover on the module pull the module from the slot as shown in the illustration at right As shown in the illustration a long flat tip screwdriver is used as an extraction lever Insert the screwdriver tip into the extraction tab on the front of the module cover and rotate the
64. screwdriver handle toward the back using the top edge of the rack as a fulcrum 4 Verify that the replacement module is of the proper type Then carefully insert it into the slot in the rack so as to make proper contact with the connector in the backplane 5 Replace the terminal block on the module 6 If the rack was powered down for the procedure restore power to the rack 7 Re connect signals to field devices Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 195 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Installation Replacement Advisory Regarding Battery Installation Memory for the CPU in the Controller Module includes e Volatile memory and e Non volatile memory Flash Only volatile RAM requires battery backup When power is applied to the Controller Module the CPU is initialized automatically If the batteries are is installed after initialization and if site power is maintained the current draw from the battery is very low approximately 4 microamps If site power is disconnected with the batteries in place and with the CPU in the initialized state the current draw on the battery is approximately 6 ma for C30 C50 and 9 ma for C70 C75 CPUs However if the battery is installed before power is applied and the CPU initializes the SDRAM will draw approximately 40 milliamps At the 4 microamp level the batte
65. screwdriver to lift C up gently plastic is fragile to disengage at B Lift up and over rail then disengage at A 248 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Declaration of Conformity Analog Input Digital Input Digital Output Analog Output Declaration of Conformity Honeywell 51452401 Revision E DECLARATION OF CONFORMITY CE We declare that the following product HC900 Hybrid Controller Models 900A01 900A16 900B01 900B08 900B16 900G01 900G02 900G03 900G32 900H01 900H02 900H03 900H32 900K01 900RSM 900PSM 900C31 900C32 900C51 900C52 900C53 900C71 900C72 900C71R 900C72R 900C73R 900P01 900P02 900P24 900RTA 900RTR 900RTC 900R04 900R08 900R12 900RRO 900RO8R 900R12R 900RPE is in conformity with the protection 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 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 equip
66. set switches 1 8 for Ohms Note Install jumper wires 3 23 6 26 8 28 12 32 13 33 16 36 17 37 20 40 Input 6 Input 8 Figure 102 Two wire RTD or ohm input connections 216 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Note You must set switches 1 8 for Ohms Input 2 Input 3 Input 4 Input 6 Input 8 Figure 103 Slidewire feedback connections for actuators Analog Input accuracy specification Range Al Module Accuracy RTP Cable Accuracy Al Module RTP Accuracy 1000 Plat RTD 0 1 of Range 0 04 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 2002 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 2 1 HC900 Process amp Safety Controller User and Installation Manual 217 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input RTP Internal schematic HC900 Terminal Block J1 TB1 1 6 C i SW 1 2 250 Ohm 22 2 7 o a 23 ia 4 3
67. switches settings for each input type Step 3 5 ko S power gt switch Red 1 0 Figure 97 Analog input terminals i OOOOOOoO oN T ODOOG O You must set switches 1 8 for transmitters 5 26 Input 1 Q Transmitter Transmitt pea a npaee ae ransmitter npu ransmitter Inpu Input 2 Transmitter Transmitter nsmitter Input 8 Transmitter Transmitter Figure 98 Two wire transmitter connections with common 24 VDC supply 214 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Ea OSTE TOUTO COREE Note You must set switches 1 8 for Milliamp OG A A A Input 8 Figure 99 Milliamp input connections with 250 ohm shunt resistance VMOOOOODOOOOOOOOOOOO Note You must set switches 1 8 for Volts Millivolts 2 V mV Input 6 V mV Input7 V mV Input 8 V mV Input 1 V mV Input 2 Figure 100 Volt millivolt input connections Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 215 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Input 5 Input 7 Note You must set switches 1 8 for RTD Input 1 Input 2 Input 3 Input 4 Input 8 Figure 101 Three wire RTD input connections Input 5 Input 7 Note You must
68. this port to the Operator Interface must be made during installation because it will probably be necessary to run the cable through conduit On C75 connect cable from each CPU s galvanically isolated RS 485 port to the Operator Interface See Operator Interface manual 51 52 25 108 for connection details Table 18 Parts needed to make RS 485 Cable Belden 9271 or equivalent Variable Commercially available communication with 120 ohm resistors 2 000 cable feet Maximum Or Belden 9182 or equivalent with 150 ohm resistors 4 000 feet maximum 10 terminal connector Supplied with the operator interface Phoenix 1840379 or Connector 3 pin Supplied with the equivalent for C30 C50 controller CPU module Phoenix 1803581 for C75 047260 1 Ferrite cable clamps Supplied with the operator interface 089037 Nylon cable ties Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 127 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Connecting the HC900 Controller to a PC with the Designer Software To establish communications between the HC900 controller and the Process Control HC Designer configuration software use any of the following methods e A Direct Serial RS 232 connection See page 129 Direct with RS 485 and RS 485 to USB converter with supplied instructions e B Modem connection See page 132 e C Dire
69. through either port e Controller can be slave to masters such as On Legacy systems Operator Interface 1040 559 Must be on galvanically isolated RS 485 port S2 Honeywell HC Designer PC software Third party PC HMI software Third party Operator Interface e Controller can be master to slaves such as Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 39 January 2014 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems Any Honeywell Modbus device e g recorders controllers flame safety Any non Honeywell Modbus device e Only one master port at a time can t have both serial ports as master ports e Modbus master ports default to slave ports ELN protocol when CPUs are in Program mode e Baud rates to 115 200 40 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems Setting serial ports S1 and S2 to RS 232 or galvanically isolated RS 485 For legacy systems S1serial port default setting is RS 232 S2 serial port default setting is RS 485 Each port can be set to RS 232 or RS 485 not shown For new systems the serial ports S1 and S2 are galvanically isolated RS 485 unterminated See Table 3 below Functi
70. to networks with more stringent addressing requirements it is necessary only to configure the Router with address mapping and connect it between the existing LAN and the other existing network Connections to other networks vary in purposes and methods some of these are described below E Mail Communications The HC900 Controller includes e mail software that enables communication of Alarms and Events to up to three Internet addresses Implementing this feature consists of e Using the Designer Software to configure Alarm Groups and Event Groups Assignment of specific alarms to priority and e mail enabling E Mail address lists SMTP mail server IP address Default gateway must be configured in order to send e mail With redundant controllers two default gateways need to be configured one for each of the redundant networks assuming both are being used This will typically be the LAN side IP address of the routers used to connect the controller to the external network e Installing and configuring hardware Note This data is included for reference The following items should be implemented by qualified IT MIS personnel Install and configure a Router to provide isolation and security Figure 21 This should be part of standard network installation Install and configure internet access to Simple Mail Transport Protocol SMTP server This may include the location of an existing server on an existing network
71. use fiber optic cable for connections between the controller and a remote rack Distances up to 750m 2460 ft are possible with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint See page 209 Configuration 1 is the C30 C30S C50 C50S C70 C70S CPU with I O but no I O expansion racks Configuration 2 shows the C50 C50S C70 C70S CPU with 1 I O expansion rack The Ethernet cable connects directly between the 10 100 Base T connectors on the C50 C70 CPU Controller Module and the Scanner Module ATTENTION For 2 or more I O expansion racks a switch is required Use only Honeywell recommended switches part no 50008930 001 50089785 001 002 The total number of switches is limited to 2 in series between a CPU and its scanners Configuration 3 shows the C50 C50S C70 C70S CPU with 3 I O expansion racks Since there are at least 2 T O expansion racks a switch is required When an Ethernet switch is used to connect to expansion I O a cable goes between the I O port on the controller to the switch Two cables go from the switch to 2 scanners A third cable goes from the switch to a second switch which connects to a third remote scanner Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 31 January 2014 Components and Architecture Ethernet Open Connectivity Network T O implementation requirements include e Constructing a configur
72. which the procedures are used Safety Considerations PLAN AHEAD When using the procedures in this section plan the sequence of procedural actions so as to ensure e The safety of personnel e The protection of property e The integrity of operating processes The first consideration is safety of personnel While there is always an inclination to preserve the materials and time invested in a running process no action should ever be taken that would risk injury to personnel Protection of personnel property is an important consideration that always requires comprehensive knowledge of the entire control process the control equipment the process control strategy and the conditions and circumstances that exist when the removal and replacement procedures are taken The procedures in this section include notices of potential hazard as they apply to various components in the controller Because each control process and the set of conditions and circumstances at each user site are unique it is the user s responsibility to know the potential consequences of each action as it relates to a running process It is recommended that the user becomes familiar with the significant aspects of each set of circumstances and has a plan for execution of the proper action sequence Ay CAUTION All of the modules input output RSM PSM available for use in the HC900 Controller have a RIUP designation That is they can be Removed and Inserted Under Po
73. wiring is shown in Figure 50 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Isolation The four outputs are isolated from each other Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section Ay WARNING A 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 96 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams OUT 1 OUT 1 wa OUT 1 OUT 1 OUT 2 OUT 2 OUT 2 out OUT 3 OUT 3 OUT 3 outs OUT 4 OUT 4 OUT 4 OUT 4 Figure 50 4 channel Analog Output Wiring Diagram 8 and 16 channel Analog Output Module Wiring Examples of high level Analog Output Module wiring are shown in Figure 51 and Figure 52 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp
74. works well avoid pencils Honeywell wer Repeat steps 1 through 3 for each I O expansion rack Then for each I O expansion rack insert the Scanner Module immediately to the right of the Power Supply and secure it in place with the two captured screws in the faceplate I O will be installed later See Page 73 Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 73 Assemble I O Expansion Racks This page is intentionally left blank 74 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring Overview I O Module Installation and Wiring Overview This section contains descriptions of and procedures for installing I O Modules in controller racks all CPU models and in I O expansion racks C50 C70 C75 CPU only Module Placement in Racks Each input or output module is placed in an I O slot in a rack as shown in Figure 37 Each slot in a rack includes a set of guides that locate the circuit board in the rack and a 20 pin 4 x 5 socket in the backplane that receives the associated 4 x 5 pin plug at the back of the I O module At the front of each I O module a 20 or 36 pin plug receives the associated socket on the back of a terminal block When the I O module is inserted into the rack and the termi
75. 0 Steps per sequence 64 64 64 64 Support of dual port scanner No No No Yes Tag descriptor Quantity based on available memory Text bytes Quantity based on available memory Variables 2000 2000 2000 2000 Variables in a Recipe 50 50 50 50 208 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications Fiber Optics Recommendations Fiber Optics Recommendations Honeywell recommends that you use the following equipment for extended distances Table 43 Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 100BaseT X to 100BaseFX multi mode fiber port with SC connectors require 24VDC power Fiber Cable Multi mode Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet FO Connector SC Type Figure 94 and Figure 95 are examples of Extended Distance configurations Moxa Switch 10 100 EDS 308 MM SC 10 100 HC900 Copper Main Rack ital PP Rack 1 Fiber Cable Distance 750M 10 100 Copper Fiber Cable Distance 750M Moxa Media Converter IMC 101 M SC 10 100 Copper Moxa Switch EDS 308 MM SC As a Repeater Fiber Cable Distance 750M Moxa Media Converter IMC 1
76. 0 Controller e Parity None e 1 stop bit e 8 data bits e No handshaking e Ignore DTR e Suppress result codes e Suppress echo e Auto answer e Disable command recognition only necessary if the modem has this capability Some of these settings may be settable via switches Others may require command strings to be written to the modem using a PC terminal program such as Hyperterminal You will need to refer to your modem s documentation to make this determination Those settings that are configured using command strings must be saved to the modem s non volatile RAM NVRAM and the NVRAM must be configured as the profile that gets loaded when the modem is powered up Most modems are equipped with auto recognition to set the baud rate parity stop bits and data bits If your modem has no means of setting these using switches then most likely it is equipped with auto recognition To configure the port settings of a modem with auto recognition do the following Step Action 1 Connect the modem to a PC 2 Power up the modem 3 Start up a PC terminal program such as Hyperterminal 4 Configure the PC COM Port for 1200 2400 4800 9600 19200 38400 57600 baud must match Baud Rate configured in HC900 Controller no parity 1 stop bit and 8 data bits recommended 5 Establish communications with the modem A common way of doing this is simply entering the AT E1 Q0 command and seeing if the modem respo
77. 00C70S 0360 00 Yes Controller C75 CPU SIL 900C75S 0360 00 Yes I O Scanner 1 Port 1 per I O rack SIL 900S50S 0360 00 Yes I O Scanner 2 Port 1 per I O rack SIL 900S75S 0360 00 Yes Documentation Full Document set on CD SIL 900ME1S 0060 00 Yes Full document set SIL hard copy 900ME2S 0060 00 Yes English I O Modules Analog Input 900A01 0202 Yes 8 channel Analog Input Hi level 16channel 900A16 0101 Yes Analog Output 0 to 20mA 4 channel 900B01 0301 Yes Analog Output 0 to 20mA 8 channel 900B08 0101 Yes Analog Output 0 to 20mA 16 channel 900B16 0101 Yes Digital Input Contact type 16 channel 900G01 0202 Yes Digital Input 24VDC 900G02 0202 Yes 16 channel Digital Input 120 240 VAC 16 channel 900G03 0202 Yes Digital In 120 240 VAC 125VDC 900G04 0101 Yes 16 channel lsolated Digital Input 24VDC 900G32 0101 Yes 32 channel Digital Output Relays 900H01 0202 Yes 8 channel Digital Output 24VDC 900H02 0202 Yes 16 channel Digital Output 120 240 VAC 8 channel 900H03 0202 Yes Digital Output 24VDC 32 channel 900H32 0101 Yes Pulse Freq Quad 4chan 1Quad 900K01 0201 No Low VoltageTerminal Block Euro style 900TEK 0101 Yes Low VoltageTerminal Block Barrier style 900TBK 0101 Yes High VoltageTerminal Block Euro style 900TER 0101 Yes High VoltageTerminal Block Barrier style 900TBR 0101 Yes High Density Terminal Block Euro style 900TCK 0101 Yes Filler Block Terminal
78. 01 M SC Figure 94 Extended Distance Example 1 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 209 January 2014 Specifications Fiber Optics Recommendations Moxa Switch Moxa Switch EDS 308 mM Sc 10 100 hcgoor 110 100 EDS 308 MM SC P Copper Redundant Copper itch ontroller Rack Swit Copper HC900R Copper VO Rack1 10 100 Copper HC900R Cop Fiber Cable Distance 750M Fiber Cable Distance 750M Moxa Media Converter 10 100 IMC 101 M SC Moxa Media 10 100 Canverter HC900R Copper IMC 101 M SC VO Rack 3 Moxa Switch EDS 308 MM SC As a Repeater Moxa Switch EDS 308 MM SC As a Repeater HC900R Copper VO Rack 4 Moxa Media Moxa Media Fiber Cable Converter 10 100 10 100 Converter Fiber Cable Distance 750M IMC 101 M SC Copper HC900R Copper IMC 101 M SC Distance 750M VO Rack5 Figure 95 Extended Distance Example 2 210 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Overview Appendix Installation of Remote Termination Panels RTPs Overview The Remote Termination Panel RTP provides an easy way to connect the HC900 controller to the field wiring The RTP integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectiv
79. 1 Table 11 Assemble I O Expansion Racks 0 escceescceescecssceesseeeessecesseeesacessaecesseeesseessseecsseecssaeesnaesesaeessatersaees 72 Table 12 Minimum Recommended Wire Sizes cccessssceceeseceeeseseeeceeneececenaecesseeecessaeeeeeeeaeecenseeeeeeneeeesaaes 77 Table 13 RIUP Potential Hazards and Recommended Actions cccccccceeesceeeeneeeeeeneeeecenaeeeeseuseeeeenneeeeeaees 80 Table 14 Connect Input Output Wiring ee eee eeeeeseecsneecesceceseecesaeeesaeessaecesaeeesseecsseecsseeceseesssaesesaeessaeessaees 81 Table 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F o cee eeeeeeeseeeeneeeenees 88 Table 16 Connect Communications Wiring and Cabling cece eesccsseceeeessneeesneeeeseecssaessaeesseeessaeeesaeeesaes 123 Table 17 Links to Controller Communication Ports cccsesccceseseeceeeeeceeeeeaeeeeeeneeeessaeeeesseeeeseneesesseneeeeesae 124 Table 18 Parts needed to make RS 485 Cable ees eesceescecsseeceseeceseeessaeessaeeesaeessaeessseecsaeecseeseneeseseeeesaeensas 127 Table 19 Null Modem Cable Connections eceesceeesecsseesssceceneecsseeeessecesaecssaeeesseeesaeecsseecsaeessneesssaeeeaeessas 130 Table 20 Redundant Network connections in Figure 74 0 0 eesceesessseessseecsseeesneeesneeeeseecesaeceaeceeesesaeeesaeeesaes 142 Table 21 Redundant network connections cceeeseceeseneceeseeeeeeenneeeeenaeeecsseecessaeeeessn
80. 10 100 Base T RJ45 E110 100Base T RJ45 E2 10 100Base T RJ 45 Link Type Controller to Modbus slave network controller is master Host Peer and Internet Devices Host Peer and Internet Devices Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Designer configuration software Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition Cable Type Belden 9271 or equivalent Shielded CAT5 cable up to 100 meters Shielded CAT5 cable up to 100 meters To Device Port Refer to device s port instructions RJ45 connector on Host Peer or Internet Device RJ45 connector on Host Peer or Internet Device Details SIL applications require shield drain wire to be connected to grounding bar Default IP address is 192 168 1 254 Default IP address is 192 168 2 254 Default IP address is 192 168 1 254 Default IP address is 192 168 2 254 software packages and Designer Software configuration software I O Single I O rack Shielded Ethernet C50 C70 Controller s I O No foreign messaging 100Base T CAT5 cable with RJ 45 port to Scanner 1 s I O port permitted connectors I O Single I O rack Shielded Ethernet C75 CPU A s I O port to No foreign messaging 100Base T CAT5 cable with RJ 45 Scanner 2 s I O A port permitted conne
81. 2 or 9 11 to L2 N Figure 57 AC Input Module Jumper 104 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC DC Isolated Input Module Wiring The AC DC Input Module has sixteen isolated inputs An example of AC Input and DC input Module wiring is shown in Figure 54 Specifications for this module and for other modules are given in the Specifications manual Requires Low Voltage Euro style 36 terminal terminal block Isolation Inputs must be powered from external voltage sources Inputs are isolated from each other and from controller power IM 2 INJ IH d IN d IN IN INA IH IN IM 2 IN IN IM 14 CHEE elle S e Nad a Ce e i t KERE REINENENEIN BERBMEBOBEGBEEBEEEGEGIL Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 105 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams N Z Q ZN QMOO OO O OQ OO OOOQOQ00O0C fe e Legend gt External j Disconnect i r E oo Fuse Figure 58 AC DC Isolated Input Module Wiring 106 HC900 Process amp Safety Controller User and Installation M
82. 235 Dual DI DO AO RTPs and cables are used with the following modules See page e 16 point Analog Output 238 e 16 point Analog Input 240 e 32 Point DC Digital Output 242 e 32 Point DC Digital Input 244 4 Point Analog Output E 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal block to allow mating with the module See page 82 e Connect desired cable to AO module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install AO module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Latch to rail See page 247 Connect cable to RTP 2 Mount RTP to DIN rail e e Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 4 Point Analog Output Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 234
83. 360 00 900C30S 0360 00 900CS5O0S 0360 00 900C70S 0360 00 900C75S 0360 00 900SSOS 0360 00 900S75S 0360 00 ATTENTION For the Legacy systems it is specifically mentioned in the guide wherever applicable The other text is applicable to the new HC900 system Modems are not qualified with the new HC900 system Checking HC900 Model Numbers for Compatibility ATTENTION Be sure to check your model numbers for compatibility before installation For a HC900 system to be fully compatible all components must have matching model numbers Each component s model number format is XXXXXXX XXYY ZZ For example HC900 CPU is 900C71R 0000 40 For redundant CPU systems component model numbers ZZ numbers must match For non redundant CPU systems component model numbers YY numbers must match See examples below Example of a compatible redundant system Component Model Number XXXXXXX XXYY ZZ HC900 CPU 900C71R 0000 40 Scanner 2 900C73R 0000 40 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 Example of a compatible non redundant system Component Model Number XXXXXXX XXYY ZZ HC900 CPU 900C51R 0040 00 Scanner 1 900C53R 0040 00 HC Designer Software 900W01 0040 40 Manuals CD 900ME1 0040 40 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 7 January 2014 Introduction Functional Description Funct
84. 3b to Ethernet port 3a Ethernet switch for CPU A E1 port 3b Ethernet switch for CPU B E1 port 4a Connect CPU A I O port to Ethernet switch 5a 4b Connect CPU B I O port Ethernet switch 5b 5a Ethernet switch for CPU A s I O racks 5b Ethernet switch for CPU B s I O racks 6a Connect Ethernet switch 5a to each I O rack s I O A port 6b Connect Ethernet switch 5b to each I O rack s I O B port 7 I O Racks 8 Connect the primary Ethernet port of the 900 control Station to the Ethernet switch which is assigned to port E1 of the controller CPUs 9 Connect the Auxiliary Ethernet port of the 900 Control Station to the Ethernet switch which is assigned to port E2 of the controller CPUs 10 Connect CPU A S1 port to PC USB port through RS 485 to USB converter 50089787 001 142 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Table 21 Redundant network connections Step Procedure 1 Make sure the PC has 2 Ethernet NICs Network Interface Cards installed and enabled 2 Connect Ethernet 10 100 Base T straight or crossover cables to the HC900 controller s E1 and E2 ports 3 Connect the other end of the cables to the PC s Ethernet ports 4 On the PC use the Utilities Worksheet in the Designer software to connect to the controller over Ethernet Every HC900 C75 contro
85. 6 Scanner Module Replacement Step Action 1 If a process is currently in operation then Either ensure that powering down the expansion rack will not have adverse consequences on any running process or bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply or supplies in the expansion rack from the site AC power source 3 Unplug the cable s from the scanner port s 4 At the top and bottom of the Scanner Module loosen the captured screws that secure the module in the rack and remove the module from the rack 5 Configure the scanner address jumpers DIP switches on the replacement module to match those of the removed module 6 Ensure that the new Scanner Module is properly aligned with the slot guides insert the new Scanner Module in the rack and secure it in place with the captured screws at top and bottom of the module 7 Re install the cable s 8 Using the external user supplied switch connect the power supply or supplies in the expansion rack to the site AC power source The Scanner Module should resume communications with I O modules in the rack and with the Controller Module with which it is connected 9 Check status indications at the Scanner Module at the Controller Module and at the OI Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 193 January 2014 Removal
86. 766694 X General Purpose Safety Compliant with EN61010 1 UL UL 61010C 1 CSA C22 2 No 1010 1 Hazardous Classified Location Safety FM Class I Div 2 Groups A B C D CSA Class Div 2 Groups A B C D Class 1 Zone 2 IIC Module Temperature Classifications Module Type T Module Type T Rating Rating Redundant CPU Rack T6 Scanner 2 T6 Redundant PS Ext Rack T6 Analog Input 8 channels T6 8 Slot Redundant PS Ext Rack T6 Analog Input 16 chan T6 12 Slot Redundant PS Ext Rack T6 Analog Output 4 chan T4 4 VO Slot Rack T6 Analog Output 8 chan T4 Analog Output 16 channel TSC 8 VO Slot Rack T6 Digital Input Contact type 16 chan T5 12 VO Slot Rack T6 Digital Input 24 Vdc 16 chan T4 Power Supply P01 T4 Digital Input 120 240 Vac 16 chan T3C Ta 60 deg C T4 Ta 40deg C Digital Input 120 240VAC 125VDC T3 Ta 60 deg C 16 Channel T4 Ta 40 deg C Power Supply P02 T4 Digital Input Vdc 32 chan T5 Power Supply P24 T4 Digital Output Relay type 8 chan T5 Power Status Module PSM T6 Digital Output 24 Vdc 16 chan T4 C30 C50 C70 C75 CPU T5 Digital Output 120 240 Vac chan T4 Redundancy Switch Module RSM T6 Digital Output Vdc 32 chan T6 Scanner 1 T6 Pulse Frequency Quadrature 4 chan T5 Environmental Conditions Ambient Reference Rated Extreme Transportation amp Storage Temperature F 77 5 32 to
87. 8 4 9 a q 7 o W 26 SW 2 2 250 Ohm ig 5 10 2 6 20 t o OW aA SW 3 2 250 Ohm d 7 19 o 29 10 18 oi 17 eee 12 o m SW4 2 250 Ohm 10 16 32 11 15 13 Oo OW SW 5 2 250 Ohm 12 14 22 14 13 13 dis 14 12 16 Oo 0 w SW6 2 250 Ohm 15 11 o ne 16 1 ie i SW7 2 250 Ohm 37 17 2 ie 18 ois 19 Lee 20 OW SW 8 2 250 Ohm 20 5 40 oe ee eo o 21 sw sw SW SW SW SW sw sw 8 1 7 1 601 5 1 4 1 3 1 2 1 161 ae o 1 F 24 NF 25 AF 30 A 31 NFS 34 AB 35 AB 38 AE 39 218 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output Relay Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 84 e Remove appropriate key tabs from terminal block to allow mating with the module See page 82 e Connect desired cable to relay output module at controller Choose from 900RTC H010 Remote Terminal High Voltage Cable assembly 1 0 meters long 9OORTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F Install relay output module label onto the module connecto
88. 9785 002 Honeywell switches part no 50008930 001 Remote I O interface None Separate Ethernet 100Base T port on CPU RJ 45 connection type dedicated communications link Remote I O Distance None 100 m 328 ft Ethernet cable controller to remote rack or controller to switch Up to two switches per connection 300m 984 ft and maximum distance 750m 2460 ft Fiber optic cable controller to remote rack or controller to switch Up to two switches per connection 1500m 4920 ft maximum distance Fiber Optics Equipment Recommendations Ethernet Switch Moxa Unmanaged Ethernet Switch model EDS 308 MM SC with 6 10 100 Ethernet ports 2 multi mode fiber ports with SC Connectors require 24VDC power Converter Moxa Media Converter model IMC 101 M SC with 1 10 100BaseT X to 100BaseFX multi mode fiber port with SC connectors require 24VDC power Fiber Cable Multi mode Duplex 62 5 125 with SC connectors on both ends Copper Ethernet Cable Shielded Cat5 Ethernet I O Capacity Combined Analog and Digital Analog Inputs Analog Outputs 384 1920 192 960 40 200 48 with heat de 240 with heat de rating rating 960 with external power source 192 with external power source Rack Size 4 I O slot chassis 8 I O slot chassis 8 I O slot chassis with redundant power support 12 I O slot chassis 5 4 137mm H x 10 5 266 7mm W x 6 0 151 7 mm D r
89. Blocks must correlate to that of the mating header on I O modules with which they are used that is e Black terminal blocks which have gold contacts are for use with I O modules that have black headers and gold pins in the 20 pin connector these include Analog Input 4 channel Analog Output DC Input DC Output Contact Input Pulse Input Pulse Output Frequency Input Quadrature Input e Red terminal blocks which have white tin contacts are for use with I O modules that have red headers and white tin contacts in the 20 pin connector these include AC Input AC Output and Relay Output e 36 pin black Euro terminal blocks which have gold contacts are for use with 8 point AO 16 point AO 16 point AI 32 point DI and 32 point DO modules e Terminal blocks must be keyed by the installer to prevent high voltage terminal blocks from being installed on low voltage modules See Table 14 76 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring Remote Termination Panel RTP e Any of the color coded labels will fit into the door of any terminal block Use care to ensure that all hardware components match each other and also match the control strategy in the configuration file Remote Termination Panel RTP The optional Remote Termination Panel RTP provides an easy way to connect the HC900 controller to
90. C MoCo 01400C 110 NiMo NiCo 32 2500 F MoCo 32 2552F 111 NiMo NiCo 0 682 C n a NiMo NiCo 32 1260 F n a NiCroSil NiSil 18 1300 C N 01200C 24 NiCroSil NiSil 0 2372 F N 322192F 25 NiCroSil NiSil 18 800 C N 0 800C 22 NiCroSil NiSil 0 1472 F N 321472F 23 R 18 1704 C R 20 1760C 28 R 0 3100 F R 43200F 29 S 18 1704 C S 01600C 30 S 0 3100 F S 322912F 31 T 184 371 C T 200 400C 40 T 300 700 F T 328 752F 41 T 129 260 C T 50 150 C 34 T 200 500 F T 58 302 F 35 W_W26 20 2320 C W_W26 20 2320 C 52 W_W26 4 4200 F W_W26 44208F 53 W5W26 18 2316 C W5W26 20 2320 C 54 W5W26 0 4200 F W5W26 44208 F 55 W5W26 18 1227 C n a Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 205 January 2014 Specifications General Specifications Type Range Range High EU Reference Corresponding Low UMC800 Input type and range W5W26 0 2240 F n a Platinel 0 1380 C PLTNL 01380C 118 Platinel 32 2516 F PLTNL 322516 F 119 Platinel 0 750 C PLTNL 70750 C 116 Platinel 32 1382 F PLTNL 94 1382 F 117 Pt100 184 816 C Pt100 200 800 C 68 Pt100 300 1500 F Pt100 328 1472 F 69 Pt100 184 649 C n a Pt100 300 1200 F n a Pt100 184 316 C Pt100 50 150 C 60 Pt100 300 600 F Pt100 58 302 F 61 Pt500 184 649 C n a Pt500 300 1200 F n a Pt1000 40 260 C Pt1000 50 400 C 120 Pt1000
91. C hosts via Modbus TCP protocol Peer to Peer UDP communication with up to 32 other HC900 Controllers C70 C70S and C70R Legacy and C75 C75S new model have 2 Ethernet ports for connection to up to 10 PC hosts They also support Modbus TCP Initiator function over both ports and automatically switch between ports to maintain Peer to Peer communications with other C70 C7 S or C70R C75 C75S redundant CPUs Private Ethernet 100 base T connection to I O expansion racks except C30 and C30S CPU Direct connection to each C70R Legacy and C75 C75S new model CPU For more information For complete feature summary and specifications see Specifications on page 199 12 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Feature Summary This page is intentionally left blank Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 13 January 2014 Components and Architecture Overview Components and Architecture Overview This section provides a description of each of the major components that can be included in an HC900 Controller physical configuration and indicates some of the methods by which they can be combined Components The Honeywell HC900 Process Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications Some of the modul
92. C75 only 6 Second Ethernet E2 Host Connection to PC applications or peer HC900 controllers C70 C70S C75 only 7 First Ethernet E1 Host Connection to PC applications or peer HC900 controllers 8 LED status diagnostic indicator for serial port S2 left 9 LED status diagnostic indicator for serial port S1 right 10 LED status diagnostic indicator for controller module Figure 12 Controller Module Redundant controller rack contains two C75s or C75Ss Left CPU is designated CPU A right CPU is CPU B either CPU can be Lead 26 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Hardware Components Redundancy Switch Module C75 only The Redundancy Switch Module RSM is shown in Figure 13 It sits between C75 C75S controllers on rack Left Controller is designated CPU A right Controller is CPU B Features include 1 Lead Reserve controller status indicators 2 Keyed switch for manual changes to controller modes or to facilitate a Manual Fail Over Figure 13 Redundancy Switch Module Scanner 1 Module S50 S50S 900S50 Scanner1 module is shown in Figure 14 It sits in the I O rack and provides the link between the controller and remote I O Features at the front of the module include C gt 1 LED status indicator for scanner functions 2 One private Ethernet 10 100 Base T Port connects to
93. CJs on the module is indicating a temperature reading greater than 70 degrees C 2 Both cold junction sensors are failing to convert 3 The CJs are converting properly but their differential is greater than 10 degrees C 6 The scanner determined that a No action is taken Refer to the Bad I O Channel module has a bad channel In this Diagnostics on page 182 to condition the module s status LED determine the nature of the will not indicate the failure problem and possible user because the Scanner determines actions the condition not the module itself 7 One of the power supplies failed No action is taken Replace the power supply Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 179 January 201 4 Diagnostics and Troubleshooting I O Module Indicators I O Module Indicators Figure 91 I O Module LED indicators Table 30 LED Indications on I O Module Figure 91 item LED LED State Color Description Module Status Off Solid Red Blinking Red Blinking Yellow Solid green Blinking Green No power Hardware failure Diagnostic Code refer to Table 31 I O Module LED Diagnostics At least one output is Forced Cold start with passing diagnostics Normal scanning Channel LEDs one per input or output Green On Off For Inputs indicates On or Off status of the field input even if Forced to the opposite state For Outputs in
94. Controller is based on the mapping structure employed in Honeywell s UMC800 Controller and the function codes and methods for parameter access are also virtually identical Modbus Maps In your controller s configuration certain parameters are each automatically assigned a Modbus address These include certain types of function blocks such as loops and set point programmers signals and variables among other items Through their addresses these parameters can be accessed or displayed remotely such as by a third party operator interface Collectively these Modbus addresses and parameters are known as the Modbus map Two Modbus Mapping options exist Fixed map and Custom map Using HC Designer you can use a pre defined fixed map where common parameters are mapped out automatically at fixed addresses or you can configure a custom map for configurations rev 4 0 or higher Function blocks added to the controller in release 4 0 and higher are not automatically included in the Fixed Modbus Map To access the registers of these function blocks the Custom Modbus Map must be used and the block data manually inserted into the custom Modbus map HMI Supervisory SCADA software is available from various suppliers and functionality and setup requirements vary with suppliers and with specific products In all cases the software selected must be compatible with Open Modbus TCP protocol The user can use the standard Modbus command set to generate a
95. Diagnostics status LEDis Overview dialog indicatingthe Box failure see If the reserve s NETWORK status LED is PORT E1 or indicating the NETWORK failure Lead Port PORT E2inthe E1 Network Port Reserve CPU Diagnostics or Diagnostics Lead Port E2 display Network Port Diagnostics in the Reserve Diagnostics Overview dialog box Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 175 January 2014 Diagnostics and Troubleshooting Scanner indicators Scanner indicators Figure 90 LED Indicators on Scanners 1 port left 2 port right See Table 28 Table 28 LED Indications on Scanner Module Blinking Green Figure 80 LED LED State Color Description item 1 Scanner Status Off No power Solid Red Failed Blinking Red Diagnostic Code refer to Table 29 Scanner LED Diagnostics Solid Green Startup Mode Scan Mode 10 100 Base T port 2 XMT upper LED Green On Off 3 LINK lower LED Green On Off On while a message is being sent from the Main CPU otherwise Off On while the Main CPU is receiving a message 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 176 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics
96. Honeywell HC900 Process amp Safety Controller User and Installation Manual Doc No 51 52 25 154 Revision 2 1 Date January 2014 Notices and Trademarks Copyright 2014 by Honeywell Revision 2 1 January 2014 Warranty Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Honeywell Process Solutions 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners ii HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 About This Document Abstract This document provide
97. IL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details A green LED on the module provides indication of an ON state for each output Requires Low Voltage Euro style 36 terminal terminal block F cacag 10 5 to 32 Vde HOP OPIS OO BHOBDABOOOODO OOOOOOOC 10 5 ta 32 Vdei Figure 62 32 point DC Output Module Wiring The AC Output Module provides eight output circuits Each output is isolated from the other outputs An example of AC output wiring is shown in Figure 63 Specifications for this module and for other modules are given in the Specifications manual SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details 112 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Output Loading Voltage 85 to 240 Vac Maximum per output 2 0A resistive load Maximum per module 8 0A NOTE When exceeding 1 0 A per output it is recommended but not required to connect the high current loads to every other output for example outputs 1 3 5 7 or 2 4 6 8 This dis
98. Insertion Under Power RIUP feature That is while the rack is powered any of the I O Modules can be removed or inserted e With no physical damage to the module to the rack or to other modules in the rack e Without disturbing the functions of other I O modules in the rack or in the system Under carefully controlled circumstances this feature enables the user to remove and insert an I O module without completely shutting down a running system However it must be recognized that removing or inserting an I O module under power is potentially hazardous to property and to personnel In new systems the CPU and Scanner modules support RIUP Circumstances that dictate prudent actions depend on conditions and specific process applications at each user facility It is the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 13 provides some general guidelines for establishing appropriate procedures at a given installation Table 13 RIUP Potential Hazards and Recommended Actions Hazard Source Preventive Action s Potentially lethal voltages on Disconnect all signals at terminal A WARNING Terminal Boards associated with blocks from sources of power before 1 O Modules removing the terminal block from Hazardous Voltages the I O module Each signal at each of the Either A CAUTION terminals for an I
99. January 2014 Operating Characteristics Controller Modes Failover RSM only N A Transfers all primary tasks to the Reserve Controller establishing this controller as the new Lead Does not affect controller mode Turn key to Failover and hold it there until both Reserve lights are on then release key Table 24 Controller Behavior in Mode Transition Initial Mode New Mode Controller Behavior PROGRAM RUN Validate configuration database Reset all I O scanners Upon startup initiate Cold Start sequence Diagnostic Identify and configure all I O racks and modules All output modules are configured with Failsafe values Any modules not included in the configuration are configured with default values which cause outputs to be Off While in transition all output modules are Off when transition procedures are completed Function Block processing begins and output values are set to Function Block output values Any calibration process that was in progress is immediately aborted and the results are discarded PROGRAM OFFLINE Same as PROGRAM to RUN transition except that Function Blocks are not processed and outputs remain Off Any calibration process that was in progress is immediately aborted and the results are discarded RUN PROGRAM Set all channels of all output modules to Off Set all output module Failsafe values to the Off state Turn off the LED indicatio
100. Manual 131 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software B Modem Connection PC Intemal Modem assigned to a COM port Figure 77 Modem Connection 132 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software ATTENTION Always observe the wiring cabling guidelines on page 52 Step Procedure 1 Connect a modem to the HC900 controller s for a list of approved modems their settings and the connection specifics 2 On the PC check on the Utilities Worksheet in the HC Designer software to see if the PC modem is properly installed A modem icon on the associated COM port button indicates the PC modem is properly installed internal or external If the modem icon is not visible on the associated COM port button use the modem supplier s instructions to properly install the modem and verify the installation using the Windows Control Panel Modem property page to confirm proper installation 3 Set up the phone book in the HC Designer software This list includes the phone numbers for each of the HC900 controllers that can be connected using a modem The phone book can be accessed from the Main Menu View Phone Book or from the Utilities Worksheet by selecting the modem port as the current port Refer t
101. Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Step Procedure Select the Set Controllers Network Parameters button Using the wizard bottom radio button select the PC COM port to be used then set the controller s new network parameters including IP address Subnet Mask and Default Gateway if required See your IT network administrator for proper entries Refer to the on line help provided with the HC Designer software Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Repeat step 4 for each controller on the same network Select the Network button at the bottom of the dialog box and Add any or all of controller IP addresses configured to the list This will allow selection of any of these Addresses for downloading or uploading configurations You may now connect the controllers to your network for access by the Designer software For the Networking Example shown connect one end of the Ethernet 10 100 Base T cable to the PC s network port Connect the other end of the Ethernet 10 100 Base
102. Modem answers on first ring 6 ON DOWN CD always ON Override 7 OFF UP Loads YO Y4 configuration from user defined nonvolatile memory NVRAM 8 OFF UP Disables command recognition dumb mode 13 Connect the modem to the 14 Connect the modem to a telephone jack 15 Power up the modem and the HC900 Controller 16 On a remote computer run Designer Software 17 Set up Designer Software to dial the HC900 Controller 18 Verify that communications is established with the remote HC900 Controller Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 137 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Zoom 56K Dualmode External Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 25 pin connector use a DB 25 male to DB 25 female RS 232 cable If your PC s RS 232 port has a 9 pin connector use a DB 25 male to DB 9 female modem cable Connect power to the modem Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected O a F WO ND Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defa
103. N and literature If present on a product the user must consult the appropriate part of the accompanying product literature for more information This CAUTION symbol indicates a potentially hazardous situation which if CAUTION not avoided may result in property damage WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury A ATTENTION Electrostatic Discharge ESD hazards Observe precautions for AN handling electrostatic sensitive devices CAUTION HOT SURFACE This symbol warns the user of potential hot surfaces which should be handled with appropriate caution j Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor LTN Functional earth terminal Used for non safety purposes such as noise immunity L improvement NOTE This connection shall be bonded to protective earth at the source of supply in accordance with national and local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective earth at the source of supply in accordance with national and local e electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment ae shall be bonde
104. RUN Mode The Run Mode is used for normal operation of the controller that is for running the control configuration that was previously downloaded Configuration download and other utility functions can be performed in this mode See the Designer Software User Guide for precautions restrictions and procedures Functions placed on the Safety worksheet may not be forced or written to in this operational mode This mode must be selected for runtime on Safety applications Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 154 Operating Characteristics Controller Modes OFFLINE Mode The OFFLINE Mode can be entered only from the RUN Mode and is intended primarily for performing AI calibration A CAUTION Because Function Blocks are not processed and outputs are Frozen in this mode inputs that is process values can vary from the values that existed when the OFFLINE Mode was entered Before entering the OFFLINE Mode e KNOW all potential consequences of suspending control action e PLAN for all operator actions required to preclude adverse consequences while processing is suspended and when resuming control processing e EXECUTE prudent control actions such as placing all control loop in the Manual Mode Failure to comply with these instructions may result in product damage Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Install
105. Red Action s Indication Utilities Indication Strobes 4 Estimated battery life is e ASYS and FSYS blocks HW Replace battery If the lead s status If the lead s status less than 5 days OK pins are tumed off LED is indicating LED is indicating Le the failure see the failure see i a upgrade is stil MEMORY inthe Memory i Lead CPU Diagnostics in Diagnostics the Lead display Diagnostics If the reserve s Overview dialog status LED is box indicating the If the reserve s failure see status LED is MEMORY inthe indicating the Reserve CPU failure see Diagnostics Memory display Diagnostics in the Reserve Diagnostics Overview dialog box 4 Battery voltage is low e ASYS and FSYS blocks Replace battery LOWBTRY pins are turned on e ASYS and FSYS blocks HW OK pins are tumed off e Firmware upgrade is inhibited until both the Lead and Reserve batteries are good 4 Flash failed to burn ASYS and FSYS blocks HW OK 1 Force a cold start pins are tumed off 2 If diagnostic does not clear replace CPU module 5 The Real time Clock 1 On power up time and date is Use HCDesigner HCUtilities or Ol to If the lead s status If thelead s status RTC is not initially set to 00 00 00 January 1 program the real time clock RTC LED is indicating LED is indicating programmed This is 1970 on both the lead and the the failure see the failure see usually a result of the reserve RTC int
106. Redundancy switch module RSM 0 1 0 0 0 1 Power Status Module PSM 0 1 0 0 0 1 Scanner 1 Port S50 S50S 3 9 0 0 3 9 Scanner 2 Port S75 S75S 5 0 0 0 5 0 Analog Input Universal 0 8 0 0 0 8 Analog Input High level 1 6 0 0 1 6 Analog Output 4 points 5 1 0 0 5 1 Analog Output 8 pts internal 24V 9 4 0 0 9 4 Analog Output 8 pts external 24V 1 1 8 3 9 4 Analog Output 16 pts internal 24V 18 3 0 0 18 3 Analog Output 16 pts external 24V 1 7 16 6 18 3 Contact Input 1 6 0 0 1 6 Relay Output 3 0 0 0 3 0 16 pt DC In 24V 0 7 2 6 3 3 16 pt DC In 32V 0 7 5 1 5 7 32 pt DC In 24V 1 1 3 1 4 2 32 pt DC In 32V 1 1 5 1 6 2 16 pt DC Out 1 7 1 2 2 9 32 pt DC Out 1 2 1 8 3 0 AC In 120V 0 7 1 9 2 6 AC In 240V 0 7 7 7 8 3 AC DC In 0 7 7 7 8 3 AC Out 1 1 12 0 13 1 PFQ 6 7 0 1 6 8 50 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Heat Rise De rating 240 VAC nennennnnnnennennes 264 VAC masntennsnans Y SS 0 95 920 25 30 325 40 45 50 55 66 Temperature C gt Figure 27 AC Input Module de Rating 12 3 11 T a Oo T 10 T a z B 0 5 10 15 20 25 30 35 40 45 50 55 60 Temperature C Figure 28 Power Supply de Rating Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 51 January 2014 Pre Installation Planning Cable Wiring Distance Planning
107. S 485 Ports Ports per controller Cable type 1042 559 Distance from controller 1042 559 Power to Ol Unit addresses Two connector supplied Honeywell or Modbus RTU protocol Only one port for 1042 559 operator interface support 2 wire plus shield Belden 9271 or equivalent 2000 ft 600 m 24VDC user provided at Ol 1 to 247 Galvanically Isolated RS 485 Ports Parity user selectable Stop bits user selectable Speed user selectable Double Register Format for Modbus RTU Slave and Master data User selectable Odd even none 1or2 1200 2400 4800 9600 19200 38400 57600 115200 Selectable byte order RS 485 Modbus Slave Operation Number of ports per controller Masters per port Principal Function Block Address Range Up to two One User selectable starting address range for registers assigned to each principal block type RS 485 Modbus Master Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed One RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up to the maximum 1024 parameters per controller Up to 32 Up to 1024 max per controller Selectabl
108. Safety Controller Safety Manual for additional details Before installing be sure to determine power requirements See page 44 and 84 Requires Low Voltage Euro style 36 terminal terminal block Isolation The outputs are grouped with 4 outputs per group outputs 1 4 5 8 9 12 13 16 Groups are isolated from each other outputs are non isolated within each group Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section A WARNING AY Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring form power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 97 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 1 LI LI Li LI LI LI Li F Pa OO LOAD Bi mmm OUT 1 Li V OQQ OO G ad N OOCMOWIOE OOOPOOD OOOOOODOOOOOY 6 QGH 24VDC 24VDC a r 24VDC I v o 7 QOVO Q 6 COCHOQOG OOOOOOOOQDOOOOOOOY OOO Ae 24VDC 24VDC Ri one 24VDC i J Figure 52 16 channel Analog Output Wiring Diagram 98 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentiona
109. Safety Controller User and Installation Manual 161 January 2014 Redundant Operating Characteristics Steady State Operations Figure 87 Modes of operation on RSM RUN Mode Locked In the Run mode the controller performs all control and communication tasks needed for steady state operation On line configuration edits and configuration changes are inhibited SIL application must operate in this position SIL requirements may not occur in other operational modes RUN PROGRAM Mode Unlocked In the Run Program mode steady state tasks are executed and on line configuration edits are permitted Configuration changes made in this mode are retained in both RAM and Flash memory in the controller PROGRAM Mode Locked In the program mode all outputs are turned OFF function blocks do not execute and configuration changes are permitted Exiting the Program Mode performs a cold start which clears all timers counters totalizers and other function blocks with residual data Function blocks are initialized to their initial state with no reference to previous history Exiting the Program mode updates the RAM and Flash memory of the controller with the most recent configuration data Steady State Operations Lead Controller issues polls to I O Racks for inputs Both Lead and Reserve read I O responses from I O Racks Lead and Reserve both execute function blocks in the control strategy Only the Lead Controller writes physical outputs to
110. TION Do not connect PE Ground Green Wire directly to terminal on Power Supply L1 Hot ade Brown Black Eure USA 14 AWG 2 1 mm Copper 75 C Blue White Eure USA le PE Ground Yellow Green 14 AWG 2 3 mm Copper 75 C Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 69 Rack Installation Assemble Controller Rack Step Procedure Commenis References Ay WARNING AY Ensure that AC power to the rack is disconnected Set controller module s communication ports to desired settings page 40 Carefully place the Controller Module in the rack immediately to the right of the Power Supply Fasten it in place with two captured screws at top and bottom ATTENTION Do not install the battery at this time Installing the battery s before the controller is configured can substantially shorten battery life Install under power after the controller configuration is complete For more information refer to Battery Installation Replacement page 196 I O will be installed later See Page 74 70 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Assemble Controller Rack Table 10 Assemble C75 Controller Rack Step Procedure Commenis References 1 Carefully place the PO2 Power S
111. TP A for Inputs 1 to 8 EXT 24V Install 24V wires as shown 22 to 10 EXT 24V RTN 22 to 12 24VRTN to 9 External 24VDC supply 24VRTN to 11 236 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP A Cable wire positions and colors for cable assembly drawing applies to 8 AO Twisted Pair Number of HC900 Module TB Position RTP A J1 Plug Connector Color Cable A 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 36 17 Black 35 16 Blue 5 36 15 Black 35 14 Yellow 6 10 12 Black 11 11 Brown 7 12 1 Black 13 2 Orange 8 15 4 Red 16 5 White 9 3 8 Red 8 18 Green 10 9 13 Red 14 3 Blue Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 237 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP A J2 J3 J4 J5 HC900 a Terminal y y y Block Ji c1 ci ci ci SW SPST TB 1 6 aeee T es 2 T TET A le _ et 3 8 ae fie A ay PTH Ss E Ff 2 4 9 en wes 5 10 ee rr 6 20 hd 7 B er 8 18 ees ee 36 17 a eT aD 35 16 _ en e
112. Table 8 Mount Racks Step Procedure Commenis References 1 Mount the Rack in the enclosure as follows e Using the diagrams below as a guide mark the locations for rack mounting in the enclosure for the top holes in the rack See CAUTION and Note at right Drill and tap for 10 or M4 screws e Start the mounting screws supplied by the user in the drilled holes e Hang the Rack on the screws at the top e Mark the locations for the bottom screws See CAUTION at right Drill and tap for 10 or M4 screws e Remove the rack from the enclosure For dimensions of the pattern for drilling holes refer to the diagram below CAUTION the electrical cabinet When drilling holes prevent metal flakes from falling into the rack or onto any surface within 66 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Mount Racks Step Procedure Commenis References 1 alt racks on alt anoeoor Reference Center for Drilled Holes _ at Top of Rack A a hars 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 Not
113. The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices or communication traffic other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings e Components of the Ethernet Open Connectivity Network are those which link an HC900 Process Controller to Peers to HMI Supervisory Stations and to other Ethernet 10 100Base T devices that support TCP IP The Ethernet Open connectivity Network is potentially more complex than the I O expansion network and in some cases may require the services of an IT networking professional 30 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture I O Network 1 0 Network I O Expansion Network C50 and C50S C70 and C70S CPU only Examples of HC900 Controller I O expansion configurations are shown in Figure 18 CE Figure 18 HC900 Controller Configurations In any of the racks shown in each controller configuration can be 4 8 or 12 slot versions The Ethernet cables for the I O expansion links are standard shielded Cat 5 cables with standard RJ45 connectors Each cable segment can be up to 100 meters 328 feet long You can also
114. aaah 54 Hardware and wiring requirements for safety CONFIQUIATION 0 0 2 cece eeeteeee eect eeeeeeeteeeeeeeeeeeeetaeeeeeeeeetes 60 System Monitor Function BIOCKS cc ccceeeeeeeeeeneeeeeeeeeeeeeecaeeeeeeeeeeeceeaaeeeeeeesegecaaaeeeeeeeseesecuaaeeeeeees 62 Rack MVS tl AOI jesus ete ca leas latin aad Se ect eee a ia Re oe NAA A ee ee alata 63 OVEN E AA as ea ee aes vevevalatons sanded 63 MOUNE RACKS esfihete tenet ied tenets believed evelsbel tetevetabetlectunet deel ATATA arana aa iaa a iania nipa ERAS 66 Assemble Controller Rack siie eel ii aes ig nee A SS eee cept ee ede geen 68 Assemble I O Expansion Racks ccceeeceeneeeeeeeeeeeeeeaeeeeeeeeecececaeeeeeeeeeeeceaaeeeeeeesegeecaaaeeeeeeeeteeenaaees 72 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual vii January 2014 This page is intentionally left blank O Module Installation and Wiring 00000008 74 VO Module Installation and Win Gx sestasstasscs ives ces adele rence detente led a 75 OVOCIVIOW siiserstetetatteteteteceuetvnectemuee ceca ech etedcthdet tated edad E iets 75 Module Placement in R CkS ccccccceeeeeeeeeeenee eee eee eeeececee steerer eeeaaeee tees eedecaaaeeeeeeeeegeegaaeeeseeeeneee 75 Remote Termination Panel RTP cccsecceeeeeeeeeeeeeeeeeeeeeeee eee ee eeeaeeeeeeee rene aaeeeeeeeetteecaaaaeeeeeeennnee 77 Terminal Block to Field Signal Wiring cccceceeceeeeeeeee
115. acy 1500 mA Controller C75 C75S New 1 0 670 mA 0 mA legacy 750 mA Scanner 1 Port S50 S50S New 1 0 770mA OmA legacy 950 mA Scanner 2 Port S75 S75S New 1 0 Power Status Module PSM 22 mA 0 mA I 0 Analog Input 8 pts 40 mA 25 mA I Analog Input 16 pts 75 mA 50 mA I Analog Output 4 pts 40 mA 200 mA I Analog Output 8 pts 225 mA 350 mA 1 Analog Output 16 pts 350 mA 700 mA I AC Digital Input 16 pts 130 mA 0 mA I 0 DC Digital Input 16 pts 130 mA 0 mA 1 0 AC DC Digital Input 16 pts 130 mA 0 mA 1 0 Contact Input 16 pts 130 mA 40 mA I DC Digital Input 32 pts 215 mA 0 mA I 0 AC Digital Output 8 pts 220 mA 0 mA 1 0 DC Digital Output 16 pts 340 mA 0 mA I 0 DC Digital Output 32 pts 235 mA 0 mA I 0 Relay Output 8 pts 110 mA 100 mA I Pulse Frequency Quadrature 110 mA 250 mA I 44 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning AC Power Supply Selection for racks with I O Limit 10 4 channel Analog Output modules per I O rack Total mA 5V Total mA 24V Limit 4 PFQ modules per I O rack 1 Complete columns A D and E above 1 ls column D total mA 5V le
116. al not both sides of the DC power See page 234 for RTP internal schematic 230 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 Install jumper wire DC Supply Note DC Outputs provide electronic overload protection in the module but adding a fuse see picture protects the wiring Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 231 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point AC Digital Output EA ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 8 point AC Output is limited to maximum of 2A per output for any VAC 6A per RTP for 240VAC 8A per RTP for 120VAC ATTENTION The RTP combines the 8 isolated outputs into one group of 8 Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect desired cable to 8 point AC DO module at controller Choose from 9OORTC H010 Remote Terminal High Voltage
117. an I O Terminal occupied by an I O Block assembly except that it does not include the wire module install a Filler terminating block screw terminals The Filler Block mounts in Block cover Part number the same manner as a Terminal Block with captured screws at 900TNF 0001 top and bottom Blank labels are provided for mounting in the hinged door I O Terminal Block Wiring Diagrams Universal Analog Input Module Wiring The Universal Analog Input Module has eight inputs which can include any combination of the following input types RTD TC Ohms Millivolt Volt or Milliamp Figure 43 shows wiring examples of each of the analog input types An example of wiring for eight TC inputs is given in Figure 45 Specifications for this module and for other modules are given in the Specifications section of this manual H ATTENTION To indicate sensor failure the Analog Input software will output a warning if thermocouple resistance gt 80 ohms Use appropriate gauge wiring to prevent inaccurate failure warnings Table 15 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F IAWGNo Diameter TypeK TypeJ Type T Type E Type S Type R TypeWw5 Type W inches PY PT110 PYPT113 W26 W26 10 0 102 0 058 0 034 0 029 0 069 0 018 0 018 0 023 0 020 12 0 081 0 091 0 054 0 046 0 109 0 028 0 029 0 037 0 031 14 0 064 0 146 0 087 0 074 0 175 0 045 0
118. and E2 PC hosts may include for example HMI supervisory software and or Designer Software configuration software Redundant ports may be used in a simplex mode non redundant Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 33 January 2014 Components and Architecture Ethernet Open Connectivity Network Peer to Peer Communication Peer to peer communication enables any given HC900 Controller to request a peer relationship with up to 32 other HC900 Controllers on the same subnet other controllers can request a peer relationship with the controller The total number of peers that a controller can have a relationship with is 32 Peer to peer communication uses the Ethernet Open Connectivity network and employs standard User Datagram Protocol UDP for fast and efficient transfer of information Peer to peer communication is based on fail safe and data expiration mechanisms that provide for fault and loading considerations without requiring reserved network bandwidth allocation Peer to peer is designed to be easy to configure as part of a device s standard configuration and does not require the distribution of a global database With redundant controllers peer to peer communication always stays with the Lead controller Implementing peer to peer communications involves e Interconnecting controllers with Ethernet media and networking devices cables switches etc e Configuration via Designer Software
119. and Replacement Procedures ccccccceeeeeeesecceeeeeeeeeeeeeeeeeeneaeeeeeeeeeeeenee 189 OVON OW N ea ase a CNG a a eaaa ae aaan 189 Safety Considerations PLAN AHEADI 0 ceeeeeceeeeee cece eeeeceeeee eee ee eeeeeaeeeeeeeeeeeeecaaeeeeeeesteeeesaaeeeeees 189 MD OCIICANONS c 22 ct coritas2 sates a a AG Gai a A tance ta aa 199 General Specifications cccccccceeeeeeeeececee eee eeeeeeeaeeeee eee etecaaaeeeeeeeeegseaaaeeeeeeeceegeaaaaeeeeeeeseeeneaeeeeeeess 199 System Sizing and Availability SUMMATPY 0000 2 ce cece cece cece ee eeeeneee eee eeeeeeeeaeeeeeeeeeseceaaaeeeeeeeesseenaaeeeeees 208 Fiber Optics Recommendations c cccceeeeeeeeeeeeeeeee eee eteeeeeeeeeee eee eteecaaeeeeeeeeeeecaaaeeeeeeeeegeesaeeeeeeees 209 Appendix Installation of Remote Termination Panels RTPS cccceeeeeeeeseesettneeeeeees 211 OVC OW A E E ETE E 211 Analog Ips s eita a aa aer aaa ha ot aise cee ayasha ail wen ciicsniiddsusueniesicy cnppastesuapannecet 212 Pielay Output Tenen bea eae all ade bel ac ce is lai saat oh os alaaa Studs dddeddtacetaeaeet 219 Analog Input Digital Input Digital Output Analog OUtpUt cece ceeeeeeee eee eeeeeteeeeeeeeeeeeeeneeeeeeeeeeeeeeaaes 223 Declaration Of GOMEOUMULY Faes niana es Des cot esi a oan ee ea a at he sad ec ead 249 POPE IGS FUNC OU a aes Seca Stk ea a teo ees ete tee vat eens mse esa ce dec ei beeste eee AAT 250 IIIB EE EETA r stem enmacen E EE EET ate 251 Revision 2 1 HC900 Pr
120. and Troubleshooting Scanner indicators Scanner Diagnostic LED Indication The scanner uses its LED to communicate diagnostic information These diagnostics are a subset of the main CPU s and are listed below Table 29 Scanner LED Diagnostics Number Possible Cause Scanner Action User Action of Strobes 1 RAM or ROM failed diagnostics on Executes an infinite loop that toggles the LED 1 Cycle power power up Communications and module scanning are 2 Repl disabled Module outputs are in the power off nce ore ne state DO outputs are off and AO outputs 3 Replace rack are at zero milliamps 4 Check grounding 5 Ensure system is properly isolated from noise 2 The scanner has no configuration Modules are not scanned and the outputs are 1 Verify that the address data because it is unable to communicate to the controller CPU Possible causes include Scanner address switches are not correctly set C75 only The C75 I O port is connected to the wrong Scanner 2 I O port If a switch is used there may be a problem with it Cables are defective or are not properly shielded Controller CPU is not powered Controller CPU and Scanner firmware versions are incompatible Defective Controller CPU Scanner power supply or rack either at failsafe or in the power down state If communication was lost while the modules were being scanned then the module outputs are in their failsafe sta
121. ansition can be initiated by operating the Mode switch on the controller or RSM or by exiting the Program mode at a Control Station e When initiated by the user after download with Cold Start selected or any transition from PROGAM Mode to RUN Mode 152 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Operating Characteristics Power Down Power Up database invalid database Operate in RUN Mode Operate in PROGRAM wi initialized process values Mode w all outputs off Figure 84 Cold Start Operation Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 153 January 2014 Operating Characteristics Controller Modes Execution sequence e The type of control functions executed during a scan is determined by the system configuration Controller configurations contain a series of algorithms in the form of function blocks that get executed in a fixed sequence The first 100 function blocks are pre assigned by the system to handle communication tasks alarm processing system monitoring functions etc and cannot be changed by the user Starting with function block number 101 the user may select the type of function to be executed e The sequence of function block execution is initially determined by the sequence in which the function blocks are placed on the graphic diagram in HC Designer Final desired sequence must be set by th
122. anual Revision 2 1 January 2014 This page is intentionally left blank 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 59 SIL applications require an external blocking diode used to insure inputs are protected from ground faults See HC900 Process amp Safety Controller Safety Manual for additional details Specifications for the Contact Input Module and other modules are given in the Specifications manual Internally Powered Input Channels The Contact Input Module provides voltage to the field contacts A CAUTION Do not apply any external power to the field device or to the input terminals Doing so could damage the module Common terminals Four common terminals are provided for the 16 inputs Terminals 9 10 11 and 12 are connected in the Contact Input module A WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 107 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Contact Input aS O sam IN
123. as with high levels of moisture dust and corrosive materials 52 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Cable Wiring Distance Planning How to make Ethernet cables Ethernet cable shielded Cat 5 contains 4 twisted pairs of wires and a drain wire Each pair consists of a solid color wire and a color wire with a white stripe 1 Hold the cable ends and RJ45 connectors side by side as shown 2 For straight through cable arrange wires as shown in the following table Wires go straight through no crossovers Straight through cable assembly Cable left end 10Base T 100Base T Cable right end Left to right Signal Description Left to right Wire color pin number Wire color pin number white orange 1 TX white orange 1 Orange 2 Tx Orange 2 white green 3 Rx white green 3 Blue 4 Unused Blue 4 white blue 5 Unused white blue 5 Green 6 Rx Green 6 white brown 7 Unused white brown 7 Brown 8 Unused Brown 8 3 Crimp an RJ45 connector to each cable end To ensure reliability do not untwist the pairs any more than necessary to complete the crimp connection Use care to ensure that the cable drain wire is securely connected to the shield of the RJ45 connector when the cable is crimped Reference the manufacturer s instructions Revision 2 1 HC900 Process amp Safety Controller User and Installa
124. as a Master of Slave Use HC Designer software to configure the controller s RS 232 port as a master or slave 150 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Operating Characteristics Introduction Operating Characteristics Introduction This section applies to all controllers that is non redundant and redundant For operating characteristics unique to redundant controllers see Redundant Operating Characteristics on page 161 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 Locke
125. ation Manual 155 Operating Characteristics Controller Modes Table 22 Controller Operating Modes Mode Name Functions in selected mode RUN I O scanning Controller and Expander Racks Function block execution outputs are set according to function block algorithms Monitoring of Diagnostics controller rack and I O expander racks Detection of I O Modules Other functions permitted e Downloading of configurations e Indications of Forces at Status LEDs on I O modules Other functions NOT permitted e Al calibration e AO calibration PROGRAM I O scanning Controller and expansion Racks is performed but function blocks are not executed and all outputs digital and analog are set to OFF See Note 1 Monitoring of Diagnostics Controller and Expander Racks Detection of I O Modules Other functions permitted e Al calibration e AO calibration e Downloading of configurations e Downloading controller firmware Program Locked or Program Other functions NOT permitted e Indications of Forces at Status LEDs at I O modules OFFLINE IO scanning Controller and Expander Racks is performed but function blocks are not executed and all outputs digital and analog are Frozen see Note 2 at the states they were in when the OFFLINE mode was selected Monitoring of Diagnostics local and expanded racks Detection of I O Modules Other functions permitted e Al calibration e Indications of Force
126. ation file and loading it into the Controller Module This file includes I O numbering assignments for each I O Function Block regarding Rack Number Module Number slot number or position in the rack starting from the left and Channel Number e Physically assigning Rack Numbers by positioning DIP switch settings in the Scanner Module for each rack e Placing the appropriate module type in each slot in each rack The I O expansion network uses Honeywell private protocol that optimizes I O performance and security The configuration and operation of the I O expansion network is automatic it is entirely under control of built in private software that resides in the Controller Module and in each Scanner Module included in the HC900 system The controller examines the control strategy stored in its memory verifies that the physical configuration Rack Numbers and I O Module type by Module Number matches the stored control strategy and establishes communication with each of the I O modules in each of the I O racks I O Expansion Network C75 C75S T O for redundant controllers is the same as I O Expansion Network page 31 with the following exceptions notes e In Figure 18 any of the racks shown in each controller configuration can be 4 8 or 12 slot versions Redundant I O power not available with 4 slot e Double the amount of Switches and Ethernet cables are required to configure the redundant I O Link e Maximum of 2 switches
127. atures hardware 11 LO network 32 VO wiring 52 network 33 network connections 143 networks 141 operating characteristics 1 151 161 peer to peer 34 Power Status Module 25 power supplies wiring of 56 power supply installation 72 rack dimensions 47 start up 161 steady state operations 162 Relay Output Module Wiring 116 118 Removal and Insertion Under Power 80 Removal and Replacement Procedures 189 Replacing an I O Module 194 Replacing the Controller Module 192 Replacing the Power Supply 190 Replacing the Scanner Module 193 Reserve Power Supply 22 23 RIUP 80 189 194 Router 34 37 RS 232 129 130 RS 232 Modem 29 RS 232 Port 26 RTD Input Wiring 91 RTD Inputs 88 RTU 35 RUN Mode 154 S SCADA 36 Scanner 2 Module 22 28 Scanner Diagnostics 177 Scanner Module C50 27 scanner rack assembly 72 Serial port accessing See Controller access Serial ports 39 RS485 RS232 39 S1 S2 39 service provider 37 shielded twisted pair 57 Signal Grounding 78 Simple Mail Transport Protocol 37 Site and Equipment Preparation 64 SMTP 37 sockets 35 Specifications 199 SpecView32 36 Status 151 Subnet Mask 34 System Monitor Function Blocks 62 T tagnames 81 TCP IP 35 Telephone and Email Contacts iv telephone links 29 terminal block 75 Terminal Block Colors 76 Terminal Block Styles 76 test points 69 The Fix 36 transmission delays 52 U UDP 34 Universal Analog Inp
128. ble 24 Run Run Pgm Fail Pgm L Over Run Pgm Pg Run Run Pgm Figure 85 Mode Switches Controller left RSM right Table 23 Mode Switch Functions Mode Name Mode Selections at Switch Function Operator Interface RUN None locked in RUN In this position the Controller is locked in the RUN mode of Locked operation Run mode configuration changes are disabled and mode cannot be changed at any operator interface SIL application must operate in this position SIL requirements may not occur in other operational modes RUN PROG PROGRAM In this position the mode can be changed at any operator interface using screen selections PROGRAM RUN or RUN OFFLINE OFFLINE PROG None locked in Program In this position the Controller is locked in the PROGRAM Locked mode of operation Mode cannot be changed at any operator interface While in PROG position the S1 serial port is set to Honeywell ELN protocol This temporarily overrides the configured settings for S1 port With your PC s serial com port connected to S1 use Designer Software s Utilities to view any setting of any controller port such as network IP address and change if needed Refer to Designer Software documentation for details Placing the Run Program switch in RUN or RUN PROG mode returns S1 to its configured protocol and settings Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 157
129. cates a bad power supply diagnostic and replace the defective supply See POWER SUPPLY DIAGNOSTICS in the associated rack s Rack Diagnostics Overview display See Power Supply Diagnostics in Rack Diagnostics dialog box 174 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Number Possible Causes Lead and or Reserve Controller User Action Honeywell Ol HCDesigner HC of Red Action s Indication Utilities Indication Strobes 8or9 If 8 flashes the S1 1 ASYSandFSYS blocks HW t Check baud rate serial port is reporting a OK pins are turned off gt Check connectors diagnostic 2 If configured as a Modbus 3 Check cable polarity If 9 flashes the S2 master serial port is reporting a ASYS and FSYS blocks 4 Isolate cabling from electrical diagnostic Modbus Master Fail pi nee pins are Possible causes are tumed on 5 If RS 232 to RS 485 converter is i used check its power switch jumper e Ifthe portis e Slave and read blocks settings and polarity configured as a associated with the slaves Modbus or ELN experiencing the failure have 6 If configured as a Modbus master slave the data link their read pins frozen tothe last USe the slave status screens to layer is reporting value read determine which slaves are that at least 75 of r
130. cs ccccccceeeeeeeeeseeeeeeeeeeeeeeeeeeseeceeaeeeeeeeeeeeeeees 161 OVENVICW AA Ye A E AN 161 SAE o EEE AE EPE EATE EET E E E EET 161 Modes of operation Figure 87 cccccccceceeeeeeeeneeeeeeeeeeeneeaeeeeeeeeteeaaaaeeeeeeeeeegaaaaeeeeeeetteesaaaeeeeeees 161 Steady State Operations ss arr aaraa aa aa a aa a aa aaia EaR ES 162 FAN OW Cleo ieee eaen n e e Mea a Ae e RN cal a aa i aaae aea a oea oar 164 File Download Upload Functions cccccccceceeeceeeneeeeeeeeeeeeeceeeeeeeeeeeeeceaeeeeeeeeeesecaaeeeeeeeeeseeessaeeeeeees 165 Diagnostics and Troubleshooting cccceeeeeeeeeeeeeeeeeeeecceeeeeeeeeeeeeeeeeeneneeeeeeeeeeeenee 167 OVENWIOW sitet cree BARR SN RAE A tea talanadadede fudan denuded E 167 External Indications of Diagnostic Information ccccccceeceeeceeeeeeeeeeeeneeeeeeeeeeseeeneeeeeeeeeeseeesneeeeees 167 Controller CPU indicators so eee ge e pea nc vraag pag ee ESP aa a eee event ae eg ecient 168 SCANNMEMUMGICALOMS arria Peete EENE A Ea a a aaa aa Aaa aE E BARRARE 176 VO Mod l Indicators ee a aaaeaii tatad tad nara a r Aeara Ka aaa aaia lest testi a eieaa aaia aata En 180 This page is intentionally left blank Analog Calibration sssseeeseeeeeeeeeeeeeeeeeeeees 184 viii HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 A na l g Calibratio M Asiria E aE E at ee aes pede 185 OE EE Ste da a eh E E AE E 185 Removal
131. cseecsscecseeeseeesseecssaeesseesseeessaeeesaeeesaes 106 Figure 59 Contact Input Wiring Diagram 00 ee eeseeeseceseeesseeceseeescecesaeessaecesaeessacessseecsaeessseesseesenaeeesaeensas 108 Figure 60 DC Output Module Wiring Diagram eeeecceseeceeneeeeneecsseecsacessaeeesseeesacesssaecsaeesesaesseesesaeeesaes 110 Figure 61 DE Output Jumpers as scons eee dese A Re ee ede st ele 111 Figure 62 32 point DC Output Module Wiring ee eeeseseseeeeneeeseecsseecsacecsaeecseeesaeecsaecseeseeesesaeeesaeeesaes 112 Figure 63 AC Output Module Wiring Diagram eeceeeesseeceeseeeeseecsaeeesaeessseessaeeesseecesaessaeecsseeseseesesaeeesaes 114 Figure 64 AC Output Module Jumper ec eeeeessccescecsneecssceceseecsseeeesaeessaecssaeeesacecsseecsaeecseessneesesaeeesaeesses 115 Figure 65 Schematic Example Relay Output and External Wiring ee eeceeeeeeeeeeeeneeesneessaeessaeessaeeesneeesaes 116 Figure 66 Relay Output Module Wiring Diagram eeceeeeessseeesseecseeeseesseeesseeesseecssaecsaeecssaeceeesssaeeesaes 117 Figure 67 Relay Output Module Jumper 0 0 0 0 ceescceeseecesceesseeceseeesseeesaeessseecsaeessaeesssaecsseecseesesseseseeeesaeersas 118 Figure 68 Pulse Counts Wirt ois sch ees iea ti bidebaendpetacdesdeter alas deccie assets SEEE EEEE ESG 119 Figure 69 Pulse Output WTNS esiaren a ae E EEEa EET adelaide EEE a E EEEE EEE 119 Figure 70 Fre uceney WIEME aiana EE E ce
132. ct Ethernet connection See page 145 e D Networked Ethernet connection See page 146 These methods are described below ATTENTION Always observe the wiring cabling guidelines on page 52 128 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software A Direct Serial RS 232 Connection Legacy Controllers Com1 Com 8 du Null Modem cable RS 232 Configuration port PC Figure 75 A Direct Serial RS 232 Connection ATTENTION Always observe the wiring cabling guidelines on page 52 Step Procedure 1 Prepare a null modem cable Refer to RS 232 Converter Direct Link to PC Configuration Tool page 130 for specific instructions on the null modem cable 2 Connect one end of the null modem cable to the HC900 controller s RS 232 configuration port 3 Connect the other end to an available serial port COM1 through COM8 on your PC Refer to RS 232 Converter Direct Link to PC Configuration Tool page 130 for specific instructions on the null modem cable 4 If a configuration is not available start a new configuration in HC Designer by selecting File New After selecting controller type and revision select OK 5 From the Utilities Worksheet Utilities tab in the main window in the HC Designer software set up the PC s serial po
133. ctors C75 CPU B s I O port to Scanner 2 s I O B port Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 125 January 2014 Communications Installation Wiring and cabling Controller Link Type Cable Type To Device Port Details Port Controller to Connector Type I O 2 or more I O Shielded Ethernet C75 CPU A s I O port to No foreign messaging 100Base T racks CAT5 cable with RJ 45 approved unmanaged permitted connectors switch From this unmanaged switch to each Scanner 2 s I O A port One 1 additional unmanaged switch may be used for a total of 2 unmanaged switches between CPU A and the I O racks C75 CPU B s I O port to approved unmanaged switch From this unmanaged switch to each Scanner 2 s I O B port One 1 additional unmanaged switch may be used for a total of 2 unmanaged switches between CPU B and the I O racks 126 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the Operator Interface to the Controller Connecting the Operator Interface to the Controller Using parts in Table 18 connect the Operator Interface to the galvanically isolated RS 485 port on the controller for legacy systems For new systems the parts in Table 18 connect to either of the two galvanically isolated RS 485 ports on the controller See page 39 for port location Typically the cable that interconnects
134. custom set of drivers for his specific application or may purchase additional software for example OPC with Modbus TCP protocol to reduce or virtually eliminate development tasks HMI software HMI software available for use with the HC900 Controller includes but is not necessarily limited to the following packages e available from Honeywell Experion HS Software which operates under Windows 7 operating software provides PC based supervisory control and data acquisition This package includes a large selection of standard operating display templates which can reduce development time significantly Experion HS includes a full graphic display development environment enabling development of custom graphics that include animated responses to changing process conditions A batch reporting option is available which includes a standard template for creating batch reports SpecView32 SpecView Corporation Matrikon OPC Server works with redundant and non redundant networks e Other software available from third party sources The following software which incorporates Modbus TCP connectivity is available from third party sources The Fix Family Intellution Incorporated Wonderware Wonderware Corporation Citect CI Technologies OPC server client software various available from Kepware and others 36 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Componen
135. d Program Offline Run and Run Locked Operating Modes are selected by positioning the Operating Mode switch on the Controller Module or RSM by selecting parameters on displays Control Station Designer Software In some cases mode transitions also restart Cold Start or Warm Start controller operation e Results of diagnostics in case of system hardware or software fault the controller automatically alters operation as appropriate for the diagnosed conditions Power Down Power Up The HC900 Controller is designed to facilitate restoration of process operation after a power outage The active control configuration is maintained in battery backed RAM and the last configuration update performed in the program mode is also stored in Flash memory on the Controller Module When power is restored the system automatically enters a diagnostic procedure that checks the integrity of hardware software and the control 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 83 diagnostic testing proves the integrity of the hardware software and configuration database resulting in an automatic Warm Start of process con
136. d or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication High temperature condition in a Scanner 2 rack has been detected 1 Associated Al blocks that are configured as T Cs set their fail pin on their warn pin off and their output pin to the failsafe value 2 Associated Al blocks that are configured as T Cs set their IO status to either CJ High Temperature if one of the two CJs on an Al card is indicating a temperature greater than 70 degrees C CJ Failure if both CJ sensors are failing to convert 3 Associated rack monitor block s module fail pin is tumed on 4 Associated rack monitor block s RACK OK pin is turned off 5 Associated rack monitor block s HITEMP pin is turned on 6 ASYS and FSYS blocks HITEMP pins are turned on 7 ASYS and FSYS blocks HW OK pins are turned off Scanner 2 has a CPU or Memory diagnostic 1 Associated rack monitor block s RACK OK pin is tuned off 2 ASYS and FSYS blocks HW OK pins are turned off See CPU or MEMORY in the associated rack s Rack Diagnostics Overview display See CPU or Memory in Rack Diagnostics dialog box A Scanner 2 rack has a bad power supply 1 Associated rack monitor block s RACK OK pin is tumed off 2 ASYS and FSYS blocks HW OK pins are turned off Locate the Scanner 2 that indi
137. d to Protective Earth at the source of supply in accordance with national and local electrical code requirements Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 This page is intentionally left blank vi HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Contents a igo o Ole s q emer eee ese nar meer cere ere remy trey a ere erer rey e A O ter nr er E 1 PUPOSC strectesesect te a ierehecetehs CoP feladeta tated AE AE E Minn ator eles olng olan cede laa mote tect camera chad has ah ts ode 1 Model Selection Guderne de Ai ee het OR ee iad 2 Functional Description c cccceeeeeeeeeeeeee eee reece ence eee eter erent eee eter eet aee eee e eee aaaeeeeeeeneeeeaaaeeeeeeeeneeeea 8 FOature S mmani ed tet Shaded AeA AH Atace chen a E AAN N EEN EAEE E REAA 11 Components and Architecture sfc ess aires Saad holes eae ears ie iacaetear diate ae 15 Oveni oW niente See i ete ee eee een ached Sle nn as 15 COMPONENTS ar ssh e EE A Aaa aeaa a a E A a A AEAEE EEES 15 Redundant COMPONENS eeeeeeeeeeee cette eee e center ee eee Attert EEE EEAENEEEEEEEEEEANEEEEEEENNASEEEEEEEEEAN SEEE EEEE Enas etna 18 Hardware O20 11 00 1 0 a eaaa re aate er aaraa ae na iai ee Eep aiaa ai aaae ieaiaia eieaa 20 Ethernet Devices Considerations ccccccccccceeeeeeeeeeeeeeeceeee eee eeeeeecneee sees ee eececcaaeeeeeeeeteccaaeeeeeeeneeee 30
138. de 51 52 25 109 62 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Overview Overview Rack Installation This section contains procedures for installing one or more HC900 Controllers It is recommended that the information in this section be reviewed before beginning the installation Familiarity with the overall procedure will help to prevent errors and will promote efficiency in general Tools Required The primary tools required during installation are listed in Table 6 Table 6 Installation Tools Item Description Comments Common tools 1 e Wire strippers For Power Supply and for I O Wiring 2 e Crimper For Terminal Lugs on Power Supply wiring and on I O wiring shields Screwdrivers 3 e Small flat tip For Euro style Terminal Blocks 4 e Small medium flat tip or Phillips For Barrier style Terminal blocks also for captured screws in Terminal Blocks 5 e Large long blade For use as I O Module extractor Other 6 e Electric drill with drill bits for 10 or M4 For rack mounting screws and with drill bit extender 7 e Vacuum cleaner brush For use during and after drilling operations 8 e Pen ball point or felt tip for entering data on For entering data on labels for I O modules labels for I O modules 9 e Multi Meter Volt Ohms Amps For safety checks and for equipment test 10 e Soldering pencil or gun for attaching filter For attaching f
139. dem 4 Run a serial communication port program such as Hyperterminal 5 Within the communication program select the port to which the modem is connected 6 Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key 8 In the program s terminal window key in in the following command string AT El Q0 Then press the ENTER key The modem should give an OK response 9 Key in the following command string AT amp CO amp DO amp KO amp R1 amp SO amp YO SO 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp W0 The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem s serial cable to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 139 January 2014 Communications Installation Connecting the HC900 Controller to a PC with
140. dicates On or Off status of the output including if Forced 180 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting I O Module Indicators 1 O Module Diagnostic Indication To indicate the type of diagnostic failure the module s status LED is flashed red with a number of quick strobes followed by a long off time Table 31 outlines the potential module diagnostics Table 31 I O Module LED Diagnostics Number of Failure ae Al AOJ DI DO Contact AC Relay AC PFQ User Action FAIL SAFE The module is in the failsafe state because itis not receiving message requests from the CPU or Scanner at arate that satisfies the configured failsafe timeout VW ae Ni ae 1 If expansion I O rack go to step 2 If no expansion I O rack go to step 3 2 Check the Scanner status LED see p 176 If it s flashing 6 times proceed with step 3 If its flashing some other red status code refer to Table 29 to solve that problem first If it s flashing green the module probably is not required in the configuration If i s not on or steady cycle power to the scanner 3 Make sure the module is the correct one for the configuration 4 Remove the module and check for a bent pin then reinsert the module 5 Replace the module 6 Remove other modules and replace one at a time until the problem
141. e The plastic bag also includes four M4 screws for attaching the grounding wire lugs which are attached later Attach the M4 screws loosely to the grounding bars for safe keeping Hang the rack in the enclosure on the top screws Start all screws in the bottom of the rack then tighten all screws Note You may find it easier to postpone this step until after all components have been installed in the rack Repeat for each rack in your system Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 67 Rack Installation Assemble Controller Rack Assemble Controller Rack C30 C50 C70 Controller Rack assembly information is given in Table 9 C75 Controller Rack assembly information is given in Table 10 Table 9 Assemble C30 C50 C70 Controller Rack Step Procedure Commenis References 1 Carefully place the Power Supply in the leftmost slot in the Rack ensuring that the connector at the back seats properly Insert a slot screwdriver in the slots at the top and bottom of the power supply cover while pulling backward to open the cover Fasten the screws captured in the face of the power supply into the tabs at top and bottom of the rack Ay WARNING Ay Hazardous Voltage e Ensure that wiring to the Power Supply is disconnected from the site AC source before installing wiring e D
142. e devices and communicating with a Host PC application Detection of a fault or removing power from a Reserve Controller will initiate a diagnostic prompt in the Lead Controller but will have no impact on the process under control The detection of a fault or removing power from a Lead Controller will initiate failover that is transfer all primary tasks to the Reserve Controller establishing this controller as the new Lead Following a failover the new Lead Controller will remain the Lead even if the condition that caused the failover is corrected Start Up e Assignment of Lead and Reserve status is determined at start up First available C75 assumes Lead In case of a tie CPU mounted in the left position of the rack will Lead No user configuration or manual operations required to establish Lead Reserve status e Lead Controller assumes control of I O and all external communication interfaces e Reserve Controller receives the configuration from the Lead Controller Modes of operation Figure 87 The modes of operation are e Run e Run Program e Program You can change modes with e key switch on the redundancy control module e HC Designer software e HC Utilities software e 900Control Station e a command from a supervisory host Both Lead and Reserve Controllers maintain the same mode Placing the Lead Controller into the Program mode will also place the Reserve Controller in the Program mode Revision 2 1 HC900 Process amp
143. e per device 1 second fastest load dependent 202 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications General Specifications Communications C30 C50 C70 C75 Modbus Master Advanced Application Speed Recommended for use with gateway devices As fast as 500ms Ethernet Modbus TCP Initiator Operation Number of ports per controller Function Block Types Slave devices per controller Number of read write Modbus Parameters Double Register Format Speed One Models C30 and C50 Two Models C70 and C75 RS485 Slave 4 read and 4 write data points Read Slave extension block up to 16 parameters Write Slave extension up to 8 parameters No limit on the number of Read and Write extension blocks per Slave block up to the maximum 1024 parameters per controller Up to 32 Up to 1024 max per controller Selectable per device 1 second fastest load dependent Peer to peer 10 100Base T via Network port No of Peers Controller Update rate Peer Data Supports UDP protocol and Peer Data Exchange function blocks for peer data exchange 32 500 ms to 5 sec selectable Digital and Analog Signal Tags Variables up to 2240 parameters Ethernet Ethernet Network Connection Host Network Protocol 10 100 Base T RJ 45 Modbus TCP Maximum distances per Etherne
144. e remote I O expansion racks in 4 8 and 12 module sizes This reduces required inventories of spare parts and also simplifies removal and replacement procedures Removing the power supply from a rack will remove all DC voltages from the rack that powers the Controller Module or Scanner Module and from all I O modules within the rack NOTE The power supply includes an internal fuse rated at 5 amperes This fuse is not replaceable in the field If desired the user can provide an external fuse that has a current rating lower than that of the internal fuse See page 69 Table 34 Power Supply Replacement all except C75 Step Action 1 ATTENTION This procedure does not apply to C75 power supplies If the power supply to be replaced is powering a rack that is currently controlling a running process then Either e Ensure that powering the rack down will not have adverse consequences on any running process Or e Bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply from the source of site AC power Use a meter to ensure that power is off 3 Depending on the type of wire lugs used loosen or remove the three screws on the terminal board and remove the three wires from the terminal board NOTE DO NOT remove the nut that secures the lug for the PE Ground wire green to the grounding stake at the bottom of the rack
145. e user to achieve proper and optimum performance A CAUTION Incorrect execution sequences can contribute to delays in processing outputs and or improper or unexpected operation e The HC900 controller samples all inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The sequence order of the function block determines when in time the actual value will be updated It is important that algorithms that need updated input values for their calculations have the inputs execute first in the sequence e Except for Time Proportioning Output TPO Three Position Step Control TPSC and Position Proportional Output PPO function block types that update their physical output values while the function blocks are being executed all physical outputs are updated at the end of a scan Controller Modes The HC900 Controller includes three operating modes The purpose of each mode is described immediately below and salient characteristics of each are described in Table 22 The functions of the Mode Switch are described in Table 23 and the procedures that the controller performs in transitions between modes are described in Table 24 PROGRAM Mode In the PROGRAM Mode active control processing is suspended This mode is used for safe execution of utility functions such as configuration download and calibration of analog inputs and outputs All outputs are Off
146. ear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 16 5 419 1mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 20 9 530 9 1mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm 5 4 137mm H x 22 5 571 5mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 199 Specifications General Specifications C30 C50 C70 C75 12 I O slot chassis with redundant power support Redundant CPU rack 5 4 137mm H x 26 9 683 3mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 175 3mm N A 5 4 137mm H x 10 3 261 6mm W x 6 0 151 7mm D rear mounting plate extends height to 6 9 6 4 162 6 for 32 DI DO and 16 Al Modules 175 3mm 1 0 Wiring Type Terminal Block Styles Gauge wires Shield terminals Removable terminal blocks 20 screw Barrier or Euro style tin plated or gold plated for DC connections 36 screw Euro style gold plated Required with certain higher capacity modules 20 screw Barrier style 14 to 26 AWG solid or stranded Euro style 14 to 26 AWG solid or stranded 36 screw Euro style 12 to 26 AWG solid or stranded Optional brackets mounted top bottom of rack
147. eeeeeeeeneeeeeeeeeeteceecaeeeeeeeeeteeeceeeeeeeeeneeeaaaes 77 Removal and Insertion Under Power RIUP cecccceeseeeeeeeeeeeeeeeeeeeeeeeeeeececneeeeeeeeeeteegeneeeeeeeennee 80 I O Module Installation Procedures ceeecceeneee cere ee eeeeeneeee eee eee eceecaeeeeeee ee eteceaeeeeeeeeetecedaaeeeeeeeneeee 81 I O Terminal Block Wiring Diagrams ecceeeeeeeee eee eeeeeeeee eee eee eteeecee sneer ee etecccaeeeeeeeeeeeeccaaaeeeeeeeneeee 88 COMMUNIGATONS Installation csset a ae a Ea a aaa adaa AASA 123 OVOIVICW 50 Re PS ye a a i a E oa ean e ea a a aae a Meee ea a es 123 Aae eo CADIINO ETEA T E TE 123 Connecting the Operator Interface to the Controller ccccccseeeeeeeeeeeeeneeeeeeeeeeeecenaeeeeeeeeeseesnnaeeeeees 127 Connecting the HC900 Controller to a PC with the Designer Software ccccccccssseeeeeeeeeeeeeseaeees 128 Connecting the HC900 Controller to Modbus device s ccecceeeeeeeeeeeneeeeeeeeeeeeeneeeeeeeeeseeeeeneeeees 148 Operating ChatactenStes sis itscnnssen coercion cannes aE yale tale Utley dein Ala es 151 ITFOCUCTION AAEE TA A E EE AE fa taterseereaaastiatees 151 OETA EN AE E E A A A AAA AE AAAA Slee du alsa evened Oe ede ee 151 Power Down Power UDs rtir tnt a a aaa E A A A aaa A AE EERE 151 CoOntrollGr MOGES caie anaa eaaa eaaa tanie r e aa aaa a a Salo tht Sach aaa 154 File Download Upload Funet OS rarere renare enina aataid eda e a aeiaai 159 Redundant Operating Characteristi
148. eeeeseeeeeeenneeeeseneeeenaes 143 Table 22 Controller Operating Mod s sedii niensis chee dus oaae dad Adie E aa ia 156 Tabl 23 Mode Switch Functions se e aa R E a a E Ea E E a ER i 157 Table 24 Controller Behavior in Mode Tramsition ccceseccceeeesececeeneeeeeeneeeeeeeecessaaeeeseneeeseeeeeeeseneeeeeeees 158 Table 25 Configuration file downloading ces eescesscecescecssceceseeesscecesaeessseessaeeesseeesseecsseesseeseeesssaeeesaeensas 160 Table 26 LED Indications on Controller CPUS cceeccesesccesseeesneeeseecseeesacessaeecsseeesseecssaecsseeseseesesaeesnaeeesas 169 Table 27 Controller Status LED Diagnostics airich iieiea ie anria s aeos Te AEA EEEE aa Eei eria inii 170 Table 28 LED Indications on Scanner Module 0 ccecesccceeeeceeeeeeneeeeeeneeeeseeneeecseaeeceseaneeeeesaeeceeeaeeeesnaeeeseees 176 Table 29 Scanner LED Dia on ostics oni aian ei aarete seas dead lyoteeget stents ead AHadish ava setelesd atbyssceste dete 177 Table 30 LED Indications on I O Modulle ceeeesceeseecesceceseeceseeeessecesaeecsaeecsaeessaeecssaecseecseecssaeseseeeesaeessas 180 Table 31 1 0 Module LED Diagnostics ceiien eea a a ae ae iavar 181 Table 32 Bad I O Channel Diagnostics eeecessecsseecescecsscecsneecssaeeeseeceaecesaeessaeeesaeecsaeecsaeecseeseneeeenaeeenes 182 Table 33 LED Indications on Ethernet Switch oo ceeeeescsececssneeesseecseeesaeecsneeeseeeseecssaecsseesssaeesseeseseeessae
149. eeesaeessaeeesaeeesaes 149 Figure 82 XYR 5000 RS 485 Modbus connections with isolator eseceeescsseecsseeseneecsaeessaeessneesseessaeeesaes 150 Figure 83 Warm Start Operation ceeceessecsssecesneeesseecsscecsseecseecssaeceseecssaecessecesseeesseecsaeecsaeessseeseeesenaeeseas 152 Figure 84 Cold Start Operation seesi cee eeeeeeseecssnecesseeeseecseecsaeecsneecssaecssaecessecssaecssaecesseecsaeecsaeecseeseeesenaeenses 153 Figure 85 Mode Switches Controller left RSM right c cceesscceesesceceeeneeeeeeneeeeessaeeeeesneeeeeseeeeeseneeeenas 157 Figure 86 Pathways for Upload Download Transactions cceseceseecsseecesceceseeeesaeeesaeeesaeecsaeeesaeessaeeesaeeesaee 159 Figure 87 Modes of operation on RSM ecceeecesscecsseecsneessseeceseecesaeeesaeessaecesaeessaeessaeecsseesseesseeseseeeesaeesas 162 Figure 88 Lead Controller synchronization csscccesccceseeesscecsseeesseeeesaeesssecssaecssaeecsaeecsaeecsseeeseeseseeeesseeses 164 Figure 89 LED Indicators on Controller CPUs See Table 26 ccceecesscceeeseceeeeeneeeceneeeeesnneeeesseeeesenneeenas 168 Figure 90 LED Indicators on Scanners 1 port left 2 port right See Table 28 00 eeeceeeeeeeeeeeeteeeeees 176 Figure 91 1 0 Module PED indicators s2ic itets eetessitelestdperigssccedengiescdealovcccaetieqaeudive sai aledanseedissceapeedeees 180 Figure 92 Terminal Board Connections for AI Calibration
150. emale modem cable Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected O oa Aa WwW Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key The modem should respond with OK 136 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Step Action 8 Key in the following command string AT YO Then press the ENTER key The modem should respond with OK 9 Key in the following command string AT amp B1 Then press the ENTER key The modem should respond with OK 10 Key in the following command string AT EO Q1 amp WO The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Set the modem switches to the following Switch Setting Position Function 1 ON DOWN Modem ignores DTR Override 2 OFF UP Verbal word results 3 OFF UP Suppresses result codes 4 ON DOWN Suppresses echo 5 OFF UP
151. er grounding and noise immunity 4 Make sure the cables have the correct pinout 5 Cycle power to the Scanner 2 6 Cycle power to the switch 7 Cycle power to the reserve 8 Replace the expansion rack s scanner module 9 Ensure that the Scanner 2 and reserve software versions are compatible If not perform a firmware upgrade 10 Replace the expansion rack s power supply 11 Replace the expansion rack 12 Replace the main CPU 6 The modules installed do not No action is taken Verify that the correct modules agree with those required by the are installed for the configuration configuration 178 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Scanner indicators Number Possible Cause Scanner Action User Action of Strobes 6 The Scanner cannot communicate No action is taken For each module with a red to a module or the module is blinking LED follow the actions experiencing a diagnostic described in the I O Module condition Diagnostic Indication page 181 6 An Al module s CJ temperature No action is taken 1 Improve ventilation to rack reading is indicating a thermal 2 Replace Al module problem The scanner determines this problem not the Al module therefore the module s status LED will not indicate this diagnostic Possible reasons for this diagnostic are 1 One of the two
152. erminal boards from or to field devices will still be present it is essential that field devices are maintained in a safe condition during replacement procedures e Control to all I O expansion racks is lost If power is available to the expansion racks outputs go to configured Failsafe values C75 module e Does not impact the other C75 CPU module which will continue to control the process e Contains start up diagnostics after replacement to verify proper operation e If there is a Lead Controller the configuration database is automatically copied from the Lead to the newly replaced C75 CPU module Before replacement e If possible upload and SAVE a copy of the configuration or ensure that a previously saved copy of the current configuration is available e If possible bring the process to a safe and orderly shutdown Table 35 Controller Module Replacement Step Action 1 If a process is currently in operation bring it to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply in the Controller rack from the site AC power source 3 Observe where communications cables are plugged into the Controller Module and if necessary tag them to identify their functions Unplug all communications cables 4 At the top and bottom of the module loosen the captured screws that secure the module in the rack and remove the Controller Module from the rack
153. ers or Cable 15 24m PC modem cable if used with Modems Honeywell For new system RS 485 to USB converter connects galvanically isolated RS 485 port to USB port Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 17 January 2014 Components and Architecture Redundant components Redundant components Figure 5 Redundant Configuration with multiple I O racks CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe settings 18 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Redundant components Table 2 Descriptions of Major Redundancy Components Key No Component Description Source Name 1 Controller Includes Rack 2 Power Supplies 2 C75 Honeywell Local Rack Controllers 1 Redundancy Switch Module RSM 2 I O Expansion Includes 1 Scanner 2 module 1 Power Supply and Honeywell Rack up to 4 8 or 12 I O modules Optional second Power Supply and Power Status Module PSM on 8 and 12 slot I
154. es E E G Ems y e x ce PA Dod fs E ee 15 4 Mi d eN A bsr Ee 16 5 ct ci A F 9 13 a 3 10 12 En En BUI Ra 11 11 _ ee Pa 14 3 TT s ages rT 13 2 F 42 1 Ss j aoe st m em O 35 14 GES CONdO 16 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 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect terminal block end of desired cable assembly to 16 point Analog Output module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long 9OORTC 3250 Remote Terminal Cable assembly 5 0 meters long Install 16 point Analog Output label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Mount RTPs to DIN rail Latch to rail See page 247 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to Inputs 1 10 RTP B to Inputs 9 16 You can write on the RTPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs 238 HC900 Process amp Safety Controller User and Installation Manual
155. es are required in all configurations Others are optional they are selected as appropriate to provide optional functions and or to size the system either in initial planning or in modifying and or expanding the system to meet changing requirements An HC900 Controller configuration with multiple controllers is illustrated in Figure 4 This illustration includes key numbers that identify components that are described in Table 2 CAUTION Communications lockout is possible in high network traffic conditions Extraneous traffic is possible when sharing bandwidth with other devices We recommend putting the controller on a private network segment Failure to do so could in high traffic cases result in communications lockout requiring the controller to be power cycled Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 15 January 2014 Components and Architecture Components Expansion VO Expansion VO peal a Builg Figure 4 Configuration with Multiple Controllers CAUTION The HC900 expansion I O link is a private network and the switch used for the interconnection of the HC900 Processor and Scanners must not be connected to any other LAN or WAN Likewise no devices other than the HC900 components should be connected to the I O link Switch Failure to comply will cause communication failures on the I O link causing I O modules to go in and out of their failsafe setting
156. esigner or lus master pins to the last value HCUtiities to download a Al slave blacks have their BAD Poniguration that has no slave COMM pin on i e Allslave blocks have their NO SCAN pin on e INSCAN STATUS is set to NO for all slaves e COMM STATUS is set to BAD for all slaves in the function block diagram e Statistical counters for all slaves are 0 2 Controller mode is e Controller will not gotoRUN __ Toclear the diagnostic In HCD System changed to RUN Locked mode 1 Change mode back to RUN Diagnostics Locked while there are mode OR shows status as forces present on Invalid Change of safety worksheet 2 Clear all safety forces using HCD Mode through Monitor gt Forced Blocks OR 3 Forceacold start 2 Controller mode is e Controller will not go to RUN To clear the diagnostic In HCD System changed to RUN Locked mode 1 Change mode back to RUN Diagnostics Locked when safety modeOR shows status as configuration is Safety changed at run time 2 Force acold start Configuration mis match 3 One of the following At the time of the exception the To clear the diagnostic force acold If thelead s status If the lead s status microprocessor microprocessor resets If it s the start LED is indicating LED is indicating exceptions occurred Lead controller and there is an If the problem reoccurs try the the failure see the failure see e Watchdog timer available reserve a failover occurs following
157. ftware configuration software can be via Modbus TCP as well as serial Modbus RTU over either the galvanically isolated RS 485 or RS 232 communications ports Both ports support Modbus RTU and are configurable as master or slave For new systems connection to PC hosts can be via Modbus TCP as well as serial Modbus RTU over the galvanically isolated RS 485 communication ports The TCP hosts can be concurrent with Modbus hosts on one or both of the other ports Any given controller is capable of concurrent communication with up to 5 TCP hosts on C30 C30S controllers or up to 10 TCP hosts on C50 C50S C70 C70S or C75 C75S controllers The meaning of the term host varies but for this definition a PC host is any PC that is on the same LAN as the controller or on any LAN or WAN Wide Area Network that is network connected to the controller Each HC900 Controller has 5 or 10 sockets software and memory resources each of which can service data requests from any networked PC on a client host server controller basis The sockets are available on a first come first served basis Typically when the data service for any PC Host request is completed or times out it allows the socket to become available to any other PC Host in the hierarchy of networks Note PDE communications discussed previously do not use the PC host connection sockets PDE communications are separate from and are transmitted concurrent with PC host to controller
158. gh Voltage Cable assembly 5 0 meters long Install 16 point AC DI module label into module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 2 3 Set verify jumper positions as shown J2 J4 J J C C C Com J3 J5 J7 J9 Swi C COs Oe CO Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See page 234 for RTP internal schematic 228 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point AC Digital Input Connect field wiring Note S L1 in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 Install jumper wires 16 Point DC Digital Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 16 point DC Digital Output is rated at 8A per module and 1A per output Limited to 4A pe
159. guration validation test and report from the controller The controller then checks the new database and compares it to the current running database Using the test report as a basis the host then presents the operator user with a dialog box containing a set of choices begin using the new database with no cold start use it with a re start or abort the download Configuration Upload Controller configuration files setpoint profiles and recipe files can be uploaded for storage and archiving in a PC and or to a disk in the Control Station Using the PC the Upload function is accessed from the Designer Software For details of uploading configuration items refer to Designer Software and Control Station manuals Firmware Download Firmware Download provides a mechanism to upgrade the firmware in your CPU and Scanners It is available in Program or Program Locked modes only Specific instructions are provided with the upgrade files 160 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Redundant Operating Characteristics Overview Redundant Operating Characteristics Overview This section describes operating characteristics specific to redundant controllers In a redundant HC900 system the Lead Controller performs all primary tasks including interfacing with remote I O racks communicating with a local HMI exchanging data with peer controllers interfacing with Modbus slav
160. gure 48 Analog Input Wiring Slidewire Position Proportion BlOcKk esceeseeeseeceseeeeneeeeneeeesneeeneeenaees 95 Figure 49 16 point High Level Analog Input Wiring eee eeeecesceceneeeeneeesneeeeeeeeseeceaeessaeeesaeeesaeeesaeeesaeers 96 Figure 50 4 channel Analog Output Wiring Diagram cee eesecessecesceeeseeeeseeeesaeessaeessaecesaeeesaeessaeeeseeeeneers 97 Figure 51 8 channel Analog Output Wiring Diagram cee eesceesseecssceeeseeeeeceessaeessaeecsaecesaeessaeeesaeesseeesaeers 98 Figure 52 16 channel Analog Output Wiring Diagram eee eeeeesceeeseeeeseeesneeeesneeesaecesaecesaeessaeeesaeeeseessaeers 98 Figure 53 DC Input Module Wiring Diagram ec eee eeseeeeseeceseeeeseeesseecsaeessaeessaeecssaeesaeesseesesaesesaeeesaeereas 100 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual xi January 2014 Figure 54 DC Input Module JUMP siisii areata aaia eieaa ie Eo ava iaeia 101 Figure 55 32 point DC Input Module Wiring eescesseeeeneeeseecsneecsaeessaeessseeesseecssaecsseesseeessaeesnaeeesaes 102 Figure 56 AC Input Module Wiring Diagram s cee eeeseeeesceceseeesseeesseessseecsseeesacecsseessaeecseeseaesenaeeesaeesas 103 Figure 57 AC Input Module Jumper cee sceesccesscecsseecsscecsscecsneecssaeessaeessaeessaeessaeeesaeecsaeecseessneeseseeesnaeesas 104 Figure 58 AC DC Isolated Input Module Wiring ce eeeceescceneeesnee
161. h America contact details refer to the back page of this manual or the appropriate Honeywell Solution Support web site Honeywell Organization WWW Address URL Corporate Honeywell Process Solutions HPS Technical tips http www honeywell com www honeywellprocess com https www honeywellprocess com en US explore products control monitoring and safety systems scalable control solutions hc900 control system Pages hc900 controller aspx Telephone and Email Contacts Area Organization Phone Number United States and Canada Honeywell Inc 1 800 343 0228 Customer Service 1 800 423 9883 Global Technical Support Global Email Support Honeywell Process Solutions Email Sales FP Sales Apps Honeywell com or TAC hfs tac support honeywell com iv HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Symbol Definitions The following table lists those symbols that may be used in this document and on the product to denote certain conditions Symbol Definition This DANGER symbol indicates an imminently hazardous situation which i DANGER if not avoided will result in death or serious injury This WARNING symbol indicates a potentially hazardous situation which if AX WARNING not avoided could result in death or serious injury This CAUTION symbol may be present on Control Product instrumentation A CAUTIO
162. he Lead Real Time Clock lead s battery failing jo ASYS and FSYS blocks HW OK CPU Diagnostics Diagnostics in when it was powered pins are tumed off display the Lead oon Note If the reserve s battery fails If the reserve s rad when it is powered down The lead status LED is box o9 will automatically program the indicating the reserve s RTC with the correct date failure see RTC in If the reserve s and time when the lead and reserve the Reserve CPU status LED is are synchronized Diagnostics indicating the display failure see Real Time Clock Diagnostics in the Reserve Diagnostics Overview dialog box 172 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Diagnostics and Troubleshooting Controller CPU indicators Number of Red Strobes Possible Causes Lead and or Reserve Controller Action s User Action Honeywell Ol Indication HCDesigner HC Utilities Indication One of the following RTC conditions occurred RTC was previously programmed but when it was last read its date and time were deemed invalid An attempt was made to program the RTC but it was unsuccessful The RTC is unable to be read Usually indicating a serious hardware failure Same actions as described above 1 Use HCDesigner HCUtilities or Ol to program the real time clock RTC 2 If problem persists replace the CPU module
163. iguration in the controller Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 147 Communications Installation Connecting the HC900 Controller to Modbus device s Connecting the HC900 Controller to Modbus device s S1 RS 232 default RS 232 terminals Stand S2 can be set to RS 232 or RS 485 RS 485 Modbus connections Use Designer software to configure the controller s galvanically isolated RS 485 port as a master or slave Install resistor as shown for terminated devices except HC900 For terminating HC900 do not install resistor Instead set internal DIP switches for termination page 40 When using the HC900 XYR5000 transmitter function blocks and RS 485 serial communications ports connect Base Stations to the HC900 controller as shown in Figure 80 HC900 Controller Modbus Modbus Modbus Slave 1 Slave 2 Slave 3 s TYO ONK X KE 420 ohm TX RX Termination Figure 80 RS 485 Modbus slave wiring 148 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to Modbus device s If the RS 485 network to slave devices is intermittent or fails completely over short durations and recovers after the controller is power cycled use an external isolator with additional port biasing See Figure 81 Note Legacy Controllers do not provide biasing 120 ohm Termi
164. igure 24 Rack Dimensions acs tiei a a a a A eid ded die aA EAA EEE aE AEE pE EEEE EEA 46 Figure 25 Rack Dimensions with reserve power SUPPLY ceeseceescecsseeeeteeceseeeenaeeesaeecsaeeesaeersaeessaeeeseeeeneees 47 Figure 26 Vertical Spacing of Racks all models 0 ee eeeseeseeeseeesneeceneeeseeseeeseseeceseecesaecsseecesaesesaeeseaeeesaeers 48 Figure 27 AC Input Module de Rating nie aiin s aa ae a oaa a A aa Ea EEAS AAEE E an 51 Figure 28 Power Supply de Ratin gis as inasinta arri eresas a aa aa aaa aa A Ea kae aE E r aieo 51 Figure 29 Cabinet Wiring Single Chassis norii iniinis esaeo s ea AS aa raa akae aaas oai aan isien 54 Figure 30 Cabinet Wiring Multiple Chassis ceseescccsssecescecesseecsecesaeecscesseeesseecesaecsseesesaecesaeeesaeessaeesaees 55 Figure 31 Redundant power supplies each with external fuse and switch eeeeeeseeeseesresrrerrrerieeriserireresrrrsrees 56 Figure 32 Master Control Relay Wiring Example ccesceessccsseeceneecsseeesceescesesaecesaecesaecsseeeesaeeesaeeesaeessaeers 59 Figure 33 IO V function block CONNECtIONS ceeecceescecesceeeseeeesseecesecesaeessaeeesseeesscecssaecseecesaecesaeeesaeessaeeseaees 60 Figure 34 Individual Series DO Connections eeceescccesseceseeeesseeesseeesaeecseeeseecsscecesaecsseesesaesesaeeesaeessaeersnees 61 Figure 35 Common Series DO connections esecsesceceseceseeeesseeesseeesaeecseeeseeessee
165. ilable for use The Pulse Output functionality uses the digital output available on the module for outputting pulses Before installing be sure to set the module DIP switches for differential or single ended See page 85 118 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams eS INDEX INDEX SENSE SENSE OUTPUTT OUTPLT2 OUTPUT OUTPUT4 COM ENCODE ENCODE Too uote E H hi Figure 68 Pulse Counting Wiring OUTPUT OuTPUTZ OUTPUT2 OUTPUTZ OUTPUT4 OUTPUTS COM ENCODE ENCODE ENCODE ENCODE a p Nz Nz inz l IN 2 IN 3 E INZ NS Nas N4 INDEX INDEX INDEX INDEX SENSE SENSE SENSE SENSE a ta an E 4 ODDODEIOODTIOOSIOOA Ode Figure 69 Pulse Output Wiring Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 119 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Frequency Inputs 5 24 OUTPUT OUTPUT2 OUTPUTS OUTPUTS COM ENCODE ENCODE Attention For Input Input 2 and Index reverse polarity to IN 1 Encoder 200mV to a 6 0V a Differential g B 200mV to _ 60V lt Differential Internal
166. ilter capacitors on I O wiring capacitors to I O wiring shields shields Special tools 11 e Precision meters If required for testing Analog calibration refer to Analog Calibration in this manual Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 63 January 2014 Rack Installation Overview Equipment Preparation A checklist for site preparation is given in Table 7 Table 7 Site and Equipment Preparation Step Procedure Reference Verify that sufficient numbers of the following items are on hand Racks 4 8 and 12 slot Power Supplies 1 per rack or 2 per rack if redundant powered rack C30 C50 C70 Controller Module or Scanner 1 port 1 per rack Redundancy Each Controller Rack 2 Power Supplies 2 C75 CPUs 1 Redundancy Switch Module Each I O Rack 1 Scanner dual port module 1 Power Supply 1 reserve Power Supply optional 1 Power Status Module optional I O Modules correct type for each configured slot Terminal Blocks Barrier or Euro style 1 for each I O Module Jumpers 2 position or 10 position for designated Terminal Blocks Tie Wraps 1 or 2 for each Terminal Block I O Label one per terminal block by module type Filler Block Cover 1 for each slot not occupied by an I O Module Blank label 1 for each Filler Block Cover Grounding Bars for I O wiring shields 1 or 2 for each 4 slots in each rack Wiring terminal
167. ime Time Units Hours or Minutes Segment Time 0 99 999 999 hours or minutes Program Cycles Up to 100 or infinite configurable segment range Programmer Events Assignable to DO or internal status Setpoint Profiles 50 segments per profile Number of stored profiles is user configurable Setpoint Scheduler Ramp type Time units Hours or minutes Segment time 0 001 to 9999 999 hours or minutes Cycles Per segment to 999 or infinite Ramp time Auxiliary Scheduler Setpoints Up to 8 setpoints soak only Schedule events Up to 16 assignable to DO or internal status Setpoint Scheduler Schedules 50 segments per schedule Number of stored schedules is configurable Sequencers States 50 State text 12 characters Steps 64 Time Units Minutes or Seconds Digital Outputs 16 Analog Output 1 configurable value step Step Execution On Time Event 1 Event2 or via Advance Next Step Any step Sequences Number of stored Sequences is user configurable Recipes Variables Number of stored Recipes Variables is user configurable Recipe Parameters Up to 50 analog or digital Variables may include profile numbers Signal Tags Read only Up to 65 535 Tag Identification 16 character tagname 16 character descriptor 6 character units of measure analog only 6 character on off state digital only Variables Read Write Up to 2048 Variable
168. inite loop that toggles 1 Cycle power Not available Not available power up the LED Communications and 2 Replace CPU because the C75 because the C75 control are disabled communication communication 8 Replace power supply ports are disabled ports are disabled 4 Replace rack 5 Check grounding 6 Ensure system is properly isolated from noise 2 Atleast one function The block s output s is are forced to If itis not desirable to have forced See SYSTEM in SeeSystem block has an output the value s specified block outputs use HCDesigner to the Controller Diagnostics in that is forced locate and remove the forced outputs Diagnostics the Diagnostic Overview display Overview dialog box 2 The RAM and FLASH An empty database is created and Use HCDesigner HCUtilities or Ol to copies of the the lead and reserve will not download a valid configuration configuration database synchronize The reserve s RSM were corrupted and LED is flashing to indicate it s not are now set toa valid synchronized with the lead empty database Usually this is a result of a firmware upgrade 2 One of the following The lead uses its own switch 1 Install RSM if none present NOTE RSM failures was reading and dictates to the reserve WHEN PLUGGING IN THE RSM detected what the mode is If the lead s switch INTO ALIVE UNIT YOU MUST _ The RSM module is P Sition is invalid then the lead uses MAKE SURE THE SWITCH IS IN not installed
169. ion details S2 RS 485 port Availability depends on aaen int einerenes controller model see Figure 12 page 26 Connect communications 2 To PC applications cabling or peer HC900 controllers e For Modbus connections see page 148 RS232 RS485 connectors top to bottom Shield TX RX TX RX S1 RS 232 To PC Configuration Tool Rev en newness oe Ei To PC applications or peer HC900 co Communication Ports all ports shown Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 123 Communications Installation Wiring and cabling Step Procedure Commenis Reference Default IP addresses C30 C50 192 168 1 254 and Subnet Mask of 255 255 255 0 C70 C75 E1 192 168 1 254 E2 192 168 2 254 Must be on different subnets Set IP addresses and subnet masks Links to controller communication ports Refer to Table 17 and the figure in Step 2 above Port availability depends on Controller model Table 17 Links to Controller Communication Ports Controller Port Connector Type Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector Legacy controller only RS 232 3 plug connector RS 485 3 Plug connector RS 485 3 Plug connector Link Type Controller to Desktop or Lapt
170. ional Description All Controllers The Honeywell HC900 Process Controller is an integrated loop and logic controller that is designed specifically for small and medium scale unit operations It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range of process control applications The HC900 Process Controller can consist of a single rack as indicated in Figure 1 or can be can be networked with other controllers via Ethernet links to expand the dimensions of control over a wider range of unit processes as indicated in Figure 2 Figure 1 Small HC900 Controller Configuration 8 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Functional Description 8 slot Expansion VO Figure 2 Expanded HC900 Controller Configuration C50 C70 CPU only The HC900 Controller design enables users and OEMs who are adept in system integration to assemble a system that fits a broad range of requirements Any configuration can be readily modified or expanded as requirements dictate In initial configuration and in subsequent modifications the HC900 Controller affords an optimum balance of performance and economy Configurations such as those shown in Figure and in Figure 2 as well as many variations can be assembled from modular components Many of the components are available from Honeywell and some are available from third pa
171. its 1 stop bit and no parity Hardware handshaking can be disabled Software handshaking can be disabled Data Terminal Ready DTR input can be disabled Result codes can be suppressed Echo can be disabled Must be equipped with non volatile memory NVRAM so that settings that are configured using command strings can be retained during a power outage Must be able to load the NVRAM settings automatically on power up Cable requirements You will need an interface cable to connect the modem to the 25 pin connector be sure to use a DB 25 to DB 9 modem cable A TIP The Null Modem cable used to directly connect a PC running Designer Software to the controller may typically not be used to connect the PC to the modem or to connect the modem to the controller If your modem requires command string configuration you will need an interface cable to connect the modem to your PC Refer to your modem and computer documentation to determine this cable s requirements 134 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Modem configuration Before connecting a modem to the controller s RS 232 port marked CONFIGURATION the modem must be configured with the following settings e Baud Rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC90
172. ity of the shared terminals of the I O modules There are three RTP types See page e 8 Analog Input e Relay Output 212 219 e 16 point Analog Input Digital Input Digital Output Analog Output 223 HC900 Controller 3 Cable various a lengths available Shield drain wire RTP mounted on Terminals for field A DIN rail Figure 96 Example installation not shown 2 RTP amp cable for high capacity Al DI DO Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 211 Appendix Installation of Remote Termination Panels RTPs Analog Input Analog Input 8 Point Analog Input Eza 1 ATTENTION RTP is not for use with thermocouples ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal block to allow mating with the module See page 82 e Connect desired cable to Al module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install Al module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding sec
173. jumper J OUTPUT2 OUTPUTS OUTPUTS com ENCODE ENCODE ah Encoder power S5Vde to 24Vde Figure 71 Quadrature Differential IN 2 IN 3 IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUTI OUTPUTZ OUTPUT3 OUTPUTS COM ENCODE ENCODE IN 3 IN 1 IN 2 1N 2 IN 3 IN 3 IN 4 1N 4 INDEX INDEX D SENSE SENSE ENK OUTPUT OUTPUT2 A OUTPUT3 OUTPUTS 1 COM ENCODE i ENCODE p External Power Wiring 120 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder IN 9 IN 1 IN 2 JOSE INZ IN 3 IN 3 IN 4 ay DID 4 N4 INDEX INDEX SENSE SENSE OUTPUTI CUTPUT2 OUTPUT2 OUTPUTS COM ENCODE ENCODE ALS INDEX SENSE v Internal jumper LL Encoder power amp ig ie DOC A D un DOD Attentan For Input Inpul 2 and Index faverse polarity to Encoder 200m to Differential f 200mV to AEN SS Differential Internal jumper 5V Encoder power from Hcs00 Attention For Input Input 2 and Index reverse polarity to Figure 73 Quadrature Differential HC900 Power Wiring Revision 2 1 HC900 P
174. l Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 32 point DC Digital Output is limited to 6A per RTP and 0 5A per output Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect terminal block end of desired cable assembly to 32 point Digital Output module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long Install 32 point DC DO label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Mount RTPs to DIN rail e Latch to rail See page 247 e Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be wired to outputs 1 16 RTP B to outputs 17 32 You can write on the RTPs labels to distinguish them Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is possible but voltage is still present on the positive side at RTP and module terminal
175. lder and press on the battery see arrow so that it snaps into the holder To ensure that the battery is seated properly rotate it in the holder using finger or thumb pressure toward the positive front end of the battery While maintaining proper orientation battery toward the left slide the battery holder into the slot in the Controller Module until it snaps into place Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 197 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Replacement Procedures Table 40 Replacing a Backup Battery CPU Powered Step Action 1 A CAUTION If the battery is removed from the Controller Module when AC power is not applied the content of RAM will be lost Before beginning this procedure upload and SAVE a copy of the configuration or ensure that a previously SAVEd copy of the current configuration is available 2 Apply site AC power to the Power Supply that is associated with the controller Module 3 Press the latch on the battery cover to release the battery holder and use the molded in extension on the battery holder to extract the holder Note the orientation of the battery holder assembly for re insertion afterwards 4 The battery is retained in the holder by spring tension of the plastic holder itself Extract the battery single battery for older models t
176. ler User and Installation Manual 1 January 2014 Introduction Model Selection Guide Model Selection Guide Legacy System Racks S SSS Controllers P 900PSM 0001 Powersupes OO OOS SS S S SSS 300P02 0007 omas S S S S SS Digital Output 120 240 VAC 8 channel 900H03 0102 o Pulse Frequency Quadrature 900K01 0101 2 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Model Selection Guide ocom S S WO Components S S mms O OSS S s S sowe OOOO S yO Kits amp Accessories O 0 y O O OSS Ethernet Swfiching Hub 8 Poris 24 VDC Power Supply 51452041 501 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 3 January 2014 Introduction Model Selection Guide Operator Interface fo Description oraccessoresaks J SSCS 15 Screen Protective Films 10 New Non SIL System Ce Comos o S SSS Powersupes O T O OSS SSS 4 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Model Selection Guide SIL System Description Model Number SIL Compatible Controllers Controller C30 CPU SIL 900C30S 0360 00 Yes Controller C50 CPU SIL 900C50S 0360 00 Yes Controller C70 CPU SIL 9
177. ller is shipped with the default IP addresses for port E1 192 168 1 254 and port E2 192 168 2 254 Default Subnet Mask is 255 255 255 0 You can use these network parameters initially for testing or configuration use In the Current PC to Controller Connection Settings area of the dialog box click on the Network button to bring up the Network Port Properties dialog box and Add the default IP addresses Be sure both PC Ethernet NICs have fixed IP addresses on the same subnet as the controller 192 168 1 x and 192 168 2 x where x 2 to 253 Note 900 Control Station uses IP 192 168 1 253 as default 5 In the Current PC to Controller Connection Settings area of the dialog box select Network for the Port to be used and the default IP address for the Address Click on Loopback to assure communications between the PC and the controller You may now use the Ethernet port for configuration interface Current PC to Controller Connection Settings Port Network Device Name Honeywell HC900 Controller gt Address ise 1681 254 bd Protoc l Modbus R TCR Speed bps N A Q Loop Back Statistics PC Port Setup for Controller Access Network COMI COMZ COMS COM4 COMS COMA COMP COME 6 Consult your IT systems administrator for allocating IP addresses if this controller will require a unique IP address within a plant network Also ensure that the PC Network Interface Cards have an IP address that allows access to the controlle
178. lly left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Module Wiring The DC Input Module has sixteen inputs in two groups of eight inputs per group The groups are isolated from each other inputs are non isolated within each group An example of Digital Input Module wiring is shown in Figure 53 Specifications for this module and for other modules are given in the Specifications manual Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section Common Terminals Two common terminals are provided for each group of eight inputs Terminals 9 and 10 are connected in the input module and terminals 11 and 12 are connected in the module Jumper Comb A two position jumper comb is available as an option for barrier style terminal blocks only for connecting digital common wiring at terminals 9 and 11 or 10 and 12 See Figure 54 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 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 99 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Input Com 1 IN 1 8 Com 2 in 9 16
179. ludes HMI operating software Experion HS or f SpecView32 or from May also include Designer Software configuration tool third party supplier and utility software 6 Ethernet Enables connection of the private Ethernet 100Base T Qualified third party 100Base T port on a Controller Module to the Scanner modules devices available from Switch on 2 3 or 4 I O Expansion racks C50 C70 CPU Honeywell only If a single I O expansion rack is connected directly to a Controller Module the Switch is not required 6a Ethernet Enables inter connection of several 10 100Base T Third party suppliers 10 100Base T Ethernet devices in an Ethernet network Devices Switch or Router include other HC900 Controllers HMIs and can also include routers servers and other devices in wider networks 7 Ethernet CAT5 Connects I O expansion racks C50 C70 CPU only to Third party suppliers or shielded cable controllers and or to 10 100baseT Ethernet switches Honeywell 10 or 20 3 04 or 6 08m Fiber Optics Controller to remote rack distance up to 750m 2460 Cable ft with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint 8 Ethernet CAT5 Connects devices in Ethernet Open Connectivity Third party suppliers or shielded cable network to 900 Control Stations and PC SCADA Honeywell applications 9 Serial Interface For legacy system Null modem cable up to 50 Third party suppli
180. lugs for connecting I O shields to grounding bars Sheet metal screws steel 10 or M4 for mounting racks in enclosures 4 screws for 4 slot racks 8 screws for 8 or 12 slot racks e Section on Pre Installation Planning e Sections on installation 64 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Overview Step Procedure Reference 2 Install or verify correct installation of enclosures for HC900 Mount Racks Controllers and ancillary equipment Table 8 Mount Rack e Mounting rails or flat panels e for cabinet with multiple HC900 Chassis grounding bus barrier strip for AC power e Master control Relay 3 Install or verify correct installation of enclosures closets See Pre installation planning for networking devices sections Note Some networking devices may share enclosures with HC900 Controller components 4 Install or verify correct installation of See I O Module Installation 3 and Wiring on page 74 e External disconnect switches e Fuses at the power source associated with input sensor or output devices for I O modules 5 Arrange and organize items to be installed at or near enclosures Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 65 January 2014 Rack Installation Mount Racks Mount Racks Rack assembly information is given in Table 8
181. ment EN 61326 1998 Electrical equipment for measurement control and laboratory use EMC requirements EN 61010 1 1993 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements Manufacturer Honeywell Automation India Ltd 55 amp 56 Hadapsar Ind Estate PUNE 411 013 India EA f Eo Honeywell International Inc Le Coe Va KL 512 Virginia Drive Edward A Child Fort Washington PA 19034 Principle Engineer Regulatory Compliance amp Approvals Engineering Issue Date 25 July 20 08 HC900_51452401_E doc Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 249 January 2014 Analog Input Digital Input Digital Output Analog Output ATEX Certification Honeywell HON 08 ATEX 0001X Revision A Manufacturer s ATEX Declaration of Conformity E3 G ExnAlic CE This Declaration applies to the following apparatus HC900 Modular Control System Low Power Modules per attached list The apparatus fulfills the requirements for Group II Category 3 equipment in accordance with Directive 94 9 EC The design incorporates requirements of IEC 60079 15 2005 and is documented within Honeywell Technical File 51453806 The apparatus is incapable of producing arcs sparks or hot surfaces which may cause ignition and is designed to be installed and used in accordance with IEC 60079 14 2002 The marking of the apparatus shall include the following E II 3 G E
182. minal Block Jumper Combs Two styles of terminal block jumper combs are available for use with the barrier style terminal blocks ten position and two position Figure 41 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 41 Terminal Block Jumper Installation Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 79 January 2014 This page is intentionally left blank I O Module Installation and Wiring Removal and Insertion Under Power RIUP Removal and Insertion Under Power RIUP Ay WARNING Read and understand all of the following information regarding RIUP before attempting to remove and or replace any I O module particularly in a system that is actively controlling a process In legacy systems all of the I O Module types in the HC900 Controller System include the Removal and
183. mode If the problem reoccurs try the e Watchdog timer timeout following e Address error 1 Ensure the system is properly grounded e Prefetch error 2 Ensure the system is properly e Data abort error isolated from external noise e Software interrupt sources e Undefined instruction error Upgrade scanner firmware Replace scanner module Contact Honeywell Personnel 3 One of the exception vectors The vector is restored to the proper value and located in RAM became corrupted the Scanner continues to operate normally 4 Flash failed to burn properly when The boot code is the only software running Perform a code download the firmware was being upgraded This software waits for a request to burn the flash It does no scanning of modules Module outputs remain in their off state 5 C75 only The communications C75 only This problem may cause on C75 only iG the reserve is failing for the demand failover attempts to be unsuccessful 1 Verify that the CPU A cable is O owing Leas ons connected to the A port and There is a problem with the the CPU B cable is connected connection between the to the B port on the Scanner scanner and the reserve 2 2 The scanner port used to 2 If a switch is used check that communicate to the reserve all cables are properly has a hardware failure connected to the switch proper crossover cables are used that the switch is powered and it supports 100 Base T 3 Check cable shielding for prop
184. n A potential of 34 Volts will cause no damage to the module a reverse polarity power supply connection allows continuous current flow to the loads that are not controlled by the On Off state of the output circuits Jumper Comb Two position jumper combs are available as an option for barrier style terminal blocks only for connecting digital common wiring between terminals 10 and 12 and for connecting 24Vdc between terminals 9 and 11 See Figure 61 V Terminals The V1 terminal 9 and V2 terminal 11 are the positive power supply input to power the output circuits for the two groups of eight inputs per group The V supply must provide minimum 24 Vdc at 65 mA min per group A WARNING AY Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 109 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams OUT 10 OUT 11 OUT 12 OUT 13 OUT 14 OUT 15 OUT 16 gt _OUT9 A DOMH o OUT 10 103 a mo our i 109 ONO y o OUT 12 16 eee ti o ae See rs OUT 13 AO lo 24 Vdc QUT 14 i to C O H c OUT 15 OUT 16 DC Output out 4 T
185. nal block is placed on the circuit board two captured screws in the terminal block are fastened to metal tabs on the rack yor 4 x 5 Pin connector to Backplane T aiia 1x20 or2x 18 Pin connector to Terminal Block i ame youn Label Figure 37 I O Module Installation A WARNING AY e Do not use an input output terminal block if the terminal block is damaged if the door is missing or if one or both mounting screws are missing e Always tighten both terminal block screws before applying field power to the module e Do not apply energized live field wiring to an input output module that is not installed in one of the racks in the HC900 Controller e Do not operate the controller without a Protective Earth connection Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 75 January 2014 This page is intentionally left blank 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 38 and the Euro style shown at right Not shown a Euro style with 36 connections is also available for certain high capacity modules Terminal blocks have an embossed numbering key that shows the numbering pattern of the 20 36 connections The frame associated with the terminal block has a
186. nalog Output modules can be installed per rack Limit of 4 PFQ modules Power Supply rack space if using redundant I O power see page 47 Rack orientation and mounting see page 46 Remote Terminal Panels see page 48 Environmental conditions see page 49 Heat rise de rating see page 50 Cabling wiring distance planning see page 52 Electrical considerations controller grounding CE conformity grouping wires master control relay for emergency shutdown see page 54 System monitor function blocks see page 60 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 43 January 2014 Pre Installation Planning AC Power Supply Selection for racks with I O AC Power Supply Selection for racks with I O To determine which I O rack AC power supply to use POI or P02 calculate power requirements below H ATTENTION Using inadequate power supply will cause the controller to cycle power on and off A B Cc D E Max Max Enter Current Current Calculate 5V current Calculate 24V current Module type Quantity 5V 24 V D A B E A C 820 mA 0 mA legacy 1100 mA Controller C30 and C30S New 1 0 930 mA 0 mA legacy 1100 mA Controller C50 and C50S New 1 0 1150mA OmA legacy 1350 mA Controller C70 and C70S New 1 0 1500 mA OmA leg
187. nation Locate on physical last device on network 4 gt HC900 Controllers VDC GND Figure 81 RS 485 Modbus slave wiring with isolation For XYR 5000 base stations if the RS 485 network is intermittent or fails completely over short durations and recovers after the controller is power cycled the need for additional port biasing may be required Figure 82 shows recommended installation procedure for using an external isolator and additional port bias Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 149 January 2014 Communications Installation Connecting the HC900 Controller to Modbus device s 120 ohm Termination Locate on physical last device on network nm XYR 5000 Hae ALAN HA BL HC900 Controllers Base Stations i j ip re B amp B electronics or equivalent a 4 i q 4850PDR 120 ohm Z bs ination 5 i 2 Figure 82 XYR 5000 RS 485 Modbus connections with isolator RS 232 Modbus Connections For Legacy controllers connect to the RX TX and ground pins of the controller s 3 pin RS 232 port See page 40 for RS 232 DIP switch settings Table 19 page 130 identifies the pins For connections on other device refer to its product manual For new 6 x controllers use an RS232 RS485 converter Use Designer software to Configure the legacy controller s RS232 port or New 6 x controllers RS485 port
188. nd Scanner I O racks Redundancy e Redundant C75 CPU e Redundancy Switch Module RSM required between redundant CPUs e Redundant Power Supply provides redundant power to any CPU rack or Scanner2 I O rack e Power Status Module PSM required when using a second power supply in Scanner2 I O rack Communications All CPUs except where noted e Serial Ports Legacy Two serial ports configurable for RS 232 or galvanically isolated RS 485 communications RS232 port can be used for link to PC for 900 Designer configuration tool up to 50ft 12 7 Meters or via modem Also can be configured for Modbus RTU master or slave RS 485 port used for 2 wire link to legacy operator interface ELN protocol or can be configured for Modbus RTU master or slave communications up to 2000 Ft 600 Meters New Controllers Two isolated RS 485 communications ports USB to RS485 cable must be obtained to support link to PC for 900 Designer configuration tool Can be configured for Modbus RTU master or slave communications up to 2000 Ft 600 Meters Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 11 January 2014 Introduction Feature Summary Ethernet 10 100 Base T connection Port s configured to Auto Negotiate default to half duplex 30 C30S controller up to 5 PC hosts via Modbus TCP protocol C50 C50S C70 C70S and C70R Legacy and C75 C75S new model support up to 10 P
189. ndles see Table 5 and route the individual bundles through separate conduits or metal trays e Use shielded twisted pair cables for all Analog I O Process Variable RTD Thermocouple dc millivolt low level signal 4 20 mA Digital I O and computer interface circuits Ground shields as described in the section I O Module Installation and Wiring page 74 e Use suppression devices for additional noise protection You may want to add suppression devices at the external source Appropriate suppression devices are commercially available e Refer to document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments for additional installation guidance Grouping Wires for Routing Wires that carry relatively high electrical energy can produce unwanted noise in wires that transmit signals of relatively low energy particularly when they are placed parallel in long wiring runs Collect and bundle wires of similar type and route the bundle separate from bundles of other types Table 6 provides suggested guidelines for grouping wires Table 5 Guidelines for Grouping Wires Wire Group Wire Functions High voltage e AC Line power wiring gt 50 Vdc Vac e Earth ground wiring e Control relay output wiring e Line voltage alarm wiring Signal Analog signal wire such as lt 15 Vdc e Input signal wire thermocouple 4 mA to 20 mA etc e 4 20 mA output signal wiring e Slidewire feedback circuit wiring
190. nds with OK Once you establish communication to the modem its port settings are configured 6 Save the port settings to the profile that gets loaded on power up Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 135 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Modem configuration examples Below are procedures for setting up the following commercially available modems e 3Com US Robotics 56K Data Fax External Modem e Zoom 56K Dualmode External Modem page 138 e Best Data 56SX Data Fax External Modem page 139 e SixNet VT MODEM Industrial External Modem page 140 3Com US Robotics 56K Data Fax External Modem Step Action 1 Ensure that the switches are set to the factory settings Switch Setting Position Function 1 OFF UP Normal DTR operations 2 OFF UP Verbal word results 3 ON DOWN Enable result codes 4 OFF UP Displays keyboard commands 5 ON DOWN Disables auto answer 6 OFF UP Modem sends CD signal when it connects with another modem 7 OFF UP Loads Y0 Y4 configuration from user defined nonvolatile memory NVRAM 8 ON DOWN Enables recognition smart mode 2 Connect the modem to a PC If your computer s RS 232 port has a 25 pin connector use a DB 25 male to DB 25 female RS 232 cable If your computer s RS 232 port has a 9 pin connector use a DB 25 male to DB 9 f
191. ng is shown in Figure 56 Specifications for this module and for other modules are given in the Specifications section of this manual 102 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Common Terminals Two common terminals are provided for each group of eight inputs Terminals 9 and 10 are connected in the input module and terminals 11 and 12 are connected in the module Jumper Comb An optional two position jumper comb is available as an option for barrier style terminal blocks only for connecting digital common wiring at terminals 9 and 11 or terminals 10 and 12 See Figure 57 AA WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Com 7 IN 1 3 Com 2 In 9 16 DDOODADO ek Legend External Fuse Disconnect y gam a i User Supplied Safety Devices Figure 56 AC Input Module Wiring Diagram Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 103 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Input Jumper either 10 1
192. nostic Table 32 Bad I O Channel Diagnostics Module Failure message Description User Action Type indicated on Honeywell Ol or Honeywell HCDesigner Utilities function block monitor Al Burnout Failure The sensor T C RTD or mV source is Check terminal block failing burnout checks connections Replace source element Replace module Under range The signal at the terminals is less than Check the signal level being 10 below the range of the sensor applied to the terminals Replace module Over range The signal at the terminals is more than Check the signal level being 10 over the range of the sensor applied to the terminals Replace module Failing to convert When attempting to take a reading the Check the signal level being ADC fails This could result if the incoming applied to the terminals signal is either too large or small It also could result if the ADC circuit is failing If Replace module the problem is the ADC circuit most likely other channels will have the same failure AO Bad Channel The board indicates that the channel is Check terminal connections failing to output the correct value Replace module DO Bad Channel The number of configured channels in the Reconfigure the DO function DO function block exceeds the number of block hardware channels on the DO card Replace DO card with correct number of channels 182 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 Januar
193. ns on all output modules OFFLINE PROGRAM Same as RUN to PROGRAM transition Any calibration process that was in progress is immediately aborted and the results are discarded RUN OFFLINE Freeze output module channels Freeze Force LED indications on all output modules OFFLINE RUN Function Block execution starts immediately Any calibration process that was in progress is immediately aborted and the results are discarded 158 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Operating Characteristics File Download Upload Functions File Download Upload Functions The following is a general description of file transfers between the controller and computer devices external to the controller A CAUTION Performing download procedures incorrectly could cause loss of control in an operating process or loss of data and program files in a controller Refer to the appropriate User s Manuals for download upload procedures Failure to comply with these instructions may result in product damage Two types of software files can be downloaded to the controller e Configuration files e Firmware files Configuration files can also be uploaded from the controller for archiving Firmware can only be downloaded to the controller Pathways for file transactions between the controller and computer devices external to the controller
194. ntroller 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 D Network Access to one or more controllers 10 100BaseT LAN Litton Hub Switch 165 125 163 25 165 125 163 26 ATTENTION Always observe the wiring cabling guidelines on page 52 Step Procedure 1 Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled Be sure the NIC has an IP address fixed or DHCP served that allows access to controllers with IP addresses on the same or other subnet Consult your IT department or network administrator for allocating IP addresses to the controllers if required 2 You will need to set each controller s IP address prior to network connection since every HC900 controller is shipped with the default IP address of 192 168 1 254 Placing multiple controllers on the same network before they have been given unique IP addresses will cause problems 3 On the PC use the Utilities Worksheet in the HC Designer software to set up the serial RS 232 Legacy or USB RS485 connection to the controller at the desired baud rate see Direct Serial RS 232 Connection above This will require a null modem cable 146 HC900 Process amp Safety Controller User and Installation
195. o OUT 2 JNO Ta Sma OOE nO no OUT 4 ours OO OUT 4 ir a3 OUTS a p OuT amp OUTS ra Our i i outa OUT 8 5 V1 o V1 Eey P COM 4 Out 18 40 Com 2 Out 1 8 V2 4v2 i COM 2 Out 9 16 o G com2ioumte CIR asra u iy S Eile Eo CR a E gt a External Caine Disconnect 7 j Fuse TAO User S Supplied Safety Devices Figure 60 DC Output Module Wiring Diagram 110 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams DC Output Jumper 9 11 for one V Supply to both s groups of outputs Jumper 10 12 for one Common sapane Ground for all outputs Figure 61 DC Output Jumpers Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 111 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams 32 point DC Output Wiring AC Output Module Wiring The DC digital Output module provides 32 externally powered outputs in 2 groups of 16 Figure 62 The outputs are high side switching current sourcing type Over current protection is provided for each channel in 4 groups of 8 channels In case of short circuit for any output channel that whole group of 8 is switched off Power cycling is not required to reset the module S
196. o 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 68 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Assemble Controller Rack Step Procedure Commenits References Ensure that wiring to the Power Supply is disconnected from the site source and then connect AC wiring to the power supply as shown at right Note The Yellow Green wire is supplied with the power supply The nuts w star washers for the grounding stud are on the stud The power supply has an internal fuse that is not replaceable A second external fuse may be added if desired For P01 power supply use 3 0A slow blow for 115VAC operation 2 5A slow blow for 230VAC operation For P02 power supply use 2 5A slow blow for 115VAC operation 2 0A slow blow for 230VAC operation For P24 power supply use 7 0A slow blow CAUTION The P24 is a 24V DC Power supply Do not apply AC voltages of any kind to this power supply or you will destroy it Apply power For P01 only test voltages at the test points provided on the face of the Power Supply Note Test points are electrically connected to the backplane of the rack If the power supply is not properly seated in the backplane connectors no voltage will be measured at the test points ATTEN
197. o the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Remote Access for details on this step Select the number to call x Phone Number i 215 822 3001 M Add to List Name Remove from List Cancel HC300 Furnace 1 Comments Plant 3 Location Phone Number List oe ee E 4 Hcs00 Furnace 2 9 610 726 4530 Plant 3 Location 12 HC900 Furnace 1 215 822 3001 Plant 3 Location 4 On the PC use the Utilities Worksheet in the HC Designer software to select the modem as the current port A button will appear to allow you to dial a selected controller Current PC to Controller Connection Settings Port e eC ey ele t Gy Q BULLE Loop Back Statistics Dial Xircom CardBus Ethernet 100 Modem 56 Modem Interface Protocol Honeywell Inc ELN Speed bps N A PC Port Setup Network COM1 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 133 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Modem requirements Most commercially available modems can be used with the HC900 Controller The modem must have the following capabilities RS 232 interface Auto answer Can operate at 1200 2400 4800 9600 19200 38400 57600 baud recommended 9600 or 19200 or 38400 baud 8 data b
198. ocess amp Safety Controller User and Installation Manual ix January 2014 Tables Table 1 Descriptions of Major Components Figure 4 cesceessecssseceseeeeseeceseeeesaeessaeessaecesaeeesaeeeseesseeeeeees 17 Table 2 Descriptions of Major Redundancy Componentts ccscccsseccssceesseeceseeeeseeeesaeecsaecesaeeeseeeseessneeesaeers 19 Table 3 Serial port DIP switch settings ccc ceeseeescecsseessseeceneeceseeeesaecesaeeesaeessseeesseecsseecseeceeesssaeeesaeeesaeeraees 41 Table 4 Power Applied by Module Type eseescceescecssecsseeeeseeeeseeeeseessaeeesseeesseecsseecseecseeessaeeesaeeesaeessaees 50 Table 5 Guidelines for Grouping WiIreS ceesceesceceseessseeceseeceseecesseeesaeessaeessseeesseecsseecsseeceseesenaeeesaeeesatersaees 57 Fable 6 Installation TOS cc c5es seks dei E E EE E a a Manibe ohh E ue eaceed as beaten dea damees 63 Table 7 Site and Equipment Preparation cccceescessecsseeceseeceseeessaeeesaeessneesseeesseecsseecsaecseesssaeeesaeeesaeessaees 64 Table 8 Mount Racks 2sicecssutascssasdsaverndessesediactenedensteged syacdeseswtateesiuta tees ddeedl codddetenatrnetersee EEEE EE EE aE 66 Table 9 Assemble C30 C50 C70 Controller Rack ceceeescsesceesseecsseecsseeesneeesceseseecssaecesaecesaeessaeseseeesaeessaeers 68 Table 10 Assemble C75 Controller Rack ceeseeescecessecsscecsscecesseeessecesaeecsaeeesseeesseecsaeecseesesaeesseecesaeessaeesaees 7
199. onality is determined by DIP switch setting on see the following figure To change either port s setting use the switch settings in Table 3 Use a small slotted screwdriver or paperclip to gently move the DIP switches If you push too hard you could damage the switches or nearby circuitry Avoid using pencils because the point could break and cause damage Table 3 Serial port DIP switch settings RS 485 unterminated RS 485 terminated last link in network Figure 23 Serial Ports DIP Switch default settings Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 41 January 2014 Components and Architecture Serial Ports RS 232 and RS 485 for legacy systems and two galvanically isolated RS 485 ports for new systems This page is intentionally left blank 42 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Overview Pre Installation Planning Overview Methodical pre planning of an installation will preclude false starts and errors that can cause costly hardware re configuration and or poor system performance Factors to consider in your pre installation planning include C75 CPUs require two 900P02 Power Supply Module T O Rack can use AC Power Supply 900P01 900P02 see page 44 or 24DC Power Supply 900P24 see page 46 Limit of ten 4 channel five 8 channel or two 16 channel if powered from backplane A
200. op PC Modbus master controller is single slave Modbus master controller is one of multiple slaves Modbus slave network controller is master Operator interface Modbus master controller is slave Cable Type RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 Null Modem cable up to 50 r RS 232 PC modem cable up to 50 RS 232 to RS 485 converter RS 232 to RS 485 converter RS 232 to RS 485 converter Belden 9271 or equivalent Belden 9271 or equivalent To Device Port Serial port of PC w Null Modem cable For Wiring details of Null Modem cable see Table 19 or Modem Refer to RS 232 Remote Connection to PC Configuration Tool on page 131 Refer to device s port instructions Refer to device s port instructions Refer to device s port instructions SIL applications require shield drain wire to be connected to grounding bar Terminal connector of operator interface Refer to Table 18 Connect from each CPU A and B to the Ol SIL applications require shield drain wire to be connected to grounding bar Refer to device s port instructions 124 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Wiring and cabling Controller Port Connector Type RS 485 3 Plug connector E110 100 Base T RJ45 E2
201. ourcing type or 16 point DC digital output modules sinking type e 32 point digital output DC voltage sourcing type 1019101010101 0 0109101010101010 e 8 point relay output module four form C type and four form A type relays e 8 point Universal Analog Input module e 4 channel Pulse Frequency Quadrature I O module Figure 16 I O Module Terminal Blocks Each I O module includes a status indicator for the module Digital Input and Digital Output modules also include a status indicator for each channel Terminal blocks available include the Euro style Figure 16 left and the Barrier style Figure 16 right For more information on I O modules and associated terminal blocks refer to the section in this manual on Input Output Installation and Wiring 28 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Hardware Components Personal Computer A Personal Computer is required to create the control and data acquisition strategy configuration file that runs in the controller using the Designer configuration software The PC can also be used to download upload configuration files to from the controller and can be used to download program updates to firmware in the Controller Module and or Scanner Modules e A PC can be connected to the controller via the RS 232 port for legacy system e For the new system a PC can be connected to the controlle
202. ower supply 8 slot w 1 power supply 12 slot w 1 power supply 8 slot w redundant power supplies 12 slot w redundant power supplies A Power Status Module PSM is required with redundant power supplies High and low capacity power supplies are available Redundant Networks for Host communications Redundant Networks for Host communications are provided on the C75 CPU Both network ports are continuously active on the Lead controller The network ports on the Reserve CPU are not available for external communications Experion HS and the 900 Control Station 15 inch model support redundant Ethernet communications and automatically transfer communications to the opposite E1 E2 port during a network failure Scanner 2 module has 2 ports one for each CPU connection to I O 10 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Feature Summary Feature Summary Hardware e Modular rack structure components are ordered individually as needed e CPU with Ethernet and isolated RS485 communications e Easy to assemble modify and expand e C30 and C30S controllers provide local I O connections while C50 C70 and C50S C70S Controllers provide for remote input output rack connections over a private Ethernet linked network e Parallel processing a microprocessor in each I O module performs signal processing to preserve update rates e Power supplies provide power to CPU rack a
203. ower supply is good and that the outputs are within specified limits When the status is off either the power supply is off or the voltages are out of tolerance Figure 11 Power Status Module PSM Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 25 January 2014 Components and Architecture Hardware Components Controller Module C30 and C30S C50 and C50S C70 and C70S C75 and C75S Controllers share the same features with exceptions noted CPU model number C30 and C30S C50 and C50S C70 and C70S C75 and C75S Lithium battery battery tray which is readily accessible for field replacement Battery Tray Connection to I O port of Scanner Module C50 and C50S C70 and C70S C75 and C75S only Mode switch Pgm Run Pgm Run Not present on C75 see RSM For legacy systems two serial ports S1 and S2 each configurable as RS 232 or RS 485 provides interfaces to a PC external modem Modbus devices or Operator Interfaces For new systems two serial galvanically isolated RS 485 ports S1 and S2 provide interfaces to PC using RS 485 to usb cable External modem or Modbus devices may be interfaced using RS 485 to RS 232 converter RS 485 interfaces to PC Control Stations or Modbus devices host 1 2 3 Interfaces to PC 4 Ethernet LED status indicators for communications functions 5 Connection to I O port of Scanner Module C50 and C50S C70 and C70S
204. ownloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the controller Note Network communication will only occur with the Lead CPU If using a single network connection during initial setup verify connection is made with the Lead CPU Two redundant systems with PC supervision OPC Server to PC Software eS 10 100 baseT Peer to Peer Data Exchange a sal Controller Rack Controller Rack Up to 100m 100 baseT SS Ethernet iad Sr PPPE J Switch i tet AT 100 b TTT VO Rack Eii VO Rad cm VO Rack Figure 79 Two redundant systems with PC supervision 144 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software C Direct Ethernet Connection to one HC900 controller Defaults IP Address 192 168 1 254 Subnet Mask 255 255 255 0 Default Gateway 0 0 0 0 Ethernet 10 Base T Crossover cable q Host 10Base T Ethernet port RJ 45 connector ATTENTION Always observe the wiring cabling guidelines on page 52 Step Procedure 1 Make sure the PC has an Ethernet NIC Network Interface Card installed and enabled 2 Connect an Ethernet 10 100 Base T crossover cable to the HC900 controllers Open Ethernet RJ 45 port top
205. p Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams AC Output KK KI eI A RUSS eeee senses PENNE See eee ee rs o gt Pr 6 Figure 64 AC Output Module Jumper Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 115 January 2014 This page is intentionally left blank 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 65 SIL applications require an external series relay used to ensure outputs achieve failsafe action See HC900 Process amp Safety Controller Safety Manual for additional details Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure 66 a ers re AC S Fuses appropriate for load and for wire used a are provided by user Pal o Fuses appropriate for load and for wire used are provided by user Figure 65 Schematic Example Relay Output and External Wiring Contact Rating Maximum current outp
206. pesca dean elle eet nedare ensues deseto dienes ee iaeei 26 Figure 13 Redundancy Switch Module eesceesceesscecsscecsscecessecessecesaeecsaeesseeesseecsseessseecssaeesseeeeseeeseessaees 27 Figure 14 Scanner 1 Module coy eesse espesor er otek soeeba e eaei aaas aaen neairt aop ieas asaan et a tiene 27 Figure 15 Scanner 2 Module raees ea srs ae Ea sauce eaea aaas adden nedirete tana Ries ea raeo u as 28 Figure 16 I O Module Terminal Blocks 20 0 0 ceeseeeseeeeseecescecsseecesseeesnecesaeessaeessaeeesseeceseecseecesaeceaesesaeeesaeersaees 28 Figure 17 RS 232 Modem Devices ied coe ssi peiser naerenn sted ates ae ori dy dat sued ceed aeaeaie taa a ESENE eo eade 29 Figure 18 HC900 Controller Configurations ccceescccsssecesceceseecsseeesaeesseesseeesseecssaecsseesesaeessseeesaeessaeessnees 31 Figure 19 Modular Network Structure c0 c cscccesetecseccsteseeesecesescnsocencspenenseteadenseneeseseobesoudenenessensvertosesnessere 34 Figure 20 Modbus TCP Framing oiire anehi scandens aes raa ta aa eaa e aa aa A E Eai E EEE EEE EEES 35 Figure 21 Typical installation using a Cable Modem esseeeseeseeeseseseseseseresrresrrrsrrrstereressressrssressressesereseresrrese 38 Fig re 22 Controller Serial Ports s sire nret sai a ea A a raa aa e aAa a A Ea a aS A SEEE EEEa 39 Figure 23 Serial Ports DIP Switch default settings ces ceesccesseeceseecsseeceseeesneeceaeeesaecssaecesaeeesaeeesaeeeseeseaeers 41 F
207. ply is available for reduced I O applications and for Redundant processor rack power P24 power supply provides 5VDC and 24VDC to satisfy the power requirements of a single controller with T O a Remote I O rack or a Redundant C75 CPU The 60 watt capacity requires minimal de rating of the available HC900 I O modules A tool secured door covers the voltage connections An internal non replaceable fuse limits supply current under certain fault conditions Each power supply includes an internal 5 0 amp fuse that is not field replaceable An external fuse may be added by the user See page 22 Items shown with key numbers 1 Voltage test points PO1model only 2 AC DC Input terminal block 3 Wiring label 4 Grounding lug Reference lug is not part of Power Supply it is staked to bottom of Rack WARNING SHOCK HAZARD MORE THAN CH MAY BE RE Figure 10 Power Supply 24 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Hardware Components Power Status Module PSM The Power Status Module PSM Figure 11 sits between redundant power supplies on the I O rack see page23 It is a status module for both power supplies and indicates which are in use PS 1 left or PS 2 right or both typical When the status indicator for either or both of the power supplies is lit it is reporting that the status of the associated p
208. r Configuration ccc ceeseeeseeceseessseeeeseeeesceessaeeesaeeesaecesaeeesaecesaeessaeeseaeesseeesea 8 Figure 2 Expanded HC900 Controller Configuration C50 C70 CPU only seessccsseecsseeeeeneesnseessaeessaeeseaeeeea 9 Figure 3 Single process with redundancies cssccssscsssecesscesseecscecseesseecsneeeeseecssaecesaeceseeeesaeeeseesseeesaeers 10 Figure 4 Configuration with Multiple Controllers e cc cecceescecesecsseeceseeceneeeseeeeaeecsaecesaeeesaeessaeeesaeeesaeeesneers 16 Figure 5 Redundant Configuration with multiple I O racks 1 0 0 eee eeececeeeeeeseeceseeeenseeseneessaeessaeessaeesseesseeesseees 18 Figure 6 Controller Rack Components 0 eessceescecssecsseeceseecesseecsseeesaeecseecsseeesseecesaecsseesesaecesaeeesaeessaeesaees 20 Figure 7 Redundant Controller Rack Components cssccsssceceseecsseecseeeesseeesneeeesaeecaecesaecesaeessaeeesaeeseeeenaeers 21 Figure 8 I O Expansion Rack Components cesccesssecsscecsscecesseecsseeesaeecsacecsseeesseeessaecsseecesaeeesaeeesaeeesaeesaees 22 Figure 9 Rack OPHODS d Seernes en ae ag a E a a aiea aapt aade n p eee rea a eia eaea 23 Figur 10 Power Supply ke eio eee teers Aegean ae ee GA eia daa ee eee bois ene 24 Figure 11 Power Status Module PSM ccsscccesssceceesenceeeeeneeeeeseneeecseeeeeeseneeeesaaeecesseeeeseeaeeeeseeeeeeenaeeeesaaes 25 Figur 12 Controller Modules osi eeens enes nesr arenae esea
209. r 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 78 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP Fuses 6 3A Time Lag Littelfuse part 37416300410 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 80 for more details See page 221 for RTP internal schematic Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 219 January 2014 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output Connect field wiring O Zz Q lt O DO 6 ATTENTION e Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F e As shown in the schematic each switch is SPST and opens and closes one lead of the relay wiring If your application requires opening and closing both sides of the load wiring then an external DPST switch is required 220 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Relay Output Relay Output RTP Internal schematic HC900 Terminal Block Ji TB a e
210. r group of 8 ATTENTION The RTP combines the two groups of 8 outputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect desired cable to 16 point DC DO module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC L025 Remote Terminal Low Voltage Cable Assembly 2 5 meters long 900RTC L050 Remote Terminal Low Voltage Cable Assembly 5 0 meters long Install 16 point DC DO label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 229 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point DC Digital Output 2 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 3 Set verify jumper positions as shown J6 C C C J3 J5 J7 J9 sw C w C C Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 only disconnects the positive termin
211. r on the subnet after changing the controller s network parameters 7 You may change the controller s IP address and related network parameters from its default using the Utilities Worksheet in the HC Designer software This may be done using either the RS 232 serial port legacy systems via a null modem cable connection or the Ethernet connection from the PC to the controller If the RS 232 connection is desired make sure the proper PC serial Com port to be used has been set up See Direct Serial RS 232 Connection page 129 Attention IP addresses for E1 and E2 must be on different subnets Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 143 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Step Procedure 8 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been d
212. r up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller 140 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Connecting C75 Redundant Ethernet to a PC with Designer Software or other applications Only use Shielded CAT 5 cable for network connections See Figure 78 and Table 20 oF imi LATERALIS Figure 78 Redundant Networks see Table 20 ATTENTION Always observe the wiring cabling guidelines on page 52 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 141 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Table 20 Redundant Network connections in Figure 74 Key No Connection Description la Connect CPU A E1 port to Ethernet switch 3a 1b Connect CPU B E1 port to Ethernet switch 3a 1c Connect Ethernet switch 3a to PC Ethernet port 2a Connect CPU A E2 port to Ethernet switch 3b 2b Connect CPU B E2 port to Ethernet switch 3b 2c Connect Ethernet switch
213. r via the RS 485 to USB cable connected to RS485 Port which can be connected to external Honeywell qualified RS485 to USB converter and can also be networked to the controller via the Ethernet 10 100Base T Open Connectivity Network port Redundant controllers PC communicates with Lead Controller only NOTE For specific PC requirements and for specific software requirements refer to the Designer Software Users Manual RS 232 Modem Devices In Legacy systems the PC configuration tool can connect from the RS 232 serial port of the Controller Module to a serial port on the PC For new system the PC Configuration tool connects to the galvanically isolated RS 485 port on the Controller Module using an external Honeywell qualified RS 485 to USB converter The PC can be located remote from the Controller by using Modems and telephone links Modems and suitable cabling are available from third party vendors PC Configuration Tool Controller PC t Modam a y Cable C l pe Modem ji Modem _ Cable Telephone E ps Telephone Cable Figure 17 RS 232 Modem Devices Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 29 January 2014 Components and Architecture Ethernet Devices Considerations Ethernet Devices Considerations Ethernet device requirements vary with specific applications Regarding intended use however they fall into two categories CAUTION
214. reoccurs Most likely the last module inserted needs to be replaced 7 Replace the rack EAROM EA ROM Failed its checksum 1 Remove reinsert module 2 Replace module ROM 1 Remove reinsert module 2 Replace module 24V 1 Remove the module and check for a bent pin then reinsert the module 2 Measure power supply voltage If not correct replace power supply 3 Replace module 4 Replace rack FACTORY CAL CRC failure of primary and backup factory calibration Replace module FIELD CAL CRC failure of fied calibration values 1 Remove reinsert module 2 Replace module HARDWARE General Hardware Failure Aleconvertor not working Replace module HW SW Key The software residing on the module does not match the module type This diagnostic should only result in the factory Replace module Shift Register The loopback test of the shift register failed Replace module Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 181 Diagnostics and Troubleshooting I O Module Indicators Bad I O Channel Diagnostics Individual channels on I O modules indicate their diagnostics by 6 flashes on the Scanner and CPU the channel s LED does not indicate a diagnostic Table 32 is a list of conditions that can cause a bad channel diag
215. ring field devices to the terminal block associated with each Wiring 1 0 module Communications 123 Guidelines for installing RS 232 RS 485 to USB cable RS 485 and Ethernet Installation cabling and associated components Operating 151 Characteristics of the HC900 Process Controller as they relate to configuration of Characteristics a control strategy and to operation of an installed and running system Redundant 161 Characteristics of redundant operation Operating Characteristics Diagnostics and 167 Mechanisms that detect and react to faults in the operation of HC900 Process Troubleshooting Controller hardware and or software components Analog Calibration 184 Hardware configuration required for calibrating Al and AO modules from the configuration software Removal and 189 Guidelines for replacing system components includes Cautions and Warnings as Replacement applicable Procedures Specifications 199 Details of HC900 Process Controller design and functioning Appendix 211 The Remote Termination Panel RTP provides an easy way to connect the Installation of HC900 controller to the field wiring The RTP integrates some of the typical Remote externally connected components reducing wiring and setup time It also Termination Panels minimizes the need for multiple wires under a single screw connection by RTPs expanding the connectivity of the shared terminals of the I O modules Revision 2 1 HC900 Process amp Safety Control
216. rocess amp Safety Controller User and Installation Manual 121 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Encoder 2 A Single ended 4 B 5 Internal jumper OUTPUT4 COM ENCODE ENCODE Encoder power IN t IN t IN 2 IN 2 IN a IN 3 IN 4 IN 4 INDEX INDEX SENSE SENSE OUTPUT OUTPUT2 OUTPUTS OUTPLUT4 COM ENCODE ENCODE P 1 D D DOG Figure 74 Quadrature Single Ended HC900 Power Wiring 122 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Overview Overview Communications Installation This section contains descriptions procedures and recommendations for installing communications systems and components Wiring and cabling Table 16 Connect Communications Wiring and Cabling Step Procedure Comments Reference 1 Determine requirements for communications links See e Ethernet e For legacy system e Cabling Wiring Distance Devices Considerations on page 30 serial Ports RS 232 and galvanically isolated RS 485 on page 39 For new system two RS 432 serial ports on page 39 Planning on page 52 All ports are shown To Operator Interface Refer to the diagram at right and to Table 17 Links to Controller Communication Ports for connect
217. rounding Bar gr 14 AWG 2 1 mm BA A r 4 i r O_O fo D Field N Wiring eA Shields o o o oj ga lo o o oja L1 H L2 N PE Power Source Figure 30 Cabinet Wiring Multiple Chassis Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 55 Pre Installation Planning Electrical Considerations Li H Li H L2 N PE PE L2 N L1 H Power Source Power Source For P01 power supply use 3 0A slow blow for 115VAC operation 2 5A slow blow for 230VAC operation For P02 power supply use 2 5A slow blow for 115VAC operation 2 0A slow blow for 230VAC operation For P24 power supply use 7 0A slow blow Figure 31 Redundant power supplies each with external fuse and switch 56 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 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 recommended This may help minimize electrical noise and transients that may adversely affect the system e Separate external wiring group connecting wires into bu
218. rt attributes for use with the controller Make sure that the same baud rate is set up for the PC port and the controller In general the faster the baud rate the better the performance however your PC may not communicate reliably at the faster baud rates Refer to the HC900 Designer Software User s Guide or its respective on line help Setting Up PC Com Ports and Connections PC Serial Com Port Setup and Utilities Worksheet Set Controller Serial Port for details on this step Current PC to Controller Connection Settings ni a Loop Back Statistics Port Protocol Honeywell Inc ELN Speed bps 38400 PC Port Setup 7 Network COM1 6 On the PC use the Utilities Worksheet in the HC Designer software to select the Com port as the current port Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 129 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software RS 232 Direct Link to PC Configuration Tool Legacy Controllers The Controller can be connected directly to the PC in which case a Null Modem Cable is required The Null Modem Cable can be ordered from Honeywell Part 50004820 501 Cable connections are shown in Table 19 Table 19 Null Modem Cable Connections 9 pin D female connector 3 plug connector ofa Mm 5 8 4 1 m
219. rty suppliers These modular components are available in any quantity and mix that make the most sense for a given application As indicated in Figure 3 the HC900 Controller includes provisions for communication via Ethernet with host systems such as the Honeywell Experion HMI and other HMI software that supports Ethernet Modbus TCP protocol Also the communication structure of the HC900 Controller enables remote placement of input output components allowing significant economies in cabling and wiring Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 9 January 2014 Introduction Functional Description Redundancy ipae Experion HS or 3 Party SCADA i SCADA interface 2 Ethernet 100Base T r Da a S Mii 900 Control A Ethernet Station 15 ee ores Redundant Hc900 Ethernet darii Switches Iil G TTF wei Remote Redundant I O communications e ae mi E Ahim Figure 3 Single process with redundancies O Redundant CPUs Redundancy is provided by two C75 CPUs operating in a controller rack this rack has no I O A Redundancy switch module RSM sits between the CPUs Redundant CPU Power Two power supplies one for each C75 CPU Redundant CPU I O connection Each CPU has its own 100 base T Ethernet physical communication link with one or more racks of I O Multiple I O racks require Ethernet switches 1 0 racks 5 racks shown top to bottom 4 slot w 1 p
220. ry 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP Cable wire positions and colors Applies to 4 AO 16 DI 16 DO 8 DO Twisted Pair Number HC900 Module TB Position RTP J1 Plug Connector Color 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 9 17 Black 10 16 Blue 5 11 15 Black 12 14 Yellow 6 14 12 Black 15 11 Brown 7 16 1 Black 17 2 Orange 8 19 4 Red 20 5 White 9 3 8 Red 8 18 Green 10 13 13 Red 18 3 Blue RTP Internal schematic Applies to 4 AO 16 DI 16 DO 8 DO RTP J2 J3 J4 J5 7 swi cm TEE ne j or or or or swspst m 1 6 2 7 Ea 3 8 o mr 4 9 i 6 20 8 18 12 9 17 oa C ja a J9 J7 J8 J6 at Lel ee ee ee 4 n T K Ny y 20 5 X ct ct ct or 13 13 14 12 a mi 15 11 ae ee eT i H 17 2 n 16 1 Se ee 27 es 11 15 a 12 14 a0 CON40 234 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output ATTENTION RTP and cables are intended for permanent installation within their o
221. ry will retain energy over an extended period At the 6 to 9 mA level the battery will retain sufficient energy to maintain the content of SDRAM for 30 days for C30 C50 and 20 days for C70 C75 controllers of backup service At the 40 milliamp level battery life is severely reduced The battery could be rendered useless in less than 60 hours CAUTION Installing the backup battery when the CPU is not initialized will cause undue battery drain Do not install or replace the backup battery until after site power is applied 196 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Battery Installation Procedures Table 39 Installing Backup Battery CPU not initialized Step Action 1 Ay CAUTION Improper application of site power can cause damage to equipment Ensure that the controller rack is ready and safe for application of AC power Apply site AC power to the Power Supply that is associated with the controller Module Press the latch on the battery cover 1 to release the battery holder and pull on the handle 2 to remove the battery holder Note the orientation of the battery holder assembly battery toward the left The battery is retained in the holder by spring tension of the plastic holder itself Insert the negative end of the battery into the back end of the ho
222. s 16 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Components and Architecture Components Table 1 Descriptions of Major Components Figure 4 Key No Component Description Source Name 1 Controller Includes Rack Power Supply Controller Module and Honeywell Local Rack I O modules 2 I O Expansion Optional Includes Rack Power Supply Scanner Honeywell Rack Module and I O modules C50 C70 CPU only 3 Control Station 900 Control Station operator interface communicates Honeywell via Ethernet or galvanically isolated RS 485 serial link 4 PC e For legacy system The PC configuration tool PC is from third party Configuration connects from the RS 232 serial port of the supplier Configuration Tool Serial Controller Module to a serial port on the PC software is from connection Honeywell RS 485 to option e For new system The PC Configuration tool USB converter is a third connects from the galvanically isolated RS 485 port party device available of the Controller Module using an external from Honeywell Honeywell qualified RS 485 to USB converter 5 HMI Human Optional PC link to Ethernet network which may PC is from third party Machine include other HMls other HC900 Controllers and supplier HMI software is Interface other networks including Internet available from Honeywell Typically inc
223. s Hazard Source Preventive Action s A CAUTION Each signal at each of the Either L f control terminals for an I O module has a P oss OF contro or view ota specific function Any or all of the 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 i l sae and or to process product signal that is necessary to maintain safe process control Or Bring the process to a safe stop before initiating the removal or insertion procedure A WARNING Potentially lethal voltages on Disconnect all signals at terminal Terminal Blocks blocks from sources of power Human contact with high before removing the terminal voltage sources will result block from the I O module in death or serious injury Ensure that the Protective Earth PE ground is properly connected and properly functioning 194 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD Table 38 I O Module Replacement Step Action Ay CAUTION Removal or Insertion Under Power of an I O module is an option but if operating circumstances permit disconnecting power from the rack is the preferred option Plan and develop an action sequence before beginning the replacement
224. s Set verify jumper positions on each RTP as shown See page 246 for RTP internal schematic 242 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Output Connect field wiring RTP A for outputs 1 to 16 Install jumper wire DC Supply RTP B for outputs DAA Install jumper wire DC Supply refers to the switched negative side of the DC supply Note SDC Note Terminals 9 and 11 DC are connected through the RTP cable Same for terminals 10 and 12 DC 243 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 32 Point DC Digital Input ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect terminal block end of desired cable assembly to 32 point Digital Input module at controller Choose from 9OORTC 3210 Remote Terminal Cable assembly 1 0 meters long 9OORTC 3225 Remote Terminal Cable assembly 2 5 meters long
225. s 183 Table 34 Power Supply Replacement all except C75 ceeseeeseesseecsneeesceesneeeseeeseecsaecscessaecssaeeenaeeesaee 190 Table 35 Controller Module Replacement ceeseeeseecsseecsseeceneeesseecesaecesaecesaeessaeessaeecsaceceaeecseeseseeeeaeesses 192 Table 36 Scanner Module Replacement eeceescceeseecsseeeeseeceneeessaeeesseessaecssaeeesseeesaeecseecsaeecseeseseeenaeessas 193 Table 37 RIUP Potential Hazards and Recommended Actions cccccceeeseceeeeneeeeeeneeeeesneeceeseneeeeeeneeeenees 194 Table 38 1 0 Module Replacement 2 222 cg2ctecsecagisctyectdeseeesie0 e e e i ria ana asii a dessctessugeotes 195 Table 39 Installing Backup Battery CPU not initialized ee eee eseceseeesneeeeneeessceceaeceeecsseecssaeeeseeeesaes 197 Table 40 Replacing a Backup Battery CPU Powered cesceesseesseceseeesnceceseeeseeesseeeeaeeeaecesaeessaeessaeeesaee 198 Table 41 HC900 PV Input Types and Ranges 2 0 eeeeeessecseeeeeseeesseecsaeessaeesseeesaeecsacecssaesseesssaeeeseeessaeeesaes 205 Table 42 System Size and Availability Summary ee cceecceeeseeceneeceeeesaceeseeeseeesseecssaecseeseaeesseesenaeessaes 208 Table 43 Fiber Optics Equipment Recommendations esceesessseecsseeceneeesneeeseeesseeceaecseecsaesesseseneeeenaes 209 x HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Figures Figure 1 Small HC900 Controlle
226. s E e ee eee 120 Figure 71 Quadrature Differential External Power Wiring eeeeeeseeeseeerresreerissrresresrresrresersressrersreereesreesees 120 Figure 72 Quadrature Single Ended External Power Wiring ccsssccsececeeeeeeseeeeseeeesaeessaeessaeessaeeesaeeesaes 121 Figure 73 Quadrature Differential HC900 Power Wiring ccesccceseceneeceseeesneeesseeeesaecesaeessaeessaesesaeeesaes 121 Figure 74 Quadrature Single Ended HC900 Power Wiring cesccesseccescecesceeesseeeseeeesaeessaeeesaeessaeessaeessaes 122 Figure 75 A Direct Serial RS 232 Connection cceeeeessseceseeeeseeesseecsseecsseesseeeseeeseecssaecsseesseeseseessseeeesaes 129 Figure 76 RS 232 Remote Access via Modems scccsssccesseessseeeseesseesseeeseesseeesseecsaecsscesseesssaeesneeeesaes 131 Figure lt 7 Modeni Contection 2 05 ei einen cles es a iE aoe heartbeat E E E EEE E desiree 132 Figure 78 Redundant Networks see Table 20 c cccesessecceeseceeeeeneeeeeseecesenaeeeeseneeeeseaaeeesenaeeeeseneeeeseneeeeeeeas 141 Figure 79 Two redundant systems with PC Supervision eesccesseeceseeesseeceseeeeseeessaeeesaeessaeessaeessaeeesaeeesaes 144 Figure 80 RS 485 Modbus slave wiring scsescsssccsseecsseecssceceseeceseeeesaeessaeeesseessaeecsseecsaeecsaeeseeeseeeeesaeensas 148 Figure 81 RS 485 Modbus slave wiring with isolation ccscceesceeseceseeessceceseeesneeeesaeeeaecesa
227. s descriptions and procedures for the installation operation and maintenance of the HC900 Process Controller hardware References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title ID HC900 Process Controller Technical Overview Specification 51 52 03 31 HC900 Module Specification 51 52 03 41 HC900 Controlware Specification 51 52 03 42 Designer Software Specification 51 52 03 43 Legacy HC900 Process Controller Installation and User Guide 51 52 25 107 HC900 Process Controller Operator Interface User Guide 51 52 25 108 HC900 Designer Software User Guide 51 52 25 110 HC900 Process Control Utilities User Guide 51 52 25 126 HC900 Process Controller Function Block Reference Guide 51 52 25 109 HC900 Process Controller Communications User Guide 51 52 25 111 HC900 Controller Redundancy Overview amp System Operation 51 52 25 133 900 Control Station For use with HC900 Process Controller 51 52 25 148 Station Designer Software manual 51 52 25 149 HC900 Process amp Safety Controller Safety Manual 51 52 25 153 Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual Revision Information Document Name Revision Number Publication Date 51 52 25 154 HC900 Process amp Safety Controller User amp 21 January 2014 Installation Manual Support and Contact Information For Europe Asia Pacific North and Sout
228. s if this controller will require a unique IP address within a plant network Also ensure that the PC Network Interface Card has an IP address that allows access to the controller on the subnet after changing the controller s network parameters Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 145 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Step Procedure 7 You may change the controller s IP address and related network parameters from its default using the Utilities Worksheet in the HC Designer software This may be done using either the RS 232 serial port legacy systems via a null modem cable connection or the Ethernet connection from the PC to the controller If the RS 232 connection is desired make sure the proper PC serial Com port to be used has been set up See Direct Serial RS 232 Connection page 129 8 Select the Set Controller s Network Parameters button Using the wizard bottom radio button select the PC port to be used then set the controller s new network parameters including IP address Subnet Mask if other than the default and Default Gateway IP address if required otherwise use default Refer to the HC900 Designer Software User s Guide or its respective online help Utilities Worksheet Set Controllers Network Parameters for further details on this step Note This step will require the co
229. sceceseeceseeceteessneeeeaeceaecesaecesaeessaeessaeeesaes 217 Figure 104 Voltage input connections 20 0 0 eeeseesseecseeceseeceeessseecseeceseecssaecssaeessaeeesaeecsaeecseeseneesenaeeeaeensas 241 Figure 105 Current connections with 2 wire transmitter ceseeseesseecsseecssceceseeesneeeesaeeesaecesaecesaeessaeeesaeeesaes 242 xii HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Introduction Purpose Purpose Introduction This publication describes the installation operation and maintenance of the Honeywell HC900 Process Controller This publication includes the following sections Chapter Title Page Content Introduction 1 Model numbers how to verify component compatibility function description of components feature summary Components and 15 Functional features and physical characteristics of the system and of each major Architecture component of the HC900 Process Controller Networking components and methods of interconnection Pre Installation 43 Pre planning considerations and procedural guidelines for planning an installation Planning Rack Installation 63 Procedures for installing the major components of the system controller rack I O expansion racks and communication interconnections I O Module 75 Procedures for installing I O modules in the controller rack and I O expansion Installation and racks and for wi
230. sesaeceseesesaeeesaeeesaeessaeeenees 61 Figure 36 Series Relay for Analog Output ceeceesseceseeceseeeeseeesseeesaeecseeeseeesseecesaeceseesesaecesaeeesaeersaeessnees 62 Figure 37 O Module Installations ni n iena eiai a ri e e aSa 75 Figure 38 Terminal Block Stylesin catenins ctu diviiee nl iedeselgestecatesdiduayl essed aa 76 Figure 39 Signal Wire Grounding siisi nans i i aiaa rie e a riai 78 Figure 40 Wire Shield Grounding ees ceeceessccesncecsseecseeceseeesneecesaecesaecesaeeesaeeesaeeesaeecseesseeseneesesaeeesaeessaees 78 Figure 41 Terminal Block Jumper Installation eee eeseeesceeeseecsseecsseeesseecseeceseecssaecesaeceseesesaeeeseeesaeeseaeers 79 Figure 42 RTD INpuls is resin orii te ang aai EEE Ee Eas AE a ea N A AS e E E EE e a RE 89 Figure 43 Universal Analog Input Wiring Diagram 00 eee eeseeeseeceneeeeeeeeeeeeaecsanecesaecesaecesaeeesaeeeseeesaeers 90 Figure 44 Examples of RTD Input Wiring eee eeeeceeecsseeeesseeeseeeesaeecsaeeesaeeesseecsseecsseecesaeeesaeeesaeeesaeesaees 91 Figure 45 Analog Input Wiring Eight TCs 0 eeecesseeceseeceseeeseeesaeecsaeeesseeesseesesaeeseecssaeessaeeesaeeesaeessaees 92 Figure 46 Analog Input Wiring Eight Resistance Inputs ecceeecesesceceseeeeseeeesceeesaeessaeeesaeessaeeesaeesseeseaeers 93 Figure 47 Analog Input Wiring Eight RTDS 0 00 eee eeeeeceseecesneeesneeesaeecsaeeeseeesseecesaeceseecesaecesaeeesseeesaeessnees 94 Fi
231. sis Rack height height components 5 4 For 32 DUDO amp 175 137 16Al Reference Center Figure 24 Rack Dimensions 46 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Rack Orientation and Mounting eereerececccoseg at i air Arle ti aac ame ae sick pag eal RS 6 0 Reference Center meerareneeneeassssan anew n eee ied Pete ween ones Figure 25 Rack Dimensions with reserve power supply Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 47 January 2014 Pre Installation Planning Remote Termination Panels Figure 26 Vertical Spacing of Racks all models Remote Termination Panels If your controller will be mounted in a separate panel with intermediate terminations between field wiring and controller wiring consider using RTPs to replace the intermediate terminations Pre wired cable assemblies for the RTPs eliminate the need for separate wiring terminations between the controller and the intermediate terminal boards For details see page 211 48 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Environment Environment The HC900 Controller must be mounted in suitable equipment enclosures That is all components such as the Controller rack I O Racks and the 900CS Control Station manufactured by Honey
232. ss than 2000mA Yes No 2 Is column E total mA 24V less than 900mA Yes No 3 If the answers to 1 and 2 are YES go to 4 If the answer to 1 or 2 is NO use power supply 900P01 0001 4 Multiple column D total by 5 1 5 Multiple column E total by 24 5 6 Sum results of 4 and 5 7 Divide results of 6 by 1000 8 Is the result of 7 less than 28 Yes No If the answer to 8 is Yes use power supply 900P02 0001 If the answer to 8 is No use power supply 900P01 0001 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 45 January 2014 Pre Installation Planning DC Power Supply DC Power Supply The P24 DC power supply is for use with 24V input power applications The wattage rating is the same as the P01 60W Rack Orientation and Mounting Racks must be mounted as indicated in illustrations throughout this manual so as to provide for vertical airflow through the racks That is racks must never be mounted vertically and must never be mounted with the backplane horizontal for example flat on a horizontal panel or tabletop Environmental specifications apply only to the normal mounting configuration Rack dimensions including overall dimensions and patterns for drilling holes for mounting are given in Figure 24 and Figure 25 Vertical spacing of racks which is required for rack ventilation and for routing wires is shown in Figure 26 Rear mounting T Total Depth plate Chas
233. st use one of the Igrp current sources Also two terminals are jumpered together as they are for two wire RTD inputs Analog channels wired for Ohms inputs differ from RTD inputs in these aspects e Ohms inputs connect to variable resistance devices other than RTDs and e Ohms inputs are configured in Designer Software as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in Figure 46 Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section Ay WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 89 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams RTD 3 Wire Input IRTD Thermocouple Se 3 amp 4 Ohms LOs SE IN 4 Input Be pe aes eens H aa i Pou e 1 i i E POF bS 1 IN Y IN t H eo oo Ni Ni Skpta2 hot 82 i IN 2 1 t N2 H Vam n IN 3 IN ERI em j 3 IN 3 hko 384 IN 4 IN4 IN 5 IN5 hoo 5 amp 6 hw 5 amp 6 poe neenenmmene IN G4 IN 6 s s NG IN6 IN7 INT ko 7 amp B len 7 amp 8 grm IN 8 IN 8 d paana NB N8 Figure 43
234. t S OR Di 32 900H01 PEN 900602 L 900H01 Fel 900632 OR DH32 DOs q 900632 900H03 2 S 2 S DI DH6 DI s z DI 900603 a 900604 9 5 V gt VALID HIGH lt 32 0 V 0 0 V gt VALID LOW lt 3 5 V o lt 24VDC 72VDC g Relay Output Q 9 Aas 2 nee 900H01 le 900602 4 ae Relay Output OB DE 32 900632 Bris S00HO1 enn Relay Output Sats 900603 om 900HO4 Raley aoe 900604 Ge A Sinking DO 16 DI DI 900H02 Relay Output 900H01 Note j DI Sense is inverted when Load is placed a Co on High side relay sinks power T H DI Sense is NOT inverted when Load is Note DI Sense is inverted located on Low side relay sources power Note DI Sense is inverted Figure 34 Individual Series DO connections 24VDC yO a 110 220 a 9 5 V gt VALID HIGH lt 32 0 V b 4 0 0 V gt VALID LOW lt 3 5 V lt E Sarg Relay Output a 900H32 DI 16 PODEU T 900G02 Y A DO 8 or DI 32 I gt 900H03 900G32 a B DI DI 16 3 o DI 16 2 ose PI 900604 900632 900604 75 VAC gt VALID HIGH lt 250 VAC 0 0 V gt VALID LOW lt 20 VAC ae i a 9 900G02 eS 3 or DI 32 4 900632 Relay Output Sinking DO 16 900H01 900H02 ean fa DI 16 S Di 900603 DI 16 DI i E 900G04 i 900G02 or DI 32 Se 900632 ont Eee Note DI Sense is inverted Note _ DI Sense is inverted when Load is placed on High side relay sinks power DI Sense is NOT inverted when Load is located on Low side
235. t Digital Output Analog Output 16 Point DC Digital Input Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc Please see page 80 for more details ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 234 for RTP internal schematic Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 Install jumper wires DC Supply Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 227 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point AC Digital Input ESS 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP combines the two groups of 8 inputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 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 900RTC H050 Remote Terminal Hi
236. t 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 58 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Electrical Considerations Power Supply in HC900 Controller Rack Power Supply i in HC900 O Expansion Rack I Ea e Multiple I O Expansion Racks Power Supply in HC900 I O Expansion Rack Power Emergency Power ON Sto OFF he 7 facr 2 et s J a e MCR F Input Modules ea e O 2 Y E Input F ge swo BP Output Modules i F Figure 32 Master Control Relay Wiring Example Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 59 January 2014 Pre Installation Planning Hardware and wiring requirements for safety configuration Hardware and wiring requirements for safety configuration For the function blocks for safety a special hardware configuration and wiring is required Below high level diagram explains the wiring concept for using the validation function blocks Independent Relays hooked in Series LIBR hannal tg Dhanna ts abtine A No
237. t specifications Controller rack to I O Rack Ethernet CAT5 cable with RJ 45 connectors Fiber Optic cable with switch Fiber Optic cable with switch and repeater 100m 328 ft 750m 1500m see page 209 Controller to Ethernet Switch Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Ethernet Switch to I O Rack Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Controller to Network Switch Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Network Switch to PC Ethernet CAT5 cable with RJ 45 connectors 100m 328 ft Controller to 1042 Operator Interface Shielded Twisted pair 610m 2000 ft Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 203 Specifications General Specifications Approvals CE Conformity This product is in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed EN61326 Electrical Equipment For Measurement Control and Laboratory use EMC requirements ATEX The apparatus fulfills the requirements for Group Il Category 3 equipment in accordance with Directive 94 9 EC ABS Type Approval Certificate of Design Assessment No 06 HS186538 PDA Certificate of Manufacturing Assessment No 06 BA
238. te If communication was never established to the Scanner then the module outputs are in the power off state 12 13 switches on the scanner are set correctly C75 only Verify that the CPU A cable is connected to the A port and the CPU B cable is connected to the B port on the Scanner 2 If a switch is used check that all cables are properly connected to the switch proper crossover cables are used that the switch is powered and it supports 100 Base T Check cable shielding for proper grounding and noise immunity Make sure the cables have the correct pinout Cycle power to the Scanner Cycle power to the switch Cycle power to the controller CPU Replace the expansion rack s scanner module Ensure that the Scanner and Controller CPU software versions are compatible If not perform a firmware upgrade Replace the expansion rack s power supply Replace the expansion rack Replace the main CPU Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 177 Diagnostics and Troubleshooting Scanner indicators Number Possible Cause Scanner Action User Action of Strobes 3 One of the following Scanner restarts The main CPU detects that Cycling power to the scanner will microprocessor exceptions the Scanner restarted and places the clear the diagnostic occurred Scanner back into the scan
239. the Designer Software SixNet VT MODEM Industrial External Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 25 pin connector use a DB 9 male to DB 25 female modem cable If your RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232cable 2 Connect power to the modem You will need to supply an external power supply with a DC voltage between 10 and 30 VDC Power up the modem Run a serial communication port program such as Hyperterminal Within the communication program select the port to which the modem is connected O oa Aa Ww Configure the port to these settings baud rate 1200 2400 4800 9600 19200 38400 57600 Must match Baud Rate configured in HC900 Controller data bits 8 parity none stop bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT amp FO Then press the ENTER key 8 In the program s terminal window key in the following command string AT E1 Q0 Then press the ENTER key The modem should give an OK response 9 Key in the following command string AT amp Y0 amp CO amp DO amp R1 amp S0 amp K0 S0 1 The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp WO The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the 13 Connect the modem to a telephone jack 14 Powe
240. the I O expansion port on Controller Module or to a port on a Switch that connects to the Controller Module 3 LED status diagnostic indicators for communications functions Figure 14 Scanner 1 Module Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 27 January 2014 Components and Architecture Hardware Components Scanner 2 Module S75 S75S only 900S75 Scanner 2 Module is shown in Figure 15 The dual ports provide redundancy through the 2 CPUs Features at the front of the module include 1 LED status diagnostic indicator for scanner functions 2 I O port A Private Ethernet 10 100 Base T Port Connects C2 directly to I O port on CPU A or indirectly through a switch 3 I O port B Private Ethernet 10 100 Base T Port Connects directly to I O port on CPU B or indirectly through a switch 4 LED status diagnostic indicators for communications functions Figure 15 Scanner 2 Module Input Output Modules T O module types e 16 point high level analog input module each point is configurable for V or mA Point to point isolation e 4 point isolated analog output module Supports from 0 to 20mA each e 8 or 16 point analog output module Supports from 0 to 20mA each Isolated in groups of 4 channels e 16 point digital input modules Contact closure type DC voltage and AC voltage types e 32 point digital input module DC voltage e 8 point AC s
241. the I O Racks Lead Controller responds to communication messages from host devices on the Supervisory Network and RS 485 interfaces Lead Controller handles communications with HC900 peers Lead Controller handles communications with Modbus RTU slave devices Lead and Reserve exchange system status data to determine conditions for failover 162 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Redundant Operating Characteristics Steady State Operations e T O Scanners relay system status data between each Controller to determine conditions for failover Execution time HC900 Controllers are designed to execute control functions within fixed scan cycles for analog data types and logic data types In redundant controllers the default scan time is 500ms for analog data types and 53ms legacy 25 mS for new controllers for logic data types Execution sequence e The type of control functions executed during a scan is determined by the system configuration Controller configurations contain a series of algorithms in the form of function blocks that get executed in a fixed sequence The first 100 function blocks are pre assigned by the system to handle communication tasks alarm processing system monitoring functions etc and cannot be changed by the user Starting with function block number 101 the user may select the type of function to be executed e The sequence of function block exec
242. the field wiring The RTP integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I O modules See Appendix Installation of Remote Termination Panels RTPs page 211 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 block Wiring Rules and Recommendations In general stranded copper wire should be used for non thermocouple electrical connections Twisted pair wiring with shielded cable will improve noise immunity if wire routing is suspect Wire Gage Observe all local codes when making power connections Unless local electrical codes dictate otherwise the recommended minimum wire size for connections is given in Table 12 Table 12 Minimum Recommended Wire Sizes Wire Wire Application Gauge 14 Earth ground to common power supply 14 to 16 AC to power supply 10 to 14 Earth ground wire 20
243. the rack DC isolation Capacitor Shield wire Figure 39 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 40 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 gt T 9 a L lt module and is the preferred method 8 for a limited number of wires CHO SIselelgelslel1 For a larger number of wires or for wires of a heavier gauge it is advisable to route some wires through the top of the terminal block and some through the bottom as indicated in Figure 40 In this case it is necessary to adjust wire length so as to ensure adequate PA flexibility of the twisted wires and to provide clearance sufficient to remove the I O module lelelelelels Figure 40 Wire Shield Grounding 78 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank I O Module Installation and Wiring Terminal Block to Field Signal Wiring Ter
244. tion page 78 2 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 212 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Set DIP switch positions SW1 through SW8 Set each input s DIP switch positions according to the input type For Input n use Switch n For example for Input 1 use Switch 1 for Input 2 use Switch 2 etc If an input is not used set its DIP switch positions to OFF Fuses 80mA Time lag Littelfuse part 37400800410 UL CSA approved Transmitter Loop Powered Volt millivolt Milliamp Transmitter Externally Powered SW9 is the red power switch for 24 volt supply Module RIUP is not affected by using the RTP See page 218 for RTP internal schematic Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 213 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input 8 Point Analog Input Connect field wiring Refer to Figure 97 through Figure 103 for field wiring Any input type can be wired to any of the 8 inputs After wiring double check DIP
245. tion procedure For AI channels configured as thermocouple inputs the stored calibration values are compensated by the measured temperature of the terminals Because of this observe the following rules e If you plan on calibrating the 2 cold junction compensation devices perform this operation first before performing any thermocouple calibrations However because cold junction measurement inaccuracies will 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 92 is an adaptation of the wiring diagram given in the installation section of this manual This figure indicates how a calibration device can be connected to the appropriate terminals of an analog input module The calibration device s must have the following precision characteristics e TC mVolts Volts inputs 1 microvolt resolution e Ohms RTD inputs 01 ohm resolution e 4 20mA inputs 4 microamp resolution 186 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 This page is intentionally left blank Analog Calibration Overview
246. tion Manual 53 January 2014 Pre Installation Planning Electrical Considerations Electrical Considerations All racks should be mounted in an appropriate metal enclosure A diagram that shows recommended wiring practice for the cabinet enclosure is given in Figure 29 Cabinet Wiring Single Chassis and Figure 30 Cabinet Wiring Multiple Chassis When Redundant power supplies are used in Redundant controller racks or I O racks separate line power sources are recommended to provide the highest level of redundancy and system operation Deviations from the installation conditions specified in this manual may invalidate this product s conformity with Low Voltage and EMC Ay WARNING Ay Hazardous voltages exist in the equipment enclosure e Identify and avoid contact with voltage sources Failure to comply with these instructions could result in death or serious injury Controller Grounding PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National Electrical Code ANSI NFPA 70 and with local electrical codes Shields Grounding Bar ge 14 AWG 2 1 Mmm Q ola Shields Seg Field Cray Wiring Li H L2 N PE Power Source Figure 29 Cabinet Wiring Single Chassis 54 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Electrical Considerations G
247. transparent hinged door The hinged door is a tool secured cover To open the door insert a flat screwdriver into the slot at the top and bottom of the door while pulling out The door has molded in tabs that hold labels which are uniquely color coded to identify each module type Each label is printed on both sides On the front visible when the door is closed are I O channel numbers with spaces in which tag names can be written On the back visible when the door is open are wiring patterns for the type of module located in the slot Figure 38 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 The 36 pin Euro terminal blocks must be used with High Level AI High Level AO 32 DI and 32 DO modules ATTENTION Before mounting terminal blocks in the rack be sure they are properly keyed to the module type they will be used with See I O Module Installation Procedures page 81 Terminal Block Colors and Keying Both the barrier style and the Euro style are available in two colors red and black Black terminal blocks which have gold contacts are used for low voltage low energy signals such as analog inputs contact inputs and low DC voltages Red terminal blocks which have tin contacts are used for higher voltages such as 120 240 Vac Colors of each Terminal
248. tributes 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 64 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 Ay WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 113 January 2014 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams L2 N Legend External Disconnect Out 4 H Oul 1 M Out 1 NO Oul 1 NO iE Oued H eee Oul 2 NO Out 2 NO E Out 3 H Out 3 H F Out 3 NO Out 3 NO A Rep ei ut H DND da Oul 4 NO 4 55 Out 5 H Outs H E Oul 5 NO Oul 5 NO jE Outs M Out 5 H Cite NO E Out 6 NO M Out 7 H Out 7 H EE Out 7 NO Out 7 NO H Out 8 H Out 8 H 4 Out 8 NO Oul 8 NO User Supplied Safety Device Figure 63 AC Output Module Wiring Diagram PDOOOOTGOOGOOS as e tee O9 OOeK 114 HC900 Process am
249. trol Control action is resumed exactly as it was before the outage This flowchart also indicates actions that would be taken by the controller in case of fault Notice that if primary diagnostic testing determines that RAM or firmware is faulty all process control functions cease and the Status LED red color strobes one blink periodically If RAM and firmware tests pass but the database in RAM is faulty the controller initiates the Cold Start operation Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 151 January 2014 Operating Characteristics Power Down Power Up Cold Start 7 X Hot Start f Copy new configuration in RAM Initialize all control blocks data Initialize modbus and PDE tables Start copying config data to Flash in background Controller goes to RUN mode f a e Figure 83 Warm Start Operation 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 84 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 83 e Ona Mode transition from PROGRAM to RUN This Mode tr
250. ts and Architecture Ethernet Open Connectivity Network Inter Connection to Other Networks In many cases an HC900 Controller application will include a single free standing controller that involves no connections via the Ethernet Open Connectivity network In other cases the HC900 Controller will be a member of a Local Area Network LAN as indicated in Figure 19 The HC900 controller LAN may be very simple or it may include many devices in a complex and very sophisticated structure In any case it must always be regarded as a single modular entity that can be protected from intrusion by any other networking device to which this LAN is connected Various types of networking devices that enable selective connection to other networks are available A Router is commonly used for this purpose Routers can examine and filter message packets permitting passage of wanted messages and denying passage of all others The feature that gives the Router its name is it enables translation of IP addresses which enables networks with dissimilar network IP addresses to communicate as though they were members of the same network This feature is particularly useful when an HC900 Controller LAN is installed under local addressing rules That is IP addressing can be assigned without approval of or conflict with world Internet governing bodies A default IP address is provided in each HC900 Controller 192 168 1 254 Later when connecting
251. ual 245 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP A Cable wire positions and colors for cable assembly drawing applies to 16 Al 32 DI 32 DO Twisted Pair Number of HC900 Module TB Position RTP A J1 Plug Connector Color Cable A 1 1 6 Black 2 7 Red 2 4 9 Black 5 10 White 3 6 20 Black 7 19 Green 4 18 17 Black 17 16 Blue 5 18 15 Black 17 14 Yellow 6 10 12 Black 11 11 Brown 7 12 1 Black 13 2 Orange 8 15 4 Red 16 5 White 9 3 8 Red 8 18 Green 10 9 13 Red 14 3 Blue RTPA J2 J3 J4 J5 sw a r EEL TT a Terminal y y f Block Ji c1 c1 c1 c1 SW SPST TB1 1 6 2 7 Ss SSS Eee T 3 8 SSS SS es Semen er 4 9 v aod 5 10 t i 7 19 0 18 17 E ai 17 16 e ap E T COR A EE ee DEn rt ee rT 15 4 age 16 5 X X of X 2 9 13 10 12 A eee iz 11 11 C E i H 13 2 36 12 1 ee j es i a aaa 18 15 Td 17 14 a CON40 246 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output RTP B Cable wire positions and colors
252. ults by keying in the following command string AT amp FO Then press the ENTER key 8 In the program s terminal window key in the following command string AT El Q0 Then press the ENTER key The Modem should respond with OK 9 Key in the following command string AT amp Y0 amp CO amp DO amp R1 amp SO amp KO S0 1 Then press the ENTER key The Modem should respond with OK 10 Key in the following command string AT EO Q1 amp W0 Then press the ENTER key The Modem will not respond 11 Power down the modem and disconnect it from the PC 12 Connect the modem to the 13 Connect the modem to a telephone jack 14 Power up the modem and the HC900 Controller 15 On a remote computer run Designer software 16 Set up the PC software to dial the HC900 Controller 17 Use the PC software Loop back feature to verify that communications are established with the remote HC900 Controller 138 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Communications Installation Connecting the HC900 Controller to a PC with the Designer Software Best Data 56SX Data Fax External Modem Step Action 1 Connect the modem to a PC If your PC s RS 232 port has a 2 pin connector use a DB 9 male to DB 25 female modem cable If your PC s RS 232 port has a 9 pin connector use a DB 9 male to DB 9 female RS 232 cable 2 Connect power to the modem 3 Power up the mo
253. upplies in the slots in the Rack ensuring that the connector at the back seats properly See Table 9 steps 1 and 2 for power supply wiring details Note It is recommended each power supply be powered from a separate power source and a power switch be installed to allow for servicing of each Processor Supply separately 2 Set controller See page 40 communication ports Ay WARNING AY Ensure that AC power to the rack is disconnected See figure in step 1 Carefully place the Controller Modules in the rack adjacent to the Power Supplies Fasten them in place with captured screws at top and bottom ATTENTION The CPU battery comes installed with a plastic tab protruding from the battery cover This tab breaks the battery circuit Do not remove this tab at this time Removing the tab before the controller is configured can substantially shorten battery life Remove the tab under power after the controller configuration is complete For more information refer to Battery Installation Replacement page 196 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 71 January 2014 Rack Installation Assemble I O Expansion Racks Step Procedure Commenis References 4 Insert the RSM in the middle slot and attach with screws at top and bottom See figure in step 1 Assemble I O Expansion Racks T O Expansion Rack assembl
254. ut 4A at 250Vac 30Vdc with resistive load Maximum current per module No de rating per module but ensure compliance with maximum ratings for each output Note specified relay life is 1 000 000 cycles For applications requiring constant cycling of output Honeywell recommends using a solid state AC or DC output module Required Output Fusing Outputs are not fused in the Relay module Install a fuse for each output at the field device that is appropriate for the load and the wire used HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 116 This page is intentionally left blank I O Module Installation and Wiring I O Terminal Block Wiring Diagrams Jumper Comb A ten position jumper comb available for the AC Output Module can be cut in half and used as shown in Figure 67 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common Ay WARNING Ay Hazardous voltages exist at terminal blocks e Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these instructions could result in death or serious injury Relay Output Form C Cart COM Du51 No Ou l No Dil COM Qu 1 Ne Ou Ne Form C Form C Oud COM smmm LOAD 3 OXO LOAD 3 eae Form A ui L2 N Oul 3 Na ues No ook Owed CO Forma 4 No semen Qul 4 No Form
255. ut Digital Output Analog Output Connect field wiring Refer to the appropriate figure for your type of analog input pd alge eh Nada RTP A for amp 26646 inputs 1 to 10 BSOSODSONDOOD QOQOQOOHOOD ZEEZa 4 ae ee aad RTP B for inputs 9 to 16 DBOSVSOVDSOVNDHOOD Notice that Inputs 9 and 10 are connected across RTP A and RTP B Figure 104 Voltage input connections inputs 1 to 10 RTP B for inputs 11 to 16 S yN ZINI IN S ZNI S Lg 9a g 900 9 9a S ga 0 lt gas sein O 0S y N 9as 09S 00 900 stNl 90 9as Not shown recommended external current loop fuses Additionally on RTP A connect the following terminals 3 22 4 23 7 24 8 25 15 26 16 27 19 29 20 30 On RTP B connect the following terminals 1 22 2 23 5 24 6 25 13 26 14 27 17 28 18 29 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual January 2014 241 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 16 Point Analog Input Fi Figure 105 Current connections with 2 wire transmitter 32 Point DC Digita
256. ut Wiring 90 96 User Datagram Protocol 34 y Vertical Spacing of Racks 48 Voltage test points 24 W WAN 34 Warm Start 151 Wire Gage 77 wire size 77 wire tie 86 Wiring Rules 77 X XYR 5000 149 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 253 January 2014 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC Honeywell Process Solutions TAC hfs tac support honeywell com EMEA Australia Honeywell Limited Phone 61 7 3846 1255 FAX 61 7 3840 6481 r Toll Free 1300 36 39 36 Toll Free Fax TAC 1300 36 04 70 hfs tac su China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 For more information To learn more about HC 900 Process Controller visit www honeywellprocess com Or contact your Honeywell Account Manager Process Solutions Honeywell 1250 W Sam Houston Pkwy S Houston TX 77042 Honeywell Control Systems Ltd Honeywell House Skimped Hill Lane Bracknell England RG12 1EB Shanghai City Centre 100 Jungi Road Shanghai China 20061 www honeywellprocess com Honeywell Process Solutions Phone 80012026455
257. ution is initially determined by the sequence in which the function blocks are placed on the graphic diagram in HC Designer Final desired sequence must be set by the user to achieve proper and optimum performance CAUTION Incorrect execution sequences can contribute to delays in processing outputs and or improper or unexpected operation e The HC900 controller samples all inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The sequence order of the function block determines when in time the actual value will be updated It is important that algorithms that need updated input values for their calculations have the inputs execute first in the sequence e Except for Time Proportioning Output TPO Three Position Step Control TPSC and Position Proportional Output PPO function block types that update their physical output values while the function blocks are being executed all physical outputs are updated at the end of a scan Lead Reserve controller synchronization e Lead Controller automatically synchronizes the Reserve with the configuration database During download of a configuration from a Host to the Lead During process operation to bring a Reserve Controller from the Unavailable state to the On Line state e Lead Controller automatically synchronizes the Reserve with run time data during each function block execution cycle e Both the
258. w DOV 4 SS Fundlinn Glock Figure 33 IO V function block connections Figures 34 35 and 36 demonstrate the connection of a series output relay s normally OPEN contact to protect against outputs that are stuck ON This relay may be added individually as shown in Figure 34 and 36 or common for multiple channel outputs as shown in figure 35 and 36 The series output must be configured to operate when the DO V s or AO V s Fail pin or VFail pin goes ON 60 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Pre Installation Planning Hardware and wiring requirements for safety configuration 24VDC 24VDC ON Sourcing as An 0 220 DO 32 o 7 00H32 pe elay Output fa E AC 900H01 iia bhd d TEA i Relay Output Sa a J 900H01 DI 46 SS 900602 Relay Output D16 Relay Outpu
259. well must be mounted in approved furniture designed for industrial applications Consideration should be given to the installation so that the potential for the build up of static electricity is minimized or eliminated See Environmental Conditions and Approvals on page 204 Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 49 January 2014 Pre Installation Planning Heat Rise De rating Heat Rise De rating The HC900 is rated to operate at 60 C However for maximum reliability the following guidelines should be observed for applications above 52 C 1 Locate lower power modules Analog Input Contact Input etc beside the Controller Scanner Module and keep higher power modules AC Output AC Input etc away from it For power consumption of each module see Table 4 2 For 240 Vac applications and temperatures above 56 C or 264Vac 52 C de rate the number of ON inputs per AC input module See AC Input de rating data see Figure 27 3 Limit the number of Analog Output modules to a maximum of 10 per rack see Figure 28 Table 4 Power Applied by Module Type Module HC900 Hardware Field Power Total Power Power Watts Watts Watts Controller C30 and C30S 6 0 0 0 6 0 Controller C50 and C50S 6 0 0 0 6 0 Controller C70 and C70S 7 1 0 0 7 1 Controller C75 C75S 7 8 0 0 7 8
260. wer where power refers to DC power at the backplane of the rack It does not refer to power for field wiring at the terminal board associated with the I O module which must be disconnected using a user supplied switch at the field device before removing or inserting the module For all other components of the controller AC power to the controller must be removed before removal or replacement of the component A WARNING A Hazardous voltages exist at the Power Supply and at the terminal boards on I O Modules e Only trained and authorized personnel should perform the procedures in this section e Disconnect all sources of power associated with these components before removal or insertion Failure to comply with these instructions could result in death or serious injury Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 189 January 2014 Removal and Replacement Procedures Safety Considerations PLAN AHEAD A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I DIVISION 2 A WARNING A EXPLOSION HAZARD Class 1 Division 2 Installations e DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN NOT TO BE HAZARDOUS Replacing the Power Supply The power supply for the HC900 Process Controller is available in two models and is used in the local controller rack and in th
261. wn enclosure Mount RTP cable assembly to HC900 Controller Figure 96 e Remove appropriate key tabs from terminal board to allow mating with the module See page 82 e Connect terminal block end of desired cable assembly to 8 point Analog Output module at controller Choose from 900RTC B810 Remote Terminal Cable assembly 1 0 meters long 9OORTC B825 Remote Terminal Cable assembly 2 5 meters long 900RTC B850 Remote Terminal Cable assembly 5 0 meters long Install 8 point Analog Output label into the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 78 2 Mount RTP to DIN rail e Latch to rail See page 247 e Connect cable to RTP 3 C C Com Set verify jumper positions on each RTP as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 80 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See page 237 for RTP internal schematic Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 235 January 2014 Appendix Installation of Remote Termination Panels RTPs Analog Input Digital Input Digital Output Analog Output 8 Point Analog Output R
262. wo batteries for new models from the holder by using your thumb to apply pressure to the front end of the battery and rotating it to the left Insert the negative end of the new battery into the back end of the holder and press on the battery so that it snaps into the holder To ensure that the battery is seated properly rotate it in the holder using finger or thumb pressure toward the positive front end of the battery 5 While maintaining proper orientation battery toward the left slide the battery holder into the slot in the Controller Module until it snaps into place 198 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Specifications General Specifications Specifications General Specifications C30 C50 C70 C75 Controller Design Modular design with metal rack enclosure power supply controller CPU and user selectable I O module types Rack Mounting and Surface mounting with 4 screws in back of rack Installation Installation Category Il Pollution Degree 2 IEC 664 UL840 Installation coordination Controller I O 4 8 or 12 I O slots per Rack None requires support remote I O racks Remote I O racks None 1 w o switch using Ethernet direct cable Up 1 wo switch using to 4 with recommended Honeywell switches Ethemet direct cable Up part no 50008930 001 50089785 001 to 5 with recommended 5008
263. x nA IIC T Ta lt 60 C Doc No HON 08 ATEX 0001X Manufacture of the apparatus is controlled by an ISO 9001 approved system The apparatus satisfies the EMC requirements of IEC 61326 related to measurement control and laboratory equipment and satisfies the requirements of IEC 61010 1 for operator safety See attached list of modules for individual Temperature Classifications Conditions for the installation of the apparatus in Zone 2 hazardous areas 1 The HC900 must be mounted in an enclosure that provides a degree of protection not less than IP54 per EN60529 2 External transient protection is required at the power supply terminals and shall not exceed 140 of the rated power supply voitage 3 Modules are not to be inserted or removed unless the area is known to be non hazardous 4 All necessary precautions are to be taken to avoid the danger of ignition due to electrostatic charge build up during installation use and maintenance Manufacturing Location Honeywell Automation India Ltd 55 amp 56 Hadapsar Ind Estate Pune 411 013 india Honeywell International inc By re Z AEA 512 Virginia Drive Edward A Child Fort Washington PA 19034 USA Regulatory Compliance amp Approvals Engineering Issue Date 12 May 2007 ATEX_CERT_HC900 1of2 Revision 2 1 January 2014 HC900 Process amp Safety Controller User and Installation Manual 250 Analog Input Digital Input Digital Output Analog Output A
264. y 10 100Base T Ethernet devices in an Ethernet network Devices suppliers Switch or include other HC900 Controllers HMIs and can Router also include routers servers and other devices in wider networks 7 Ethernet CAT5 Connects I O expansion racks to controllers and or Third party suppliers or shielded cable to 10 100baseT Ethernet switches It also connects Honeywell to 900 Control Stations and PC SCADA software applications Fiber Optics Controller to remote rack distance up to 750m 2460 Cable ft with one fiber cable Distances up to 1500m 4920 ft are possible with a fiber switch used as a repeater at the midpoint 9 RS 232 For legacy system Null modem cable up to 50 Third party suppliers or 15 24m PC modem cable if used with Modems Honeywell For new systems RS 485 to USB converter connects galvanically isolated RS 485 port to USB port Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 19 January 2014 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 the following figure As indicated in this figure the Controller Rack includes 1 Rack available in 4 8 or 12 slot versions 2 Power Supply 3
265. y 2014 Diagnostics and Troubleshooting I O Module Indicators Ethernet Switch indicators Table 33 LED Indications on Ethernet Switch LED LED State Color Description 10 100 Base T port XMT upper LED Green On Off On while a message is being sent from the Main CPU otherwise Off LINK lower LED Green On Off On while the Main CPU is receiving a message Remains On as long as host is present Off when the host is removed from the link NOTE These LEDs indicate activity on the communication port they are controlled by hardware PHY chip not by software Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 183 January 2014 I O Module Indicators This page is intentionally left blank Revision 2 1 HC900 Process amp Safety Controller User and Installation Manual 184 January 2014 This page is intentionally left blank Analog Calibration Overview Analog Calibration Overview All calibration data for Analog Input Modules and Analog Output Modules is stored in non volatile memory in the I O modules Calibration data is stored for each channel of each AI or AO module Calibration data for each channel can be either e Factory calibration which is stored permanently in the module and e Field Calibration which is entered from an HMI OI on the galvanically isolated RS 485 Port and or a PC on the RS 232 Port and or the Ethernet 10 100 Base
266. y information is given in Table 11 Table 11 Assemble I O Expansion Racks Step Procedure Comments References 1 Insert power supply into If using redundant power your I O rack will contain a second left most slot in the I O smaller compartment see 1 in the following figure Insert first rack See Table 9 steps 1 power supply in the larger compartment as shown to the and 2 for wiring details immediate right of the plate dividing the two compartments 2 Redundant Power See 1 in figure above See Table 9 steps 1 and 2 for wiring optional Insert the second power supply in the left side of the smaller compartment see 1 in figure above See Table 9 steps 1 and 2 for details Insert the PSM between the 2 power supplies Fasten it in place with screws at top and bottom details 72 HC900 Process amp Safety Controller User and Installation Manual Revision 2 1 January 2014 Rack Installation Assemble I O Expansion Racks Step Procedure Commenits References Set scanner address for the I O rack using the Scanner Module DIP switches on SW3 shown at right For C50 C70 use addresses 1 4 For C75 use addresses 1 5 DIP switches 6 8 must be OFF Only one DIP switch may be ON DIP switch 1 ON Scanner 1 DIP switch 2 ON Scanner 2 DIP switch 3 ON Scanner 3 DIP switch 4 ON Scanner 4 DIP switch 5 ON Scanner 5 A small slotted screwdriver or paperclip

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