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2

Summary of Contents for ControlEdge 900 platform

Page 1: ...ControlEdge 900 Platform Hardware Planning and Installation Guide HWDOC X430 en J November 2018 ControlEdge PLC ControlEdge UOC ...

Page 2: ...al Sàrl While this information is presented in good faith and believed to be accurate Honeywell disclaims the implied warranties of merchantability and fitness for a purpose and makes no express warranties except as may be stated in its written agreement with and for its customer In no event is Honeywell liable to anyone for any direct special or consequential damages The information and specifica...

Page 3: ... O 34 Non Redundant or Redundant Star to 900 I O 36 DLR Direct Connection to 900 I O and EIP devices 38 DLR ETAP Connection to 900 I O and EIP Devices 39 Non Redundant Star to 900 I O and EIP Devices 41 Hardware configuration of UOC CPM 43 Hardware Configuration of UOC EPM 46 Hardware configuration of I O 46 Device Replacement 47 Chapter 5 ControlEdge 900 Common Reference Information 53 Installati...

Page 4: ... supply 158 Replacing an EPM 160 Replacing an I O module 161 Spare parts and model numbers 164 Chapter 8 Diagnostics and Troubleshooting 169 EPM Indicators 169 Serial Communication Module Indicators 171 I O Indicators 172 UIO Indicators 176 Chapter 9 Special Condition of Use and Approved Standards 179 Approval Rating 179 Special Condition of Use for Division 2 Zone 2 Hazardous Location Installatio...

Page 5: ...TP to field wiring the 16 Point AC DI 199 Using an RTP to field wiring the 16 Point DC DI 202 Using Dual RTPs to field wiring the 32 Point DC DI 204 Using an RTP to field wiring the 8 Point AC DO 207 Using Dual RTPs to field wiring the 32 Point DC DO 210 Using an RTP to field wiring 4 Channel Analog Output 212 Using an RTP to field wiring the 8 Channel Analog Output 214 Using an RTP to field wirin...

Page 6: ...6 Contents ...

Page 7: ...owered 4 wire transmitter for UIO AI l Add 900RTP H1xx RTP Cable l Add MOXA Unmanaged Ethernet Switch EDS 308 and EDS 316 MM SC C April 2017 Update for the PLC R140 Release including l Five new I O modules l Add new RTP and RTP Cables l New Terminal Blocks l New accessory parts D June 2017 Update for PLC Adding the following items l Add UIO wiring limitation and hardware version comparison l Add R...

Page 8: ...on Module l EtherNet IP Intended audience This guide is primarily intended for Honeywell field personnel who do hardware planning installation operation and maintenance for the Honeywell ControlEdge 900 Controller Related documents The following list identifies publications that may contain information relevant to the information in this document PLC Specific Doc Name PLC document Set ControlEdge ...

Page 9: ...ing User s Guide EPDOC XX19 Firmware Manager User s Guide EPDOC X404 ControlEdge UOC Software Change Notice EPDOC X166 Control Builder Parameter References Guides EPDOC XX18 UOC User s Guide EPDOC X512 Control Builder Components Theory EPDOC XX16 Introduction to ControlEdge Technology Item Description ControlEdge PLC ControlEdge 900 controllers running the eCLR IEC 61131 3 execution environment wi...

Page 10: ...stems ControlEdge Builder Software configuration tool for PLC Control Builder Experion Control Builder configuration tool for UOC COTS Commercial Off the Shelf CPM Control Processor Module commonly referred to as the controller The ControlEdge 900 CPM can be loaded with PLC firmware to become the PLC or with UOC CPM firmware to become the UOC CPM DCS Distributed Control System DI Digital Input DLR...

Page 11: ...y Unit PWA Printed Wiring Assembly Redundant Controller Rack ControlEdge 900 rack capable of hosting a redundant pair of CPMs RM Redundancy Module RTP Remote Termination Panel RIUP Removal and Insertion Under Power SCADA Supervisory Control and Data Acquisition UIO UIOM Universal Input Output Module UOC Unit Operations Controller Experion This is a term used to refer to the CPM when used as a cont...

Page 12: ...12 Chapter 1 About this guide ...

Page 13: ...th the UOC and PLC use it but with different firmware loaded ControlEdge PLC can be deployed standalone or with a SCADA system including Experion PKS Within Experion ControlEdge PLC can also communicate in a peer relationship to the DCS controllers such as C300 and ContorlEdge UOC ControlEdge UOC is a DCS controller always deployed within Experion PKS This document has been divided into three majo...

Page 14: ...ware components Plan the wiring of the system See the section Wiring and cabling planning Install the racks to house the system See the section Rack installation Install and wire the I O modules See the section I O Module installation and wiring Troubleshoot the system See the section Diagnostics and Troubleshooting Remove or replace system components See the section Maintenance Software configura...

Page 15: ...s provisions for communication via Ethernet with host systems such as the Honeywell Experion Human Machine Interface HMI and other HMI software that support Modbus TCP or OPC UA protocols The communication structure of the ControlEdge PLC enables remote placement of input output components allowing economies in cabling and wiring The Ethernet ports provide a layer of protection against cyber attac...

Page 16: ...ault port numbers Port number Port number type Description 41103 Fixed destination port Builder protocol 24558 Fixed destination port Discovery protocol 9050 Fixed source port Discovery protocol 123 Fixed source port SNTP protocol 123 Fixed destination port SNTP protocol 68 Fixed destination port DHCP Client for uplink 500 Fixed destination source port IPSec for uplink IKE ports 4500 Fixed source ...

Page 17: ...pported in the network Ring and Star n Up to 144 I O modules can be configured Rationale 12 racks x 12 modules per rack n Up to 4608 channels can be configured Rationale 12 racks x 12 modules per rack x 32 channels per module applicable for certain I O module types only Figure 3 1 System architecture with non redundant PLC CPM ...

Page 18: ...right side of the above illustration must be connected as follows n CPM port 3 ETH3 must be connected to CPM port 4 ETH4 or EPM port 2 ETH2 n CPM port 4 ETH4 must be connected to CPM port 3 ETH3 or EPM port 1 ETH1 n EPM port 1 ETH1 must be connected to EPM port 2 ETH2 or CPM port 4 EHT4 n EPM port 2 ETH2 must be connected to EPM port 1 ETH1 or CPM port 3 EHT3 18 ...

Page 19: ...roller racks or 1 EPM for I O racks l Up to 4 8 or 12 I O modules l 1 or 2 Power Supplies Optional second Power Supply and Power Status Module PSM on 8 and 12 slot I O rack A Power Status Module PSM is required with redundant power supplies 2 Redundant CPM Rack l 1 Redundant Controller Rack l 2 Power Supplies l 2 CPMs Redundancy is provided by two CPMs operating in a Redundant Controller Rack this...

Page 20: ... other networks including Internet Typically includes HMI operating software which includes configuration tool from Honeywell HMI software is available from Honeywell or from third party supplier 5 Configuration Station Connects from ETH1 ETH2 of the certain CPM or network switch linking CPMs Configuration software is from Honeywell 6 Un managed Ethernet 100Base T Switch Only for Star topology Ena...

Page 21: ...required 9 Communications cable Ethernet able or Fiber Optic Cable connects devices icn Ethernet Open Connectivity network to SCADA applications Third party suppliers Following sections provide information about installing racks EPM power supply and so on Table 3 3 Reference about installing racks EPM power supply and so on Components Reference section Racks For information about options and types...

Page 22: ...in this figure CPM includes Table 3 4 CPM Components Item Description 1 Status LED indicator for the CPM For more information see CPM Indicators section 2 Role LED indicator for the CPM For more information see CPM Indicators section 3 SD card slot supports 32GB Class 6 Class 10 industry standard not hot swappable maximum weight 3g 0 0066 lb 0 1058 oz 4 Mode switch For more information see CPM mod...

Page 23: ...r more information see CPM Indicators section CAUTION Do not remove or insert the Ethernet connection when the CPM is powered unless the area is known to be non hazardous PLC CPM mode switch There are four mode switch positions on CPM STOP RUN and two REMOTE positions which are identical Figure 3 4 Mode switch on CPM The switch can be rotated in a clockwise or counter clockwise fashion in order to...

Page 24: ...of mode switch in primary PLC CPM in this box determines the system operating mode If the mode switches on the primary and secondary CPMs are in different positions the system will drop sync Do not rotate the Mode switch when the CPM is powered unless the area is known to be non hazardous PLC CPM Rotary Switch PLC CPM system does not utilize the Rotary switches They are set to zero as indicated in...

Page 25: ...25 PLC CPM Indicators The following diagram displays the location of the LED indicators on the CPM The following table explains the meaning of each LED state Figure 3 6 LED Indicators on PLC CPM ...

Page 26: ... controller is upgrading firmware 2 Role OFF It is a non redundant system or On Green The controller is in primary role and the system is synchronized or On Orange The controller is in secondary role and the system is synchronized Blinking Green 1HZ The controller is in primary role and the system is synchronizing Blinking Orange 1HZ The controller is in secondary role and the system is synchroniz...

Page 27: ...r more information see Chapter 9 in the ControlEdge PLC and ControlEdge RTU Network and Security Planning Guide Replacing a non redundant or unsynchronized primary PLC CPM ATTENTION This procedure can only be performed while off process We recommend that you proceed with extreme caution whenever replacing any component in a control system Be sure the system is offline or in a safe operating mode C...

Page 28: ... the new CPM in the rack and secure it in place with the captured screws at top and bottom of the module 6 Re install communications cables 7 Set the new CPM s mode switch position to STOP to prevent an old stale configuration from running and to enable firmware update and configuration load 8 Using the user supplied switch re connect power supply in the rack associated with the new CPM the source...

Page 29: ...to disable and prevent synchronization first by issuing the redundancy disable synchronization command from ControlEdge Builder 2 Using an external user supplied switch disconnect the power supply in the rack associated with the CPM to be replaced from the source main power 3 Observe where communications cables are plugged into the CPM to be replaced and if necessary tag them to identify their fun...

Page 30: ... a synchronized primary CPM can be performed while on process or off process Replacing an unsynchronized primary CPM can only be performed off process We recommend that you proceed with extreme caution whenever replacing any component in a control system Be sure the system is offline or in a safe operating mode Component replacements may also require firmware update and or downloading appropriate ...

Page 31: ...oosen the captured screws that secure the module in the rack and remove the CPM from the rack Note that an up down rocking motion helps with removal of the module 5 Ensure that the new CPM is properly aligned with the slot guides insert the new CPM in the rack and secure it in place with the captured screws at top and bottom of the module 6 Re install communications cables 7 Set the new CPM s mode...

Page 32: ...e 3 6 Component Replacement Reference Component replacement Reference EPM For information about replacing EPM see the section EPM device replacement I O Module For information about replacing I O Module see the section I O module replacement Spare parts For information about replacing spare parts see the section Spare parts 32 ...

Page 33: ...n Power System n RTP Kit n Barrier Terminal Blocks n Accessories switches jumpers resistors Points to note specific to the use of the CPM as a UOC in Experion n SD card slot on CPM is currently not utilized and is reserved for use in future n The CPM Mode switch is not utilized by UOC firmware Honeywell recommends that it be covered using HW part number if available after conversion of the PLC CPM...

Page 34: ...wnlink subnets must be unique The Downlink subnet mask must be limited to the number of addresses expected in that subnet For example if a max of 64 addresses is expected you could use a mask of 255 255 255 192 HSR Ring to 900 I O When connecting to ControlEdge 900 I O only a redundant ring topology may be used The ring type is HSR High Availability Seamless Redundancy In this topology no third pa...

Page 35: ...OC CPM The UOC CPM must be connected to the downlink I O ring such that even numbered ports always connect to odd numbered ports Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder This includes configuration of the UOC DHCP server for assigning EPM IP addresses It also includes setting the Downlink Network Configuratio...

Page 36: ...ant or redundant star topology may be used The network redundancy type is PRP Parallel Redundancy Protocol In this topology no third party redundancy boxes are required The UOC CPM connects directly using its two downlink Ethernet ports Similarly EPM modules connect directly using their two Ethernet ports When a UOC downlink is constructed in this fashion it is not possible to connect third party ...

Page 37: ...nfiguration of the UOC DHCP server for assigning EPM IP addresses It also includes setting the Downlink Network Configuration to Non redundant in the case of a non redundant star network or Star PRP in the case of a redundant star network ControlEdge 900 I O Racks with EPMs Before it is inserted into its slot the 100X rotary switch on an EPM board must be set to indicate I O network connectivity F...

Page 38: ...rm ring nodes DLR network contain a maximum 50 IP address nodes This is Honeywell specification DLR network should have at least one node configured as ring supervisor If there are multiple nodes configured as supervisor then the node with highest supervisor precedence value becomes active supervisor others will be backup Supervisors Ring supervisor connects to CPM through a third party devices Th...

Page 39: ...des redundancy protection against a single network ring fault Installation and maintenance of a downlink EtherNet IP network must be done in accordance with the best practices of Ethernet networking in general and EtherNet IP in particular In Experion R510 UOCs will be directly connected to DLR network and EPMs must be connected to a DLR ring using redundancy boxes called ETAPs EtherNet IP Taps Th...

Page 40: ...C CPM based on the module number set on the 10X and 1x rotary switches These switches must also be set before the EPM is inserted into its slot EtherNet IP TAPs ETAPs UOC systems use redundancy boxes called ETAPs for connectivity to downlink DLR rings For further information on the use of ETAPs see EtherNet IP User s Guide_EPDOC X399 en 510A pdf ControlLogix PLC UOC can communicate with Rockwell A...

Page 41: ...ruct UDT data references from UOC For further information see EtherNet IP User s Guide_ EPDOC X399 en 510A pdf While using DLR Device Level Ring on Stratix 5700 Switch DO NOT CONNECT a DLR network to a Non DLR port on the Switch DLR should be connected only to the DLR ports on the switch Doing this will result in the entire down link network going down The recovery is to only remove the DLR connec...

Page 42: ...ring networks Component Type Comments ControlEdge UOC CPM The UOC CPM connects to a downlink EtherNet IP network through its ETH3 and ETH4port Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder This includes configuration of the UOC DHCP server for assigning EPM IP addresses It also includes Downlink Network Configurat...

Page 43: ...o deploy and configure Stratix switches see EtherNet IP User s Guide_ EPDOC X399 en 510A pdf Following section provides information about installing racks EPM power supply and so on Table 4 1 Reference for installing racks EPM power supply and so on Components Reference section Racks For information about options and types of racks see the sections Rack Options and Rack Types For information about...

Page 44: ...ts Item Description 1 Status LED indicator for the CPM 2 Role LED indicator for the CPM 3 SD card slot Reserved for future use 4 Mode switch 5 Ethernet port 1 ETH1 and Ethernet port 2 ETH2 for uplink connectivity to an Experion FTE network ETH1 should be connected to the FTE A yellow and ETH2 should be connected to FTE B green networks For more information see Experion documentation 6 Ethernet por...

Page 45: ...e CPM is programmed as PLC it is not used when programmed as UOC Figure 4 2 UOC CPM Rotary Switch The FTE Device Index uniquely identifies the controller on the FTE Network The FTE Device Index is configured in two places First the CPM rotary switches are used to set the FTE device index of the UOC Second Experion PKS Control Builder is used to configure the FTE Device Index in the UOC Platform Fu...

Page 46: ... Index according to their Control Builder configured Device Indexes will lead to failure in establishing Control Builder controller communication thereby preventing configuration load For in rack redundancy the left controller is recommended to be configured as the odd device index and the right controller as the event device index of the consecutive device index pair Redundancy communication betw...

Page 47: ...ant or unsynchronized primary UOC CPM ATTENTION This procedure can only be performed while off process We recommend that you proceed with extreme caution whenever replacing any component in a control system Be sure the system is offline or in a safe operating mode Component replacements may also require downloading appropriate configuration data to the replaced component through Control Builder We...

Page 48: ... removed module 6 Ensure that the new CPM is properly aligned with the slot guides insert the new CPM 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 an external user supplied switch re connect the power supply in the rack associated with the new CPM to the source main power 9 Use the Firmware Manager to load fi...

Page 49: ...s properly aligned with the slot guides insert the new CPM 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 an external user supplied switch re connect the power supply in the rack associated with the new CPM to the source main power 9 Use the Firmware Manager to load firmware to the new CPM to match the version ...

Page 50: ...rnal user supplied switch disconnect the power supply in the rack associated with the CPM to be replaced from the source main power If the optional switchover command was not issued this step 1 transitions the synchronized secondary redundant partner CPM into the primary role and 2 the CPM to be replaced restarts into the secondary role 3 Observe where communications cables are plugged into the CP...

Page 51: ...n for this information Following section provides information about replacing EPM I O Module and Spare parts that are common to both PLC and UOC Table 4 3 Reference for replacing EPM I O Module and Spare parts that are common to both PLC and UOC Component replacement Reference EPM For information about replacing EPM see the section EPM device replacement I O Module For information about replacing ...

Page 52: ...52 ...

Page 53: ...formation n See Rack installation on page 64 for more information n See Power Supply on page 77 for more information n See Environmental considerations on page 81 for more information n See ControlEdge 900 I O on page 87 for more information n See Terminal block styles on page 100 for more information n See Terminal Block to Field Signal Wiring on page 106 for more information Rack options I O rac...

Page 54: ...ou have two single slot racks deployed separately in different areas The distance between the two racks can be 100 meters if you use a Cat6 shielded cable Each one slot rack hosts a power supply a controller module and a redundancy module Redundancy Module RM is being introduced as part of the dual rack redundancy solution Another one slot rack with the same modules is deployed at a different loca...

Page 55: ...ntroller supports the following types of racks n Redundant Controller Rack n Non redundant Rack containing 4 8 or 12 I O slots Containing 1 CPM or EPM and 4 8 or 12 I O slots There are 3 types of I O racks n Single Controller Rack Currently this option is supported only for UOC for Experion R510 release I O slot numbers are assigned from left to right from 1 to n where n represents the maximum num...

Page 56: ...Figure 5 2 Rack Types Installation Category II Pollution Degree 2 IEC 60664 1 UL840 Installation coordination 56 ...

Page 57: ...57 One Slot Rack 1 CPM 1 EPM 1 P S 1 RM ...

Page 58: ...5 3 Redundant Controller Rack Components As indicated in Redundant Controller Rack Components section the Redundant Controller Rack includes Item Description 1 Redundant Controller Rack 2 Redundant Switchover Module Slot Filler 3 Two CPMs Redundant Primary and Secondary 4 Two Power Supplies 58 ...

Page 59: ...59 One Slot Rack ...

Page 60: ...t modules The I O rack inserted with an EPM enables I O modules to be located close to the field devices and remote from the CPM Figure 5 4 I O rack with non redundant power supply Figure 5 5 I O rack with redundant power supplies As indicated in I O rack with non redundant power supply section and I O rack with redundant power supplies section the I O rack includes 60 ...

Page 61: ...pply Rack orientation and mounting Racks must be mounted horizontally and must never be mounted with the backplane flat on a horizontal panel or tabletop This allows airflow and ventilation through the racks The Environmental specifications provided in this guide apply only when using the recommended mounting configuration Rack dimensions including overall dimensions and patterns for drilling hole...

Page 62: ...Figure 5 7 Rack dimensions with redundant power supply 62 ...

Page 63: ...with redundant power supply 5 4 20 9 6 0 12 slot 5 4 22 5 6 0 12 slot with redundant power supply 5 4 26 9 6 0 Redundant Controller Rack 5 4 10 3 6 0 1 slot 5 4 5 9 6 0 Recommended vertical spacing of racks which is required for rack ventilation and for routing wires is shown in Vertical spacing of racks all models Figure 5 8 Vertical spacing of racks all models ...

Page 64: ...tion be reviewed before beginning the installation to help to prevent errors and promote efficiency Pre requisites Before the installation of the racks and modules check that the required tools and equipment s are prepared The dimension and spacing details in the Rack orientation and mounting section should also be checked 64 ...

Page 65: ... and with drill bit extender For rack mounting Vacuum cleaner brush For use during and after drilling operations Pen ball point or felt tip for entering data on labels for I O modules For entering data on labels for I O modules Multi Meter Volt Ohms Amps For safety checks and for equipment test Soldering pencil or gun for attaching filter capacitors to I O wiring shields For attaching filter capac...

Page 66: ...near enclosures Mount racks ATTENTION Never mount racks vertically or with the backplane horizontal or upside down Figure 5 9 Incorrect rack mounting direction CAUTION Mark hole locations then either remove or cover any equipment below to ensure metal chips generated from drilling tapping do not migrate causing electrical hazard or damage 1 Mount the Rack in the enclosure by completing these steps...

Page 67: ...holes d Hang the Rack on the screws at the top e Mark the locations for the bottom screws f Drill and tap for 10 or M4 screws g Remove the rack from the enclosure 2 Aluminum grounding bars for the I O module wiring are optional They can be mounted at the top at the bottom or at the top and bottom of the rack as indicated below If grounding bars are ...

Page 68: ...or attaching the grounding wire lugs which are attached later Attach the M4 screws loosely to the grounding bars for safe keeping 3 Hang the rack in the enclosure on the top screws as shown below Install the mounting screws in the bottom of the rack then tighten all screws CAUTION Postpone this step until all components have been installed in the rack 68 ...

Page 69: ...n the card with the rack Press the module to ensure that the backplane connector is fully inserted Secure the module to the rack using the top and bottom screws Ensure that the screws are properly secured Assembling the Redundant Controller Rack To assemble the Redundant Controller Rack assembly ...

Page 70: ...a flat blade in the slots at the top and bottom of the power supply cover while pulling backward to open the cover 3 Fasten the screws located in the face of the power supply into the tabs at the top and bottom of the rack Set the Torque to 0 4 0 5 N m 3 5 4 4 Lb In See the following figure for power supply mounting details 70 ...

Page 71: ...d from the site source and then connect the AC or DC wiring to the power supply as shown below CAUTION Hazardous Voltage Ensure that wiring to the Power Supply is disconnected from the site AC source before installing wiring Do not remove Yellow Green wire from grounding stud on the power supply Do not connect PE Ground Green Wire directly to terminal on Power Supply Failure to comply with these i...

Page 72: ...pply being destroyed and vise versa Apply power For AC power supply only test voltages at the test points provided on the face of the Power Supply ATTENTION Test points are electrically connected to the backplane of the rack and voltage is measured at the backplane Therefore if the power supply is not properly seated in the backplane connectors no voltage will be measured at the test points 5 Care...

Page 73: ...elow See Assembling the Redundant Controller Rack section If the redundant power is used the I O rack will contain a second smaller compartment as shown in item 1 in the following figure Insert the first power supply in the larger compartment as shown to the immediate right of the plate dividing the two compartments 2 If the redundant power is used the I O rack will contain a second smaller compar...

Page 74: ...ing from 01 to 99 The lower switch 10x is used to set the tens digit and the upper switch 1x sets the ones digit A small slotted screwdriver works well avoid pencils Set the network topology using the 100x switch 3 is for Ring network topology and 4 is for Star network topology b Insert EPM to the right of the power supply and secure it in place with the two captured screws in the faceplate as sho...

Page 75: ...75 c Insert the Ethernet cables and mount the security cover for the EMP ...

Page 76: ...d Optional mount a wire security seal The user should get a wire security seal themselves 76 ...

Page 77: ...re security seal Themselves 5 Repeat steps 1 through 4 for each I O rack I O modules are ready to be installed See Installing I O modules section ATTENTION Install a serial communication module in any I O slot and secure it in place with the two captured screws in the faceplate Up to six serial communication modules can be added under one CPM Power Supply Both AC power supply and DC power supply c...

Page 78: ...Figure 5 10 AC Power Supply Figure 5 11 DC Power Supply As indicated in the figures the power supplies include 78 ...

Page 79: ...ut rating 58 Watt 58 Watt Each power supply includes a non field replaceable internal fuse to protect the supply under certain conditions External circuit breaker must be added on both phases of L N or L L by the user for Division 2 and Zone 2 the circuit breaker is used for controlling power ON OFF Power consumption calculation for rack power supply The following table outlines how to calculate p...

Page 80: ...0 mA 0 DIM AC DC 16 Channel 130 mA 0 mA 0 DIM 24 VDC 32 Channel 130 mA 0 mA 0 DOM 120 240 VAC 8 Channel 220 mA 0 mA 0 DOM 24 VDC 32 Channel 235 mA 0 mA 0 Relay Output 8 Channel 110 mA 100 mA AOM 4 Channel 40 mA 200 mA AOM 8 Channel 225 mA 350 mA HLAI 16 Channel 75 mA 50 mA DIM Contact type 16 Channel 130 mA 40 mA Pulse Frequency Quadrature 110 mA 250 mA Serial Comm Module 400 mA 0 mA 0 Redundancy ...

Page 81: ...ed 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 Table 5 8 Environmental specifications Item Description Operating temperature 0 to 60 C Storage and transportation temperature 40 to 85 C Ambient Relative Humidity 5 to 95 relative humidity non conden...

Page 82: ...r both typical When the status indicator for either or both of the power supplies is lit it is reporting that the status of the associated power supply is good and that the outputs are within specified limits When the status is off either the power supply is off or the voltages are out of tolerance Figure 5 12 Power Status Module Expansion Processor Module EPM is shown in the following figure Figu...

Page 83: ...on see EPM Indicators section 2 Role LED indicator for EPM functions For more information see EPM Indicators section 3 Ethernet 10 100 Base T Ports connect to the ports on other EPMs CPM or a switch that connects to the CPM for star topology 4 Ethernet LED status indicators for communications functions For more information see EPM Indicators section CAUTION Do not remove or insert the Ethernet con...

Page 84: ...c isolation is 2000 VDC There are two DB9 connectors for RS232 and a dual row terminal connector for RS485 shown in the following figure As indicated in this figure Serial Communication Module includes Table 5 10 Serial Communication Module Components Item Description 1 Module Status LED indicator for the Serial Communication Module See Serial Communication Module Indicators on page 1 for more inf...

Page 85: ... powered unless the area is known to be non hazardous Table 5 11 RS485 Pin definition Pin Type Description T Output RS485 terminal resister T Output RS485 terminal resister A Input output RS485 A line B Input output RS485 B line Typically short T and T and a 120 ohm resistor is activated between A and B to revent signal reflections potentially interfering with communications Table 5 12 RS232 Pin d...

Page 86: ...SO1 Input Isolated ground 6 DSR Input Data set ready 7 RTS Output Request to send 8 CTS Input Clear to send 9 RI Input Ring Input Application cable n RS232 port connect to Male DB9 connector As below figure shows cable require Female Female cross connection n RS232 port connect to Female DB9 connector As below figure shows cable require Female Male direct connection 86 ...

Page 87: ...le 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 rack CAUTION The ControlEdge 900 Controller I O expansion network is a private network and the switch used for the interconnection of the CPM and EPMs must not be connected to any other LAN or WAN Likewise no devices other than the ControlEdge 900 Controller co...

Page 88: ... to metal tabs on the rack Figure 5 14 I O module installation CAUTION l 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 l Always tighten both terminal block screws to proper torque settings before applying field power to the module Torque to 0 4 0 5 Nm 3 5 4 4 Lb In l Do not apply energized live field ...

Page 89: ... Channel n Digital Relay Output 8 Channel n Pulse Frequency Quadrature 4 Channel See ControlEdge PLC Specification for details Universal Input Output Module The maximum current of the Universal Input Output Module UIO field side is 4 2 A One UIO module provides a 20 terminal block with 16 channels and it can be connected with two external 24 V DC power supplies At least one power supply must be co...

Page 90: ...ximum power delivery by I Os depends on number of channels configuration Type and the environment n 20 pin EURO style terminal block n 20 position Barrier style terminal block n HART Support AI and AO n RTP support See Installing RTP on page 185 for more information Figure 5 15 UIO module terminal block 90 ...

Page 91: ...ower Supply Loading 5 V 40 mA maximum and 24 V 25 mA maximum n 20 pin EURO style terminal block n RTP support but TC signal not support RTP solution For more information see Using an RTP to field wiring the UAI section Digital Input Module 16 channels AC Voltage Type The DI AC Voltage type module is a sinking type module and provides a 20 terminal block with 16 channels Its input voltage range is ...

Page 92: ...f 16 points to rack 30 V DC maximum n ON Voltage Level 9 5 V DC minimum n OFF Voltage Level 3 5 V DC maximum n Minimum ON Current 1 0 mA n Maximum OFF Current 0 7 mA n OFF to ON Response Time 5 ms maximum n ON to OFF Response Time 5 ms maximum n Power Supply Loading 5 V 215 mA maximum and 24 V 0 mA n 20 pin EURO style terminal block n RTP support 2 RTP are needed for each module For more informati...

Page 93: ...nfigured for any one of these four functionalities with the exception that quadrature encoder input A and B pulses can be applied to only Channels 1 and 2 respectively When configured for quadrature Channels 3 and 4 will still be available for use The Pulse Output functionality uses the digital output available on the module for outputting pulses 4 Digital Outputs Open collector 5 to 24 V DC 30 mA...

Page 94: ...10 Hz to 100 KHz l The input signal will be rejected if it is below a selected pulse width l The input signal whose pulse width is above the selected pulse width must be within the frequency range specified otherwise a invalid value NAN will be shown and a fail to convert error occurs n Digital Output ON if input frequency out of range else OFF Quadrature Input Supports n Channel Used Only channel...

Page 95: ...UP and DOWN direction of counting Analog Output Module 4 Channels n 4 channel 0 21 8 mA range selectable analog output n Load resistance 750 ohms maximum n Accuracy 0 1 full scale n D A resolution 12 Bitsat reference conditions n Modules per rack 10 max up to 12 with product ambient temperature de rating See the figure below Figure 5 16 De rating of AO modules n Update rate 500 ms n Minimum curren...

Page 96: ...e or channel diagnostics exist A user specified failsafe value is supported to allow predictable operation in the event communication between the module and the controller is interrupted Outputs are updated synchronous with control execution n Outputs per module 8 isolated in 2 groups of 4 outputs 1 4 5 8 n Current 0 to 21 0 mA selectable options 0 20 mA and 4 20 mA n Load resistance 750 ohms max ...

Page 97: ...el on the module to indicate when a digital input is ON A green blinking status LED on the module indicates when the module is being scanned A red status LED when module diagnostics exist Logic in the controller allows the state to be inverted when necessary Requires Euro style 36 terminal terminal block Nominal times excluding controllers scan time and excluding transmission time from module to r...

Page 98: ...g Line voltage Nominal 1 Source resistance 0 ohm Series mode and common mode 0 V Frequency Nominal 1 n Temp Effect on Accuracy 0 01 of full scale per degree Celsius maximum n A D Converter One per module n A D resolution 15Bits n Update rate 100ms Analog to Digital Converter per module n Long term Stability 0 1 per year n Channel Configuration Data Stored in non volatile memory n Power supply load...

Page 99: ...sient Overload Voltage Protection l Maximum Load Current 2 A per channel and 8 A max per module Resistive load l OFF to ON Response Time 3 ms 0 5 line cycle max l ON to OFF Response Time 3 ms 0 5 line cycle max l Power Supply Loading 5 V 220 mA max and 24V 0 mA l Per channel Field replaceable fuse support l 20 pin EURO style terminal block l RTP support For more information see Using an RTP to fie...

Page 100: ...maximum per channel group o 12 A maximum per module o Resistive load 0 25 A per point incandescent lamp load 5 mH maximum o OFF to ON Response Time 6 ms o ON to OFF Response Time 6 ms o Power Supply Loading 5 V 235 mA max and 24V 0 mA o 20 pin EURO style terminal block o RTP support 2 RTP are needed for each module For more information see Using Dual RTPs to field wiring the 32 Point DC DO section...

Page 101: ...el 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 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 withHigh ...

Page 102: ...include Analog Input 4 channel Analog Output DC Input DC Output Contact Input pulse Output Frequency Input Quadrature Input n 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 and Relay Output n 36 pin black Euro terminal blocks which have gold contacts are for use...

Page 103: ...ite the tag names of each configured I O Module on the label 2 Place the label supplied with each module tag name side out into the hinged door for that I O Module Use the slotted tabs molded into the door to hold the label in place ...

Page 104: ...diagram shown below CAUTION In the diagram below the white cut outs represent the cut outs on the modules that accommodate tabs on the Terminal Block That is all key tabs that line up with the white cut outs on the diagram should be retained and all other tabs should be removed The orientation of the diagrams below corresponds to the picture of the terminal block shown in the previous picture 104 ...

Page 105: ...ide strain relief and secure the wire bundle with the tie 5 Install all I O modules in the racks 6 Within each I O module install the appropriate terminal block The following figure is example for different modules the wiring details are differernt See Terminal Block to Field Signal Wiring on the next page for more information ...

Page 106: ...ck to Field Signal Wiring Terminal Block 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 The terminal block is removable The optional Remote Termination Panel RTP provides an easy way to connect the ControlEdge 900 Controller to the field ...

Page 107: ...mended Wire Sizes Wire Gauge AWG Wire Application 14 24V and COM to terminal block screw connection 20 DC current and voltage field wiring 22 DC current and voltage wiring in control room Routing and securing wires Typically field wiring is routed to connections at a terminal panel near the racks and then from the terminal panel to the terminal blocks on the I O modules Whatever method of routing ...

Page 108: ...Controller and at the field device If the ground voltage potential at the field device is different from that at the ControlEdge 900 Controller a DC isolation capacitor 1nf 2000V should be used between the shield and the grounding bar on the rack Figure 5 20 Wire signal Grounding for high frequency noise rejection Wire shield grounding Aluminum grounding bars for I O wiring are available as option...

Page 109: ...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 Wire Shield Grounding section In this case it is necessary to adjust wire length so as to ensure adequate flexibility of the twisted wires and to provide clearance sufficient to remove the I O module UIO module wiring It is 16 Channel...

Page 110: ...power error is reported ATTENTION Calibrate the power output at 24 V DC to limit the PWB thermal rise See the following table for the UIO specification of different hardware versions Table 5 14 UIO specification of different hardware versions Item Hardware Version B Hardware Version D E ControlEdge Builder Display Version 01 00 Version 02 00 AO Channel Specs without DO channels used Maximum of 5 i...

Page 111: ...wire or 4 wire transmitters All 16 channels can accept inputs from most 2 wire 3 wire or 4 wire transmitters without any special wiring The following are the items that UIO AI supports n 4 20 mA 0 20 mA current inputs n Devices that accept external power to power a 0 4 20 mA current source and optionally the device n Devices that return the current to the ground terminal of the external 24 V power...

Page 112: ...rder low pass 100Hz The following items are not directly supported by UIO AIs n Voltage inputs 1 5 or mv n Thermocouples n RTDs n NAMUR devices n Devices that supply current which is not first supplied by the external 24V to the device For example a device that creates current even if referenced to Honeywell ground Standard 2 wire transmitter with UIO Figure 5 23 Standard 2 wire transmitter with U...

Page 113: ...o have the common wire and the current source wire under the same terminal blocks screw If the site wiring does not permit this method then a separate external terminal block must be used The device must reference its DCS side common to ControlEdge 900 common Figure 5 24 Self powered 3 wire transmitter with system ground Current Sink ...

Page 114: ...Self powered 4 wire transmitter This wiring method can be applied to any of the channels 1 through 16 Figure 5 25 Self powered 4 wire isolated sourcing type transmitter with UIO 114 ...

Page 115: ...wered 4 wire sinking type transmitter with UIO UIO does not support the following input types n Self powered 4 wire transmitter with ground referenced current source This is because the current return path is on the negative ...

Page 116: ...tion Rmax 19 0 Vtx 0 022 Where Vtx Voltage required at the transmitter terminal Field wiring for Analog Output The UIO can drive 4 20mA See the following list for AO specification n No load restrictions 6 channels with no other channels configured n With load restrictions o channels into 250 ohm load with no other channels configured o channels into 250 ohms remaining channels may be configured fo...

Page 117: ...UIO for DI Dry Contact Specifiction Item Description Signal type Dry contact With Open Wire Detection Short circuit detection I 6mA 5 Closed contact detection 2 8mA I 6mA 5 Open contact detection 0 9mA I 2 4mA 5 Lead Breakage Detection I 0 9mA 5 Input filter First order low pass 100Hz Without Open Wire Detection Closed contact detection I 2 8mA 5 ...

Page 118: ... low pass 100Hz See the following wiring diagram of the UIO channel configuration Figure 5 28 Digital input When the DI channel is configured with open wire detection OWD a 15K shunt resistor is required in the field near the switch contact as displayed in the above figure 118 ...

Page 119: ...ng table for the specification of DO Table 5 18 UIO Specification for DO Item Description Open wire detection Configurable Short circuit detection Enabled by default and un configurable Maximum resistive Load 500mA Minimum Load 20mA with OWD and 0mA without OWD Maximum load capacitance 1 uF Voltage Drop 1 V at 500mA Off Current 0 1mA Lead breakage test current Approx 10 mA Output Current 0 23 mA T...

Page 120: ...r up to 1 Ampere 1 5 Amperes or 2 Amperes current respectively to the field A two pin branch with a pitch of 0 2 inches 5 08 mm can be used for interconnecting two DO channels The following table lists the pins branch for interconnecting the DO channels Table 5 19 UIO pins branch for interconnecting the DO Pins No of DO channels Two pins Two pins branch 2 Three pins branch 3 Four pins branch 4 120...

Page 121: ...put Module UAI section ATTENTION To indicate sensor failure the Analog Input software will output a warning if thermocouple resistance 80 ohms Use appropriate gauge wiring to prevent inaccurate failure warnings Table 5 20 Typical Thermocouple resistance in Ohms per Double Foot 68 degrees F AWG No Diameter inches Type K Type J Type T Type E Type S Pt PT110 Type R Pt PT113 Type W5 W26 Type W W26 10 ...

Page 122: ...except for RTD current sources RTD Inputs RTD inputs share current sources two RTD inputs per source as shown below Figure 5 30 RTD Inputs For example the current source for the RTD input at channel one terminals 1 and 2 is terminal 3 IRTD 1 2 This same current source IRTD 1 2 is also used for an RTD input at channel two terminals 4 and 5 Figure on RTD Inputs and Figure on Universal Analog Input M...

Page 123: ... resistance devices other than RTDs and n Ohms inputs are configured in ControlEdge Builder as Ohms inputs rather than as RTD inputs Examples of wiring for resistance inputs are given in RTD Inputs section Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this guide CAUTION Hazardous voltages exist at terminal blocks Using switches at field devices d...

Page 124: ...Figure 5 31 Universal Analog Input Wiring Figure 5 32 Examples of RTD Input Wiring 124 ...

Page 125: ...125 Figure 5 33 Analog Input Wiring Eight TCs Figure 5 34 Analog Input Wiring Eight Resistance Inputs ...

Page 126: ...ded for each group of eight inputs Terminals 9 and 10 are for input 1 to 8 and terminal 11 and 12 are for input 9 to 16 as shown in AC Input Module Wiring Diagram section 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 Digital Input Module 1...

Page 127: ...127 power sources before servicing Failure to comply with these instructions could result in death or serious injury Figure 5 36 AC Input Module Wiring Diagram Figure 5 37 AC Input Module Jumper ...

Page 128: ...rminals 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 Figure 5 38 32 point DC Input Module Wiring 128 ...

Page 129: ...lated from the other outputs An example of AC output wiring is shown below Specifications for this module see Digital Output Module 8 Channels AC Voltage Type section Output Loading Voltage 85 to 240 V AC Maximum per output 2 0 A resistive load Maximum per module 8 0 A TIP When exceeding 1 0 A per output it is recommended but not ...

Page 130: ...lable for inter connecting all L1 Hot terminals 1 3 5 7 9 11 13 15 17 19 See AC Output Module Jumper section 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 V AC Figure 5 39 AC Output Module Wiring Diagram Figure 5 40 AC Output Module Jum...

Page 131: ...g type Over current protection is provided for each channel in 4 groups of 8 channels In case of short circuit for any output channel that whole group of 8 is switched off Power cycling is not required to reset the module A green LED on the module provides indication of an ON state for each output It can be used with Low Voltage Euro style 36 terminal terminal block Figure 5 41 32 point DC Output ...

Page 132: ...uts 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 below Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown below Figure 5 42 Schematic Example Relay Output and External Wiring 132 ...

Page 133: ...t cycling of output Honeywell recommends using a solid state AC or DC output module Required Output Fusing Outputs are not fused in the Relay module Install a fuse for each output at the field device that is appropriate for the load and the wire used Jumper Comb A ten position jumper comb available for the AC Output Module can be cut in half and used as shown below to reduce the number of wires re...

Page 134: ...witches 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 Figure 5 43 Relay Output Module Wiring Diagram Figure 5 44 Relay Output Module Jumpers 134 ...

Page 135: ...e of these four functionalities with the exception that quadrature encoder input A and B pulses can be applied to only Channels 1 and 2 respectively When configured for quadrature Channels 3 and 4 will still be available for use The Pulse Output functionality uses the digital output available on the module for outputting pulses Before installing be sure to set the module DIP switches for different...

Page 136: ...Settings using input 1 as example Single ended factory setting Differential Figure 5 46 Pulse Counting Wiring 136 ...

Page 137: ...137 Figure 5 47 Pulse Outing Wiring Figure 5 48 Frequency Wiring ...

Page 138: ...Figure 5 49 Quadrature Differential External Power Wiring Figure 5 50 Quadrature Single Ended External Power Wiring 138 ...

Page 139: ...139 Figure 5 51 Quadrature Differential ControlEdge 900 Power Wiring Figure 5 52 Quadrature Differential ControlEdge 900 Power Wiring ...

Page 140: ...lds must be grounded as described under Shield Grounding at the beginning of this section CAUTION Hazardous voltages exist at terminal blocks 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 Figure 5 53 4 channel Analog Output Wiring Diagram 140 ...

Page 141: ...o comply with these instructions could result in death or serious injury Examples of high level Analog Output Module wiring are shown below Before installing be sure to determine power requirements 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 grou...

Page 142: ...t module set its DIP switch as follows Switch is located at edge of module marked SW1 n For internal rack power set DIP switch to ON n 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 Figure 5 54 Dip Swith Position of ...

Page 143: ...e the following diagram This requires Low Voltage Euro style 36 terminal terminal block Requires Low Voltage Euro style 36 terminal terminal block Set its SW1 and SW2 DIP switches to ON This connnects an internal 250 ohm resistor A small slotted scredriver or paperclip works well avoid using percils Figure 5 56 HLAI Switch ...

Page 144: ...Figure 5 57 16 point High Level Analog Input Wiring 144 ...

Page 145: ...l 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 CAUTION Hazardous voltages exist at terminal blocks Using switches at field devices disconnect the field wiring from power sources before servicing Failure to comply with these...

Page 146: ...f AC Input and DC input Module wiring is shown below And it 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 Figure 5 59 Isolation of Ac DC Isolated Input Module 146 ...

Page 147: ...147 Figure 5 60 AC DC Isolated Input Module Wiring ...

Page 148: ...148 ...

Page 149: ...rical enclosure When redundant power supplies are used in Redundant Controller Racks or I O rack 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 CAUTION l Hazardous voltages exist in the equipment enclosur...

Page 150: ...wiring with single rack Figure 6 1 Protective electrical enclosure wiring Single Rack For 2 phase power source external circuit breaker must be included in both L1 and L2 See the following figure for the protective electrical enclosure wiring with multiple racks 150 ...

Page 151: ...lectrical enclosure wiring Multiple Racks For 2 phase power source external circuit breaker must be included in both L1 and L2 for each rack See the following figure for redundant power supplies each with external circuit breaker ...

Page 152: ...er supply 24 V DC 7 0 A CE Conformity Electrical noise produces undesirable effects in measurements and control circuits Digital equipment is especially sensitive to the effects of electrical noise The following methods can help to reduce these effects n Use separate external wiring group connecting wires into bundles see Guidelines for grouping wires section and route the individual bundles throu...

Page 153: ... VAC AC Line power wiring Signal 15 Vdc Analog signal wire such as Low voltage 50 Vdc VAC Low voltage alarm relay output wiring Wiring and cabling distance guidelines Two network topologies are supported in I O network Ring and Star n For Ethernet connections cable length must be less than 100 m The use of Ethernet cables in excess of 100 meters and or devices other than recommended switches will ...

Page 154: ...is a private network and other devices including health monitor application must not connect to it or it may result in critical performance and security issues Fiber Optics Recommendations Honeywell recommends to use the fiber optic cable for distances longer than 100m Equipment tested with the fiber optic cable is listed in the following table Table 6 3 Fiber optics equipment recommendations Item...

Page 155: ...hould 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 pot...

Page 156: ...ocedures in this section l Disconnect all sources of power associated with these components before removal or insertion l Failure to comply with these instructions could result in death or serious injury l EXPLOSION HAZARD Class I Division 2 Zone 2 Installations l SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I DIVISION 2 ZONE 2 l EXPLOSION HAZARD Class I Division 2 Zone 2 Installati...

Page 157: ...ean vent holes remove obstructions Removal and Insertion Under Power RIUP CAUTION All of the I O module types in the ControlEdge 900 Controller System include the Removal and Insertion Under Power RIUP feature That is while the rack is powered any of the controllers or I O modules can be removed or inserted Read and understand all of the following information regarding Removal and Insertion Under ...

Page 158: ...ic function Any or all of the signals may be vital for safely controlling a process Either Replacing the power supply The power supply for the ControlEdge 900 Controller is used in all Racks 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 CPM or EP...

Page 159: ...ling a running process use one of the following methods l Ensure that powering down the rack will not have adverse consequences on any running process l Bring the process to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply from source main power Use a meter to ensure that power is off 3 Depending on the type of wire lugs used loosen or remove the thr...

Page 160: ...process to a safe and orderly shutdown 2 Observe where communications cables are plugged into the EPM to be replaced and if necessary tag them to identify their functions Unplug the communication cable s from the Ethernet port s 3 At the top and bottom of the EPM loosen the captured screws that secure the module in the rack and remove the module from the rack Note that an up down rocking motion he...

Page 161: ...s 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 Removal and Insertion Under Power and to take actions to prevent all adverse consequences before removing or inserting an I O module under power The following table pro...

Page 162: ...ewdriver To replace an I O module CAUTION Explosion hazard Removal and Insertion Under Power is not supported in Division 2 Zone 2 1 Disconnect all signals from power sources Use a meter to ensure that all voltages are disconnected 2 If a power down replacement procedure is opted also disconnect power from the rack using the user supplied switch in the source main power 3 Loosen the captive screws...

Page 163: ...ge of the rack as a fulcrum 6 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 7 Replace the terminal block on the module 8 If the rack was powered down for the procedure restore power to the rack 9 Re connect signals to field devices ...

Page 164: ...sal Analog Input RTD TC V 8 channel 900A01 0202 Digital Input 120 240 VAC 16 Channel 900G03 0202 Digital Input 120 240 VAC 125VDC 16 Channel Isolated 900G04 0101 Digital Input 24 VDC 32 Channel 900G32 0101 Digital Output 120 240 VAC 8 Channel 900H03 0202 Digital Output 24 VDC 32 Channel 900H32 0102 Digital Output Relay 8 Channel 900H01 0202 Pulse Frequency Quadrature 4 Channel 900K01 0201 Analog O...

Page 165: ...round Bar HC900 HC900 900TSS 0001 I O Components DI DO AO AI Remote Termination Panel RTP 900RTS 0001 Analog Input Remote Terminal Panel 900RTA L001 Relay Output Remote Terminal Panel 900RTR H001 Filler Block Cover Spare I O Slot 900TNF 0200 Terminal Block Housing Black 20 Positions Euro Style 900TEK 0200 Terminal Block Housing Red 20 Positions Euro Style 900TER 0200 Terminal Block Housing Black 3...

Page 166: ... 0M 3 28ft 900RTC R010 RTP Cable Relay Board 5 0M 16 4ft 900RTC R050 High Voltage RTP Cable AO 8 Ch 1 0m 3 28ft 900RTC BA10 High Voltage RTP Cable AO 8 Ch 2 5m 8 2ft 900RTC BA25 High Voltage RTP Cable AO 8 Ch 5 0m 16 4ft 900RTC BA50 Shield Terminal Strip package of 2 900TSS 0001 MI MP 250 OHM RESISTOR KIT 8 51205995 501 Power Supplies 120 240 VAC 60W 900P01 0301 24 VDC 60 W 900P24 0301 Redundant P...

Page 167: ...ertor 50135395 001 Ethernet to Single Mode Fiber Converter 50135395 002 MOXA MGate MB3180 Modbus Gateway NA TIP Kits Accessories are not in the scope of the certification we mentioned in the Special Condition of Use and Approved Standards section ...

Page 168: ...168 ...

Page 169: ...nal actions are required The following diagnostic indicators are provided for the ControlEdge 900 Controller Hardware Light Emitting Diodes LEDs that assist with troubleshooting activities solely at the controller LEDs are also useful for verifying indications viewed as screen items LED indicators are provided for the following hardware components n EPM n IOM EPM Indicators The following diagram d...

Page 170: ...F No power is applied to EPM On Green EPM is working normally On Orange EPM is in power up process Blink Red 1 HZ EPM is running with error Blink Red 0 5 HZ EPM is not configured Blink Red 5 HZ Communication error Blink 1 HZ Green Orange EPM is upgrading firmware 170 Chapter 8 Diagnostics and Troubleshooting ...

Page 171: ...ort Link Active Lower LED Green On Off Blinking OFF for no connection ON for connection Blinking for toggle Serial Communication Module Indicators The following diagram displays the location of the LED indicators on the serial communication module The table below explains the meaning of each LED state Table 8 2 Serial Communication Module Indicator Definition Chapter 8 Diagnostics and Troubleshoot...

Page 172: ...Blinking Green and Orange at 0 5 Hz Firmware Upgrade 2 RS232 LEDs Blinking Orange TX Blingking Green RX Blinking Yellow TX and RX OFF No communication 4 RS485 LEDs Blinking Orange TX Blingking Green RX OFF No communication I O Indicators The following diagram displays the location of the LED indicators on the I O modules The table below explains the meaning of each LED state Figure 8 2 I O Indicat...

Page 173: ... ON For Inputs indicates On status of the field input even if Forced to the opposite state Green OFF For Inputs indicates Off status of the field input even if Forced to the opposite state To indicate the type of diagnostic failure the module s status LED is flashed red with a number of quick strobes followed by a long off time The table below outlines the potential module diagnostics The followin...

Page 174: ...st If it s flashing green the module probably is not required in the configuration If it s not on or steady cycle power to the scanner 3 Make sure the module is the correct one for the configuration 4 Remove the module and check for a bent pin then reinsert the module 5 Replace the module 6 Remove other modules and replace one at a time until the problem reoccurs Most likely the last module insert...

Page 175: ...to the terminals Over range The signal at the terminals is more than 10 over the range of the sensor Check the signal level being applied to the terminals Failing to convert When attempting to take a reading the ADC fails This could result if the incoming signal is either too large or small It also could result if the ADC circuit is failing If the problem is the ADC circuit most likely other chann...

Page 176: ... bad channel diagnostic and corresponding action UIO Indicators The following diagram displays the location of the LED indicators on the UIO The table below explains the meaning of each LED state Figure 8 3 LED Indicators on UIO Table 8 5 LED Indication on UIO 176 Chapter 8 Diagnostics and Troubleshooting ...

Page 177: ...nk Red 0 5 Hz Firmware upgrade Blink Red 1 strobe Communication error Blink Red 3 strobe Running with error for module diagnostic and channel diagnostics detected by the module itself 2 Channel LEDs Digital Input OFF Channel disabled or State 0 On Green State 1 Digital Output OFF Channel disabled or State 0 On Green State 1 Analog Input OFF NA Analog Output OFF NA Chapter 8 Diagnostics and Trouble...

Page 178: ...178 Chapter 8 Diagnostics and Troubleshooting ...

Page 179: ...R12 900R08R 900R12R Table 9 1 Approval Rating Special Condition of Use for Division 2 Zone 2 Hazardous Location Installation For the United States n The installer shall provide transient over voltage protection external to the apparatus such that the voltage at the supply terminal of the apparatus does not exceed 140 of the voltage rating of the equipment n The equipment shall be mounted in an enc...

Page 180: ...529 and in a tool secured enclosure which meets the requirements of CAN CSA 60079 0 and CAN CSA 60079 15 n Equipment shall be installed in compliance with the enclosure mounting spacing and segregation requirements of the ultimate application For ATEX n The installer shall provide transient over voltage protection external to the apparatus such that the voltage at the supply terminal of the appara...

Page 181: ... Measurement Control And Laboratory Use Part 1 General Requirements UL Std No 61010 1 3rd Edition 2012 Nonincendive electrical equipment for use in Class I and II Division 2 and Class III Divisions 1 and 2 hazardous classified locations UL 12 12 01 Ninth Edition 2017 Canadian Standards Title Number Issue Date Safety requirements for electrical equipment for measurement control and laboratory use P...

Page 182: ...equirements for electrical equipment for measurement control and laboratory use Part 1 General requirements EN 61010 1 2010 EMC directive Title Number Issue Date Programmable controllers Part 2 Equipment requirements and tests IEC 61131 2 2007 Electrical equipment for measurement control and laboratory use EMC requirements Part 1 General requirements EN 61326 1 2013 Industrial scientific and medic...

Page 183: ...lectromagnetic field immunity test IEC 61000 4 3 2006 A1 2007 A2 2010 Electromagnetic compatibility EMC Part 4 4 Testing and measurement techniques Electrical fast transient burst immunity test IEC 61000 4 4 2004 A1 2012 Electromagnetic compatibility EMC Part 4 5 Testing and measurement techniques Surge immunity test IEC 61000 4 5 2014 Electromagnetic compatibility EMC Part 4 6 Testing and measure...

Page 184: ...le Number Issue Date Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements ANSI UL 61010 1 Third Edition 184 Chapter 9 Special Condition of Use and Approved Standards ...

Page 185: ...the 16 Point AI 196 Using an RTP to field wiring the 16 Point AC DI 199 Using an RTP to field wiring the 16 Point DC DI 202 Using Dual RTPs to field wiring the 32 Point DC DI 204 Using an RTP to field wiring the 8 Point AC DO 207 Using Dual RTPs to field wiring the 32 Point DC DO 210 Using an RTP to field wiring 4 Channel Analog Output 212 Using an RTP to field wiring the 8 Channel Analog Output 2...

Page 186: ...ules terminal blocks and their RTP components are listed below Table A 1 Module and RTP Matching Table I O Module Terminal Block Euro Terminal Block Barrier RTP RTP Cable RTP required per module only for RTP not for Cable UIO 900U01 0100 900TEK 0200 900TBK 0200 900RTS 0001 900RTC H2xx 1 UAI 900A01 0202 900TEK 0200 900TBK 0200 900RTA L001 900RTC L2xx 1 DI24 900G32 0101 900TCK 0200 N A 900RTS 0001 9...

Page 187: ...P not for Cable AO 4 CH 900B01 0301 900TEK 0200 900TBK 0200 900RTS 0001 900RTC L2xx 1 DI Contact 16 CH 900G01 0202 900TEK 0200 900TBK 0200 900RTS 0001 900RTC L2xx 1 RTP Dimension See the following figures for the RTP dimension when you are installing Figure A 1 Front View Dimension of RTP Figure A 2 Side View Dimension of RTP 187 ...

Page 188: ...an RTP to field wiring the 16 Point DC DI 202 Using Dual RTPs to field wiring the 32 Point DC DI 204 Using an RTP to field wiring the 8 Point AC DO 207 Using Dual RTPs to field wiring the 32 Point DC DO 210 Using an RTP to field wiring 4 Channel Analog Output 212 Using an RTP to field wiring the 8 Channel Analog Output 214 Using an RTP to field wiring Relay Output 217 RTP Cable wire positions colo...

Page 189: ...ithin their own enclosure l The RTP combines the two groups of 8 RTP side inputs into one group of 16 UIO side l For digital output up to 4 A is limited at module level and for each channel 500 mA To wire the UIO using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram a Remove the relevant key tabs from the terminal bl...

Page 190: ...g bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure the RTP to the rail See Securing the RTP to the DIN rail on page 228 for more information for details b Connect the cable to the RTP 3 Set jumper positions as shown below for use with an analog output module ATTENT...

Page 191: ...nal Wiring on page 106 for more information Using an RTP to field wiring the UAI ATTENTION l RTP is not for use with thermocouples l RTP and cables are intended for permanent installation within their own enclosure To wire the UAI using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram 191 ...

Page 192: ...ge Cable Assembly 2 5 meters long l 900RTC L1250 Remote Termination Low Voltage Cable Assembly 5 0 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure t...

Page 193: ...lt Ohms Transmitter Loop Powered Milliamp Externally Powered RTD Transimitter SW9 is the red power switch for 24 volt supply Module RIUP is not affected by using the RTP See RTP Cable wire positions colors and internal schematic on page 1 for more information 4 Connect field wiring as shown below Refer to the following figures for field wiring Any input type can be wired to any of the 8 inputs Aft...

Page 194: ...Appendix A Installing RTP Figure A 4 Two wire transmitter connections with common 24 VDC supply Figure A 5 Milliamp input connections with 250 ohm shunt resistance 194 ...

Page 195: ... Installing RTP Figure A 6 Volt millivolt input connections Figure A 7 Three wire RTD input connections Figure A 8 Two wire RTD or ohm input connections Figure A 9 Slidewire feedback connections for actuators 195 ...

Page 196: ...0Ω OHMS 0 1 of Range 0 07 Range 0 140Ω 0 17 of Range 0 10mV LINEAR 0 1 of Range 0 04 Range 0 004mV 0 14 of Range Using Dual RTPs to field wiring the 16 Point AI ATTENTION l RTP and cables are intended for permanent installation within their own enclosure l The RTP labeled DI DO AO RTP ASSY with jumpers J2 J9 is the correct one for 16 point AI To wire the 16 Point AC AI using two RTPs 1 Mount the R...

Page 197: ...tion High Voltage Cable Assembly 2 5 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure the RTP to the rail See Securing the RTP to the DIN rail on pag...

Page 198: ...ithout causing an arc 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 RTP Cable wire positions colors and internal schematic on page 219 for more information 4 Connect field wiring Refer to the appropriate figure for your type of analog input Figure A 10 Voltage input connection...

Page 199: ...ct 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 Using an RTP to field wiring the 16 Point AC DI ATTENTION l RTP and cables are intended for permanent installation within their own enclosure l The RTP combines the two groups of 8 inputs into one group of 16 To wire the 16 Point AC DI using an...

Page 200: ...ge Cable Assembly 1 0 meters long l 900RTC H225 Remote Termination High Voltage Cable Assembly 2 5 meters long l 900RTC H250 Remote Termination High Voltage Cable Assembly 5 0 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as describ...

Page 201: ... removal of the module from the rack without causing an arc ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See RTP Cable wire positions colors and internal schematic on page 1 for more information 4 Connect field wiring ATTENTION Attenion S L1 in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 201 ...

Page 202: ...16 To wire the 16 Point AC DI using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram a Remove the relevant key tabs from the terminal block to allow connection with the module b Connect the appropriate cable to the module at ControlEdge 900 Controller Possible options are l 900RTC L210 Remote Termination High Voltage ...

Page 203: ... in the shield grounding section 2 Mount the RTP to the DIN rail a Secure the RTP to the rail See Securing the RTP to the DIN rail on page 228 for more information for details b Connect the cable to the RTP 3 Set verify jumper positions as shown 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 ATTEN...

Page 204: ...n switch SW1 is open 0 Using Dual RTPs to field wiring the 32 Point DC DI ATTENTION RTP and cables are intended for permanent installation within their own enclosure To wire the 32 Point DC DI using dual RTPs 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram 204 ...

Page 205: ...el onto the module connector cover d Connect both shield drain wires to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure the RTP to the rail See Securing the RTP to the DIN rail on page 228 for more information for details b Connect the cable to the R...

Page 206: ... SW1 to allow removal of the module from the rack without causing an arc 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 RTP Cable wire positions colors and internal schematic on page 1 for more information 4 Connect field wiring 206 ...

Page 207: ...ON l RTP and cables are intended for permanent installation within their own enclosure l 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 l The RTP combines the 8 isolated outputs into one group of 8 To wire the 8 Point AC DO using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the exa...

Page 208: ...ge Cable Assembly 2 5 meters long l 900RTC H250 Remote Termination High Voltage Cable Assembly 5 0 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure t...

Page 209: ...rack without causing an arc ATTENTION SW1 only disconnects L1 not both sides of the AC powerline See RTP Cable wire positions colors and internal schematic on page 1 for more information 4 Connect field wiring CAUTION S L1 terminals in the wiring figure below are live when switch SW1 is on 1 AC Outputs are individually fused in the module but adding a fuse here protects the wiring 209 ...

Page 210: ...ount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram a Remove the relevant key tabs from the terminal block to allow connection with the module b Connect the appropriate cable to the module at ControlEdge 900 Controller Possible options are l 900RTC 3410 Remote Terminal Cable assembly 1 0 meters long l 900RTC 3425 Remote Terminal C...

Page 211: ... A and RTP B In step 4 RTP A will be wired to outputs 1 16 RTP B to outputs 17 32 You can write on the RTPs labels to distinguish them 3 Set verify jumper positions on each RTP as shown 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 ATTENTION SW1 opens current loop on the ground side so that RIUP ...

Page 212: ...me for terminals 10 and 12 DC Using an RTP to field wiring 4 Channel Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure To wire the 4 Channel Analog Output using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example installation diagram 212 ...

Page 213: ...ation High Voltage Cable Assembly 2 5 meters long l 900RTC H250 Remote Termination High Voltage Cable Assembly 5 0 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN...

Page 214: ...e positions colors and internal schematic on page 1 for more information 4 Connect field wiring Using an RTP to field wiring the 8 Channel Analog Output ATTENTION RTP and cables are intended for permanent installation within their own enclosure To wire the 8 Channel Analog Output using an RTP 1 Mount the RTP cable assembly to ControlEdge 900 Controller See the following figure for the example inst...

Page 215: ...High Voltage Cable Assembly 1 0 meters long l 900RTC H225 Remote Termination High Voltage Cable Assembly 2 5 meters long l 900RTC H250 Remote Termination High Voltage Cable Assembly 5 0 meters long c Install the module label onto the module connector cover d Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack All field wiring shields must be grounded ...

Page 216: ...mper positions as shown for use with an analog output module 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 ATTENTION SW1 opens the side of the External 24V Power so that RIUP of module is possible See RTP Cable wire positions colors and internal schematic on page 1 for more information 4 Connect ...

Page 217: ...y to ControlEdge 900 Controller See the following figure for the example installation diagram a Remove the relevant key tabs from the terminal block to allow connection with the module b Connect the appropriate cable to the module at ControlEdge 900 Controller Possible options are l 900RTC H210 Remote Termination High Voltage Cable Assembly 1 0 meters long l 900RTC H225 Remote Termination High Vol...

Page 218: ...field wiring shields must be grounded as described in the shield grounding section 2 Mount the RTP to the DIN rail a Secure the RTP to the rail See Securing the RTP to the DIN rail on page 228 for more information for details b Connect the cable to the RTP 3 Set switch positions SW1 through SW8 as shown Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow remov...

Page 219: ...s required RTP Cable wire positions colors and internal schematic RTP Cable wire positions and colors Applies to UIO 4 AO 16 DI and 8 DO See the table below for RTP Cable wire positions and colors Applies to UIO 16 DI and 8 DO Twisted Pair Number 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 Table A 3 TP Cable wire positions and c...

Page 220: ... 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 UIO 4 AO 16 DI and 8 DO See the figure below for RTP Internal schematic Applies to UIO 16 DI and 8 DO Figure A 12 RTP Internal schematic of Applies to UIO 4 AO 16 DI and 8 DO 220 ...

Page 221: ...Appendix A Installing RTP RTP Internal schematic Applies to UAI Figure A 13 Analog Input RTP Internal schematic 221 ...

Page 222: ...Appendix A Installing RTP 222 ...

Page 223: ...ted Pair Number of Cable A 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 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 Table A 4 RTP A Cable wire positions and colors Applies to 16 AI 32 DI and 32 DO 223 ...

Page 224: ...1 Plug Connector Color 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 Table A 5 RTP B Cable wire positions and colors Applies to 16 AI 32 DI and 32 DO 224 ...

Page 225: ... Plug Connector Color 8 33 4 Red 34 5 White 9 21 8 Red 26 18 Green 10 27 13 Red 32 3 Blue RTP Cable wire positions and colors applies Relay Output Twisted Pair Number 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 225 ...

Page 226: ...isted Pair Number Module TB Position RTP J1 Plug Connector Color 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 8 19 4 Red 20 5 White 9 3 8 Red 8 18 Green 10 13 13 Red 18 3 Blue 226 ...

Page 227: ...Appendix A Installing RTP Relay Output RTP Internal schematic 227 ...

Page 228: ...m twisting 2 Insert one side of the DIN rail at position A as shown below 3 Insert the other side of DIN rail at position B and push gently to snap the DIN rail 4 To remove the DIN rail use a slot screwdriver to lift the clip at position C gently the plastic is fragile to disengage the DIN rail at position B Lift the plastic clip up and over the rail then disengage at position A 228 ...

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Page 230: ...neywell using one of the following methods n Send an email to security honeywell com or n Contact your local Honeywell Process Solutions Customer Contact Center CCC or Honeywell Technical Assistance Center TAC Support For support contact your local Honeywell Process Solutions Customer Contact Center CCC To find your local CCC visit the website https www honeywellprocess com en US contact us custom...

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