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HC900 Process & Safety Controller User and Installation Manual

Revision 6

21 April 2017

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:



ASYS – System Monitor



FSYS – Fast System Monitor



RK – Rack Monitor



FMON – Fault Monitor

These function blocks are described in the HC900 Function Block Reference Guide #51-52-25-109.

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Summary of Contents for HC900

Page 1: ...HC900 Process Safety Controller User and Installation Manual Doc No 51 52 25 154 Revision 6 Date 21 April 2017 ...

Page 2: ...s 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 literatu...

Page 3: ...3 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 ...

Page 4: ... Pacific North and South America contact details refer to the back page of this manual or the appropriate Honeywell Solution Support web site Honeywell Organization WWW Address URL Corporate http www honeywell com Honeywell Process Solutions www honeywellprocess com HPS Technical tips https www honeywellprocess com en US explore products control monitoring and safety systems scalable control solut...

Page 5: ...Revision 6 HC900 Process Safety Controller User and Installation Manual v 21 April 2017 ...

Page 6: ......

Page 7: ...LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices CAUTION HOT SURFACE This symbol warns the user of potential hot surfaces which should be handled with appropriate caution Protective ...

Page 8: ...viii HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 This page is intentionally left blank ...

Page 9: ...ude 35 Ethernet Open Connectivity Network 35 Serial Ports 42 Network and Security Planning 44 Overview 44 Pre Installation Planning 45 Overview 45 AC Power Supply Selection for racks with I O 46 DC Power Supply 48 Rack Orientation and Mounting 48 Remote Termination Panels 51 Environment 51 Heat Rise De rating 52 Cable Wiring Distance Planning 54 Electrical Considerations 56 Hardware and wiring req...

Page 10: ...to the Controller 131 Connecting the HC900 Controller to a PC with the Designer Software 132 Connecting the HC900 Controller to Modbus device s 152 Operating Characteristics 155 Introduction 155 Overview 155 Power Down Power Up 155 Controller Modes 158 File Download Upload Functions 163 Redundant Operating Characteristics 165 Overview 165 Start Up 165 Modes of operation Figure 87 165 Steady State ...

Page 11: ...ifications Refer to Specification manual 206 System Sizing and Availability Summary 214 Extended distance configuration with Fiber Optics 215 Appendix Installation of Remote Termination Panels RTPs 217 Overview 217 Analog Input 218 Relay Output 225 Analog Input Digital Input Digital Output Analog Output 229 Declaration of Conformity 255 ATEX Certification 256 INDEX 257 ...

Page 12: ...e 19 Null Modem Cable Connections 134 Table 20 Dual Network connections in Figure 80 146 Table 21 Dual network connections 147 Table 22 Controller Operating Modes 160 Table 23 Mode Switch Functions 161 Table 24 Controller Behavior in Mode Transition 162 Table 25 Configuration file downloading 164 Table 26 LED Indications on Controller CPUs 175 Table 27 Controller Status LED Diagnostics 176 Table 2...

Page 13: ... reserve power supply 49 Figure 28 Vertical Spacing of Racks all models 50 Figure 29 AC Input Module de Rating 53 Figure 30 Power Supply de Rating 53 Figure 31 Cabinet Wiring Single Chassis 56 Figure 32 Cabinet Wiring Multiple Chassis 57 Figure 33 Redundant power supplies each with external fuse and switch 58 Figure 34 Master Control Relay Wiring Example 61 Figure 35 IO V function block connection...

Page 14: ...redundant systems with PC supervision 148 Figure 82 RS 485 Modbus slave wiring 152 Figure 83 RS 485 Modbus slave wiring with isolation 153 Figure 84 XYR 5000 RS 485 Modbus connections with isolator 154 Figure 85 Warm Start Operation 156 Figure 86 Cold Start Operation 157 Figure 87 Mode Switches Controller left RSM right 161 Figure 88 Pathways for Upload Download Transactions 163 Figure 89 Modes of...

Page 15: ...dule Communications Installation 127 Guidelines for installing RS 232 RS 485 to USB cable RS 485 and Ethernet cabling and associated components Operating Characteristics 155 Characteristics of the HC900 Process Controller as they relate to configuration of a control strategy and to operation of an installed and running system Redundant Operating Characteristics 165 Characteristics of redundant ope...

Page 16: ... 120 240VAC 28W 900P02 0001 No 24VDC 900P24 0001 NA I O Modules Analog Input 8 channel 900A01 0102 No High Level Analog Input 16 channel 900A16 0001 No Analog Output 0 to 20mA 4 channel 900B01 0201 No Analog Output 0 to 20mA 8 channel 900B08 0001 No Analog Output 0 to 20mA 16 channel 900B16 0001 No Digital Input Contact type 16 channel 900G01 0102 No Digital Input 24VDC 16 channel 900G02 0102 No D...

Page 17: ...ensity RTP Cable 2 5M 8 2ft 900RTC 3225 NA High Density RTP Cable 5M 16 4ft 900RTC 3250 NA Filler Block Terminal Cover 900TNF 0001 NA Shield Terminal Strip package of 2 900TSS 0001 NA Terminal board jumpers 10 two pos jumpers 900J02 0001 No Terminal board jumpers 10 ten pos jumpers 900J10 0001 No Manuals Full Document set on CD 900ME1 00XX XX NA Software HC Designer Config Software CD 900W01 00XX ...

Page 18: ...900 Control Station User Manual paper 51 52 25 148 15 Screen Protective Films 10 50038816 502 24VDC Power Supply for 15 50047098 001 GSM GPRS Cellular Modem Kit 50047099 501 New Non SIL System Description Model number SIL Compatible Controllers Controller C30 CPU 900C30 0360 00 No Controller C50 CPU 900C50 0360 00 No Controller C70 CPU 900C70 0360 00 No Controller C75 CPU 900C75 0360 00 No I O Sca...

Page 19: ...on CD SIL 900ME1S 0060 00 Yes Full document set SIL hard copy English 900ME2S 0060 00 Yes I O Modules Analog Input 8 channel 900A01 0202 Yes 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 0202 Yes Analog Output 0 to 20mA 16 channel 900B16 0202 Yes Digital Input Contact type 16 channel 900G01 0202 Yes Digita...

Page 20: ...001 No 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 Reference only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library support Public Downloads HC900 SafetyControllerModule...

Page 21: ...ller module and S designates Scanner module New System SIL and Non SIL Model Numbers 900C30 0360 00 900C50 0360 00 900C70 0360 00 900C75 0360 00 900S75 0360 00 900S50 0360 00 900C30S 0360 00 900C50S 0360 00 900C70S 0360 00 900C75S 0360 00 900S50S 0360 00 900S75S 0360 00 Reference only For the latest Hardware and firmware revision numbers can be found at https www honeywellprocess com library suppo...

Page 22: ...s 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 000...

Page 23: ...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 Although the HC900 E1 E2 ports provide protection against Cyber security DOS type attacks additional protection is required for safety applications using a firewall device configured to prevent uncontrolled m...

Page 24: ...my Configurations such as those shown in Figure 1 and in Figure 2 as well as many variations can be assembled from modular components Many of the components are available from Honeywell and some are available from third party suppliers These modular components are available in any quantity and mix that make the most sense for a given application As indicated in Figure 3 the HC900 Controller includ...

Page 25: ...Introduction Revision 6 HC900 Process Safety Controller User and Installation Manual 11 21 April 2017 Redundancy Figure 3 Single process with redundancies ...

Page 26: ... required with redundant power supplies High and low capacity power supplies are available Dual Networks for Host communications Dual 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 su...

Page 27: ...en redundant CPUs Redundant Power Supply provides redundant power to any CPU rack or Scanner2 I O rack Power Status Module PSM required when using a second power supply in Scanner2 I O rack Communications All CPUs except where noted 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 conf...

Page 28: ...on 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 C70S or C70R C75 C75S redundant CPUs Private Ethernet 100 base T connection to I O expansion ra...

Page 29: ...Introduction Revision 6 HC900 Process Safety Controller User and Installation Manual 15 21 April 2017 This page is intentionally left blank ...

Page 30: ......

Page 31: ... modules are required in all configurations Others are optional they are selected as appropriate to provide optional functions and or to size the system either in initial planning or in modifying and or expanding the system to meet changing requirements An HC900 Controller configuration with multiple controllers is illustrated in Figure 4 This illustration includes key numbers that identify compon...

Page 32: ...k 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 ...

Page 33: ...works including Internet Typically includes HMI operating software May also include Designer Software configuration tool and utility software PC is from third party supplier HMI software is available from Honeywell Experion HS or SpecView32 or from third party supplier 6 Qualified un managed Ethernet 100Base T Switch Enables connection of the private Ethernet 100Base T port on a Controller Module ...

Page 34: ...e Cable For legacy system Null modem cable up to 50 15 24m PC modem cable if used with Modems For new system RS 485 to USB converter connects galvanically isolated RS 485 port to USB port Third party suppliers or Honeywell Redundant components Figure 5 Redundant Configuration with multiple I O racks CAUTION ...

Page 35: ...e 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 ...

Page 36: ...tworks including Internet Typically includes HMI operating software May also include Designer Software configuration tool and utility software PC is from third party supplier HMI software is available from Honeywell Experion HS or SpecView32 or from third party supplier 6 Qualifies un managed Ethernet 100Base T Switch Required if using 2 or more I O Expansion racks Provides connection of the I O E...

Page 37: ... redundant configuration through a gateway to a Host server on another subnet While both the E1 E2 Ethernet can be configured with a default Gateway address only the E1 port will actually communicate across a gateway to another subnet Hardware Components This section contains general descriptions of each of the major components of the HC900 system For environmental specifications refer to the sect...

Page 38: ... 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 900P01 xxxx or 900P02 xxxx Power Supplies Figure 7 Redundant Controller Rack Components ...

Page 39: ...ller rack Scanner type must match controller type i e example S50S may only be used with C50S or C70S S50S cannot be used with a C50 or C70 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 Term...

Page 40: ...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 Figure 9 Rack Options ...

Page 41: ...and 24VDC to satisfy the power requirements of a single controller with I 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...

Page 42: ...tatus 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 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 ...

Page 43: ...de 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 4 Ethernet LED status indicators for communications functions Figure 12 Controller Module 5 Connection to I O port of Scanner Module C50 C50S C70 C70S C75 C75S only 6 Second Ethernet E2 Host Connection to P...

Page 44: ...s to controller modes or to facilitate a Manual Fail Over Figure 13 Redundancy Switch Module Scanner 1 Module S50 S50S only 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 1 LED status diagnostics indicator for scanner functions 2 One private Ethernet 10 100 Base T Port conn...

Page 45: ...8 or 16 point analog output module Supports from 0 to 20mA each Galvanically isolated in groups of 4 channels galvanically isolated chassis to output channels 16 point digital input modules Contact closure type DC voltage and AC voltage types Galvanically isolated chassis to input 32 point digital input module DC voltage Galvanically isolated in two groups 1 16 17 32 Galvanically isolated chassis ...

Page 46: ...oller Module and or Scanner Modules A PC can be connected to the controller via the RS 232 port for legacy system For the new system a PC can be connected to the controller via the RS 485 to USB cable connected to RS485 Port which can be connected to external Honeywell qualified RS485 to USB converter and can also be networked to the controller via the Ethernet 10 100Base T Open Connectivity Netwo...

Page 47: ...ntroller User and Installation Manual 33 21 April 2017 Figure 17 RS 232 Modem Devices I O Network I O Expansion Network C50 and C50S C70 and C70S CPU only Examples of HC900 Controller I O expansion configurations are shown in Figure 18 ...

Page 48: ...cks 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 The total number of switches is limited to 2 in s...

Page 49: ...n can be 4 8 or 12 slot versions Redundant I O power not available with 4 slot Double the amount of Switches and Ethernet cables are required to configure the redundant I O Link Maximum of 2 switches between each CPU CPU A and CPU B and the I O racks Ethernet Open Connectivity Network The configuration of the Ethernet Open Connectivity Network varies with specific applications in purpose and in co...

Page 50: ...width 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 Interconnecting controllers with Ethernet media and networking devices cables switches e...

Page 51: ...ent 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 r...

Page 52: ...00 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 a...

Page 53: ...ce 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 netw...

Page 54: ...ss is provided in each HC900 Controller 192 168 1 254 Later when connecting to networks with more stringent addressing requirements it is necessary only to configure the Router with address mapping and connect it between the existing LAN and the other existing network Connections to other networks vary in purposes and methods some of these are described below E Mail Communications The HC900 Contro...

Page 55: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 41 21 April 2017 Figure 21 Typical installation using a Cable Modem ...

Page 56: ...ble shield connection must be made to IO grounding bar instead of the connector shield connector Ports configurable as ELN default or Modbus RTU Controller can act as Modbus master or slave through either port 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 ...

Page 57: ...erial ports S1 and S2 are galvanically isolated RS 485 unterminated See Table 3 below Functionality is determined by DIP switch setting on see the following figure To change either port s setting use the switch settings in Table 3 Use a small slotted screwdriver or paperclip to gently move the DIP switches If you push too hard you could damage the switches or nearby circuitry Avoid using pencils b...

Page 58: ...is primarily intended for engineers system administrators and other technical staff who are responsible for planning the configuration and maintenance of a HC900 system Therefore it is assumed that the user must have technical knowledge and familiarity with the following Microsoft WindowsTM operating system 7 8 and 10 Networking system and concepts Security issues and concepts Attention As you der...

Page 59: ...an use AC Power Supply 900P01 900P02 see page 46 or 24DC Power Supply 900P24 see page 48 Limit of ten 4 channel five 8 channel or two 16 channel if powered from backplane Analog Output modules can be installed per rack Limit of 4 PFQ modules Power Supply rack space if using redundant I O power see page 49 Rack orientation and mounting see page 48 Remote Terminal Panels see page 51 Environmental co...

Page 60: ...70S 1150mA legacy 1350 mA New 0 mA 0 Controller C75 C75S 1500 mA legacy 1500 mA New 0 mA 0 Scanner 1 Port S50 S50S 670 mA legacy 750 mA New 0 mA 0 Scanner 2 Port S75 S75S 770 mA legacy 950 mA New 0 mA 0 Power Status Module PSM 22 mA 0 mA 0 Analog Input 8 pts 40 mA 25 mA Analog Input 16 pts 75 mA 50 mA Analog Output 4 pts 40 mA 200 mA Analog Output 8 pts 225 mA 350 mA Analog Output 16 pts 350 mA 70...

Page 61: ... mA 5V less than 2000mA Yes No 2 Is column E total mA 24V less than 900mA Yes No 3 If the answers to 1 and 2 are YES go to 4 If the answer to 1 or 2 is NO use power supply 900P01 0001 4 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 000...

Page 62: ...ovide 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 ...

Page 63: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 49 21 April 2017 Figure 25 Rack Dimensions with reserve power supply ...

Page 64: ...50 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 26 Vertical Spacing of Racks all models ...

Page 65: ...ate wiring terminations between the controller and the intermediate terminal boards For details see page 217 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 Honeywell must be mounted in approved furniture designed for industrial applications Consideration sho...

Page 66: ...C900 Hardware Power Watts Field Power Watts Total Power 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 and C75S 7 8 0 0 7 8 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 Inp...

Page 67: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 53 21 April 2017 Figure 27 AC Input Module de Rating Figure 28 Power Supply de Rating ...

Page 68: ... fiber optic cable for connections between the controller and a remote rack Please refer to HC900 specification document 51 52 03 31 for more details 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 215 Maximum of 2 switches between each CPU s I O port and all I O racks Cable lengths s...

Page 69: ...sembly Cable left end Left to right Wire color pin number 10Base T 100Base T Signal Description Cable right end Left to right Wire color pin number white orange 1 Tx white orange 1 Orange 2 Tx Orange 2 white green 3 Rx white green 3 Blue 4 Unused Blue 4 white blue 5 Unused white blue 5 Green 6 Rx Green 6 white brown 7 Unused white brown 7 Brown 8 Unused Brown 8 3 Crimp an RJ45 connector to each ca...

Page 70: ...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 Hazardous voltages exist in the equipment enclosure Identify and avoid contact with voltage sources Failure to comply with these instructions could result in death or serious in...

Page 71: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 57 21 April 2017 Figure 30 Cabinet Wiring Multiple Chassis ...

Page 72: ...1 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 ...

Page 73: ... devices for additional noise protection You may want to add suppression devices at the external source Appropriate suppression devices are commercially available Refer to document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments for additional installation guidance Grouping Wires for Routing Wires that carry relatively high electrical energy can produce unw...

Page 74: ... 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 The Master Control Relay does not remove power from the Controller rack or from any of the I O expansion racks Before perfor...

Page 75: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 61 21 April 2017 Figure 32 Master Control Relay Wiring Example ...

Page 76: ...wiring concept for using the validation function blocks 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 ...

Page 77: ... 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 relay sources power 110 220 AC Figure 34 Individual Series DO connections LOAD DI Relay Output 900H01 DI 16 900G02 or DI 32 900G32 LOAD DI Sinking DO 16 900H02 DI 16 900G02 or DI 32 900G32 LOAD 24VDC DI Sourcing DO 32 900H32 DI 16 900G02 or DI 32 900G32 LOAD DI Relay O...

Page 78: ... 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 ASYS System Monitor FSYS Fast System Monitor RK Rack Monitor FMON Fault Monitor These function blocks are described in the HC900 Function Block Reference Guide 51 52 25 109 ...

Page 79: ...ts 1 2 3 4 5 6 7 8 9 10 11 Common tools Wire strippers Crimper Screwdrivers Small flat tip Small medium flat tip or Phillips Large long blade Other Electric drill with drill bits for 10 or M4 screws and with drill bit extender Vacuum cleaner brush Pen ball point or felt tip for entering data on labels for I O modules Multi Meter Volt Ohms Amps Soldering pencil or gun for attaching filter capacitor...

Page 80: ...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 Mo...

Page 81: ...r control Relay Mount Racks Table 8 Mount Rack 3 Install or verify correct installation of enclosures closets for networking devices See Pre installation planning sections Note Some networking devices may share enclosures with HC900 Controller components 4 Install or verify correct installation of External disconnect switches Fuses at the power source associated with input sensor or output devices...

Page 82: ...nd Note at right Drill and tap for 10 or M4 screws Start the mounting screws supplied by the user in the drilled holes Hang the Rack on the screws at the top Mark the locations for the bottom screws See CAUTION at right Drill and tap for 10 or M4 screws Remove the rack from the enclosure For dimensions of the pattern for drilling holes refer to the diagram below When drilling holes prevent metal f...

Page 83: ...h them with two M3 screws supplied with grounding bars in plastic bag Note The plastic bag also includes four M4 screws for attaching the grounding wire lugs which are attached later Attach the M4 screws loosely to the grounding bars for safe keeping 3 Hang the rack in the enclosure on the top screws Start all screws in the bottom of the rack then tighten all screws Note You may find it easier to ...

Page 84: ...suring 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 Torque to 0 4 0 5 N m 3 5 4 4 Lb In 2 Hazardous Voltage Ensure that wiring to the Power Supply is disconnected from ...

Page 85: ... 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 P...

Page 86: ... in the rack immediately to the right of the Power Supply Fasten it in place with two captured screws at top and bottom Torque to 0 4 0 5 N m 3 5 4 4 Lb In 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 ...

Page 87: ...ee page 42 3 Ensure that AC power to the rack is disconnected Carefully place the Controller Modules in the rack adjacent to the Power Supplies Fasten them in place with captured screws at top and bottom Torque to 0 4 0 5 N m 3 5 4 4 Lb In 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 thi...

Page 88: ...f using redundant power your I O rack will contain a second smaller compartment see 1 in the following figure Insert first power supply in the larger compartment as shown to the immediate right of the plate dividing the two compartments 2 Redundant Power 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 I...

Page 89: ...switch 3 ON Scanner 3 DIP switch 4 ON Scanner 4 DIP switch 5 ON Scanner 5 Scheme 2 upto 12 racks DIP switch 6 NO Always and 1 ON Scanner 1 2 ON Scanner 2 2 1 ON Scanner 3 3 ON Scanner 4 3 1 ON Scanner 5 3 2 ON Scanner 6 3 2 1 ON Scanner 7 4 ON Scanner 8 4 1 ON Scanner 9 4 2 ON Scanner 10 4 2 1 ON Scanner 11 4 3 ON Scanner 12 A small slotted screwdriver or paperclip works well avoid pencils 4 Repea...

Page 90: ...76 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Step Procedure Comments References 5 I O will be installed later See Page 78 ...

Page 91: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 77 21 April 2017 This page has been intentionally left blank ...

Page 92: ...20 or 36 pin plug receives the associated socket on the back of a terminal block When the I O module is inserted into the rack and the terminal block is placed on the circuit board two captured screws in the terminal block are fastened to metal tabs on the rack Figure 37 I O Module Installation Do not use an input output terminal block if the terminal block is damaged if the door is missing or if ...

Page 93: ... rack be sure they are properly keyed to the module type they will be used with See I O Module Installation Procedures page 84 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 term...

Page 94: ...t 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 is recommended and will improve noise immunity if wire routing is suspect Wire Gage Observe all local codes when making power connections Unless local electrical codes dictate oth...

Page 95: ...le 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 ...

Page 96: ...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 connec...

Page 97: ...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 RIU...

Page 98: ...a Designer Software report fill in the tag names on the Label for each configured I O Module Module slot position should take heat de rating into account See Heat Rise De rating page 52 Be sure to use the appropriate label for each module type 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 an...

Page 99: ...n jumper for the DC Input Module and or on the DC Output Module Ten position jumper for the AC Output Module Five position jumper 10 position jumper cut in half for a Relay Output Module Refer to terminal block wiring diagrams for specific information 4 For each configured and labeled I O Module break off the key tabs in the pattern that identifies each module type For a diagram of each key tab pa...

Page 100: ...iagram below the white cut outs represent the cut outs on the modules that accommodate tabs on the Terminal Block That is all key tabs that line up with the white cut outs on the diagram should be retained and all other tabs should be removed The orientation of the diagrams below corresponds to the picture of the terminal block shown in the previous picture Diagrams for I O Module Key Tabs ...

Page 101: ...orks well avoid using pencils 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 For internal rack power set DIP switch to ON 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 paper...

Page 102: ...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 Settings using Input 1 as example Single ended factory setting 1 and 2 SINGLE ON 3 and 4 DIFF OFF Differential 1 and 2 SINGLE OFF 3 and 4 DIFF ON ...

Page 103: ...ser and Installation Manual 89 21 April 2017 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 ...

Page 104: ...nstall appropriate terminal block 11 In each slot location not occupied by an I O module install a Filler Block cover Part number 900TNF 0001 Note The Filler Block Cover looks much like an I O Terminal Block assembly except that it does not include the wire terminating block screw terminals The Filler Block mounts in the same manner as a Terminal Block with captured screws at top and bottom Blank ...

Page 105: ...E TypeS Pt PT110 TypeR Pt PT113 TypeW5 W26 Type W W26 10 0 102 0 058 0 034 0 029 0 069 0 018 0 018 0 023 0 020 12 0 081 0 091 0 054 0 046 0 109 0 028 0 029 0 037 0 031 14 0 064 0 146 0 087 0 074 0 175 0 045 0 047 0 058 0 049 16 0 051 0 230 0 137 0 117 0 276 0 071 0 073 0 092 0 078 18 0 040 0 374 0 222 0 190 0 448 0 116 0 119 0 148 0 126 20 0 032 0 586 0 357 0 298 0 707 0 185 0 190 0 235 0 200 24 0...

Page 106: ...e RTD inputs Analog channels wired for Ohms inputs differ from RTD inputs in these aspects Ohms inputs connect to variable resistance devices other than RTDs and 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 ...

Page 107: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 93 21 April 2017 Figure 43 Universal Analog Input Wiring Diagram ...

Page 108: ...94 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 44 Examples of RTD Input Wiring ...

Page 109: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 95 21 April 2017 Figure 45 Analog Input Wiring Eight TCs ...

Page 110: ...96 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 46 Analog Input Wiring Eight Resistance Inputs ...

Page 111: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 97 21 April 2017 Resistance Temperature Device Inputs Figure 47 Analog Input Wiring Eight RTDs ...

Page 112: ...98 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Slidewires Figure 48 Analog Input Wiring Slidewire Position Proportion Block ...

Page 113: ...Wiring An example of Analog Output Module 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 Safety Controller Safety Manual for additional details Isolation The four outputs are isolated from each other Shield Grou...

Page 114: ...rior to a cold start for the module to work properly Subsequent channels then may be added with a hot start Failure to comply with these instructions could result in death or serious injury 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 ex...

Page 115: ...s described under Shield Grounding at the beginning of this section 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 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 OUT 2 NC NC NC NC NC NC NC NC NC...

Page 116: ...re 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 Jump...

Page 117: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 103 21 April 2017 Figure 53 DC Input Module Wiring Diagram ...

Page 118: ...104 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 54 DC Input Module Jumper ...

Page 119: ... 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 55 32 point DC Input Module Wiring AC Input Module Wiring The AC Input Module has sixteen inputs An example of AC Input Module wiring is shown in Figure 56 Speci...

Page 120: ...le 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 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 instructions could...

Page 121: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 107 21 April 2017 Figure 57 AC Input Module Jumper ...

Page 122: ...solated 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 ...

Page 123: ... 2 IN 9 IN 8 IN 9 IN 11 IN 12 IN 11 IN 12 IN 13 IN 14 IN 13 IN 14 IN 16 IN 15 IN 16 IN 15 IN 10 125 VDC IN 10 120 240Vac or External Disconnect User Supplied Safety Devices Legend Fuse IN 1 IN 1 IN 2 IN 3 IN 4 IN 3 IN 4 IN 5 IN 6 IN 6 IN 7 IN 8 IN 5 IN 7 IN 2 IN 9 IN 8 IN 9 IN 11 IN 12 IN 11 IN 12 IN 13 IN 14 IN 13 IN 14 IN 16 IN 15 IN 16 IN 15 IN 10 125 VDC IN 10 120 240Vac or Figure 58 AC DC Iso...

Page 124: ...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 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 t...

Page 125: ...de 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 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...

Page 126: ...ier 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 Hazardous volta...

Page 127: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 113 21 April 2017 Figure 60 DC Output Module Wiring Diagram ...

Page 128: ...114 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 61 DC Output Jumpers ...

Page 129: ...used to ensure outputs achieve failsafe action See HC900 Process 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 Figure 62 32 point DC Output Module Wiring AC Output Module Wiring The AC Output Module provides eight output circuits Each output is isolated f...

Page 130: ...y 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 Hazardous voltages exist at te...

Page 131: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 117 21 April 2017 Figure 63 AC Output Module Wiring Diagram ...

Page 132: ...118 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 64 AC Output Module Jumper ...

Page 133: ...ntroller Safety Manual for additional details Examples of Relay Output wiring as they relate to connections on the Terminal Block are shown in Figure 66 Figure 65 Schematic Example Relay Output and External Wiring Contact Rating Maximum current output 4A at 250Vac 30Vdc with resistive load Maximum current per module No de rating per module but ensure compliance with maximum ratings for each output...

Page 134: ... 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 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 instructions could result in death or serious injury Figure 66 Relay Output Module Wiring Diagram ...

Page 135: ...ement Quadrature encoder input and Pulse Output Each of the 4 channels can be configured for any one of these four functionalities with the exception that quadrature encoder input A and B pulses can be applied to only Channels 1 and 2 respectively When configured for quadrature Channels 3 and 4 will still be available for use The Pulse Output functionality uses the digital output available on the ...

Page 136: ...122 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 68 Pulse Counting Wiring Figure 69 Pulse Output Wiring ...

Page 137: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 123 21 April 2017 Figure 70 Frequency Wiring Figure 71 Quadrature Differential External Power Wiring ...

Page 138: ...124 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 72 Quadrature Single Ended External Power Wiring Figure 73 Quadrature Differential HC900 Power Wiring ...

Page 139: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 125 21 April 2017 Figure 74 Quadrature Single Ended HC900 Power Wiring ...

Page 140: ......

Page 141: ...e Comments Reference 1 Determine requirements for communications links See Ethernet Devices Considerations on page 33 For legacy system serial Ports RS 232 and RS 485 on page 42 For new system two RS 485 serial ports on page 42 Cabling Wiring Distance Planning on page 54 2 Refer to the diagram at right and to Table 17 Links to Controller Communication Ports for connection details All ports are sho...

Page 142: ...r Modbus master controller is single slave RS 232 Null Modem cable up to 50 Or RS 232 PC modem cable up to 50 RS 232 to RS 485 converter Refer to device s port instructions Legacy controller only RS 232 3 plug connector Modbus master controller is one of multiple slaves RS 232 to RS 485 converter Refer to device s port instructions Legacy controller only RS 232 3 plug connector Modbus slave networ...

Page 143: ... PC supervisory and data acquisition software packages and Designer configuration software Default IP address is 192 168 1 254 E2 10 100Base T RJ 45 Lead CPU supports redundant Modbus TCP Protocol to OPC server PC supervisory and data acquisition software packages and Designer Software configuration software Default IP address is 192 168 2 254 I O 100Base T Single I O rack Shielded Ethernet CAT5 c...

Page 144: ... 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 No fo...

Page 145: ...obably 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 Part Quantity Description Belden 9271 or equivalent with 120 ohm resistors 2 000 feet Maximum Or Belden 9182 or equivalent with 150 ohm resis...

Page 146: ...Process Control HC Designer configuration software use any of the following methods A Direct Serial RS 232 connection See page 133 Direct with RS 485 and RS 485 to USB converter with supplied instructions B Modem connection See page 136 C Direct Ethernet connection See page 149 D Networked Ethernet connection See page 150 These methods are described below ATTENTION Always observe the wiring cablin...

Page 147: ...on Tool page 134 for specific instructions on the null modem cable 4 If a configuration is not available start a new configuration in HC Designer by selecting File New After selecting controller type and revision select OK 5 From the Utilities Worksheet Utilities tab in the main window in the HC Designer software set up the PC s serial port attributes for use with the controller Make sure that the...

Page 148: ...l 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 Signal Name Pin No Connection Signal Name Plug No DCD 1 None RXD 2 Connects to TXD 2 TXD 3 Connects to RXD 3 DTR 4 None GND 5 Connects to GND 1 DSR 6 None RTS 7 None CTS 8 None RI 9 Non...

Page 149: ...dem 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 f...

Page 150: ...136 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 B Modem Connection Figure 77 Modem Connection ...

Page 151: ...tructions 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 Wo...

Page 152: ...isabled 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 TIP The Null Modem cable used to directly...

Page 153: ...gs 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 mod...

Page 154: ...D signal when it connects with another modem 7 OFF UP Loads Y0 Y4 configuration from user defined nonvolatile memory NVRAM 8 ON DOWN Enables recognition smart mode 2 Connect the modem to a PC If your computer s RS 232 port has a 25 pin connector use a DB 25 male to DB 25 female RS 232 cable If your computer s RS 232 port has a 9 pin connector use a DB 25 male to DB 9 female modem cable 3 Power up ...

Page 155: ...to the following Switch Setting Position Function 1 ON DOWN Modem ignores DTR Override 2 OFF UP Verbal word results 3 OFF UP Suppresses result codes 4 ON DOWN Suppresses echo 5 OFF UP Modem answers on first ring 6 ON DOWN CD always ON Override 7 OFF UP Loads Y0 Y4 configuration from user defined nonvolatile memory NVRAM 8 OFF UP Disables command recognition dumb mode 13 Connect the modem to the 14...

Page 156: ...p bits 1 flow control none 7 In the program s terminal window restore factory defaults by keying in the following command string AT F0 Then press the ENTER key 8 In the program s terminal window key in the following command string AT E1 Q0 Then press the ENTER key The Modem should respond with OK 9 Key in the following command string AT Y0 C0 D0 R1 S0 K0 S0 1 Then press the ENTER key The Modem sho...

Page 157: ...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 F0 Then press the ENTER key 8 In the program s terminal window key in 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 C0 D0 K0 R1 S0 Y0 S0 1 The Modem should...

Page 158: ...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 F0 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 c...

Page 159: ...April 2017 Connecting C75 C75S dual 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 Figure 78 Dual Networks see Table 20 ATTENTION Always observe the wiring cabling guidelines on page 54 ...

Page 160: ...net switch or router firewall 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 90...

Page 161: ... 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 6 Consul...

Page 162: ...spective online help Utilities Worksheet Set Controller s Network Parameters for further details on this step Note This step will require the controller to be placed temporarily in the Program mode After the new network parameters have been downloaded the controller will conduct a Cold Start in its transition to RUN This will cause an initialization if there is a current configuration in the contr...

Page 163: ...figuration 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...

Page 164: ...e 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 D Network Access to one or more controllers ATTENTION Always observe the wiring cabling guidelines on page 54 Step Procedure 1 Mak...

Page 165: ...C s network port Connect the other end of the Ethernet 10 100 Base T cable to the Ethernet switch 8 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 or router firewall 9 You may now access any controller on the network for configuration access by assigning Net...

Page 166: ...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 42 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 Figure 80 RS 48...

Page 167: ...or with additional port biasing See Figure 81 Note Legacy Controllers do not provide biasing 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 proce...

Page 168: ...he controller s 3 pin RS 232 port See page 42 for RS 232 DIP switch settings Table 19 page 134 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 as a Master of Slave Use HC Designer software to configure the contr...

Page 169: ... In some cases mode transitions also restart Cold Start or Warm Start controller operation 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 configurati...

Page 170: ...cs indicate that the controller hardware and software program are intact but the content of the RAM database is incorrect See Figure 83 On a Mode transition from PROGRAM to RUN This Mode transition can be initiated by operating the Mode switch on the controller or RSM or by exiting the Program mode at a Control Station When initiated by the user after download with Cold Start selected or any trans...

Page 171: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 157 21 April 2017 Figure 84 Cold Start Operation ...

Page 172: ...ion 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 Ta...

Page 173: ...sume program execution with current available data when controller returns to RUN mode In Controllers with firmware version 6 0 or greater the controller s memory will get re initialized outputs will be de energized and the controller will restart when changing from Offline to Run mode Before entering the OFFLINE Mode KNOW all potential consequences of suspending control action PLAN for all operat...

Page 174: ...wnloading controller firmware Program Locked or Program Other functions NOT permitted 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 expande...

Page 175: ... 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 This RUN locked mode is the Safety mode for Safety controllers and the proper normal operational mode for All controllers RUN PROG PROGRAM RUN OFFLINE In this position the mode can be changed at any operator interface using scree...

Page 176: ...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 imm...

Page 177: ... 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 Configuration files Firmware files Configuration files can also be uploaded from the controller for archiving Firmware can only be downloaded to the controller Pat...

Page 178: ... separate from that used for running the controller and hence has no effect on the active process The host signals the controller when the download is complete and requests a configuration validation test and report from the controller The controller then checks the new database and compares it to the current running database Using the test report as a basis the host then presents the operator use...

Page 179: ...ntroller 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 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...

Page 180: ...re anticipated The Run Locked mode is the preferred operational mode to prevent any unintentional changes 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 ...

Page 181: ...ram in HC Designer Final desired sequence must be set by the user to achieve proper and optimum performance CAUTION Incorrect execution sequences can contribute to delays in processing outputs and or improper or unexpected operation The HC900 controller samples all inputs before the start of a controller scan Each input being used in the configuration must be assigned to a function block The seque...

Page 182: ...168 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 The Lead and Reserve controllers exchange system status to determine conditions for failover ...

Page 183: ...communications with I O Rack s Processor exception conditions Error conditions that occur in the following areas will not cause a failover Loss of communications to a Host on a network Loss of communications to Modbus Slave devices Loss of communications to Operator Interface Loss of communications with a Peer controller During the transition from the Lead to the Reserve analog and digital output ...

Page 184: ... 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 From HC Designer and HC Utilities PC Software Redundant System ...

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Page 186: ......

Page 187: ...ide 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 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 ...

Page 188: ...174 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Controller CPU indicators Figure 89 LED Indicators on Controller CPUs See Table 26 ...

Page 189: ...V Yellow Green Yellow when transmitting green when receiving All models 3 For legacy systems RS 232 RS 485 S2 port For new systems RS 485 S2 port XMT RCV Yellow Green Yellow when transmitting green when receiving All models 4 5 E1 port Upper LED Lower LED Yellow On Off Green On Off Flash On for 100Base T Off for 10Base T On for connection Off for no connection Flash for activity C70 C75 6 7 E2 por...

Page 190: ... locateandremovetheforcedoutputs SeeSYSTEM in the Controller Diagnostics Overview display SeeSystem Diagnosticsin the Diagnostic Overview dialog box 2 The RAM andFLASH copies of the configurationdatabase were corrupted and are nowset to avalid emptydatabase Usuallythis is a result of afirmwareupgrade Anempty databaseiscreated and theleadandreserve will not synchronize Thereserve s RSM LEDis flashi...

Page 191: ...modeback toRUN modeOR 2 Forceacold start In HCD System Diagnostics shows status as Safety Configurationmis match 3 One of thefollowing microprocessor exceptions occurred Watchdogtimer timeout Address error Prefetcherror Dataabort error Software interrupt Undefined instructionerror Atthetimeof theexception the microprocessor resets If it s the Leadcontroller andthereis an availablereserve afailover...

Page 192: ...ited until boththe Lead andReserve batteries are good Replace battery 4 Flashfailedtoburn ASYS andFSYS blocks HW OK pins areturned off 1 Forceacoldstart 2 If diagnostic does not clear replace CPUmodule 5 The Real timeClock RTC is not programmed This is usually aresult ofthe lead s batteryfailing when it was powered down 1 On power up timeanddateis initiallyset to00 00 00 January 1 1970 onboththele...

Page 193: ...ailing Scanner2is unableto communicateto a moduleora wrong moduleis installed A moduleintheI O rack is reporting a diagnostic C75 andScanner 2 firmware versions are incompatible Scanner2 I O rack orpower supplyis defective C75moduleis defective A badchannel has been detected on one of the modules 1 Associated blockssettheirfail pins on their warn pins off andtheir output pins tothefailsafevalue 2 ...

Page 194: ...block s modulefail pinisturnedon 4 Associated rackmonitorblock s RACK OK pinis turned off 5 Associated rackmonitorblock s HITEMP pinis turned on 6 ASYS andFSYS blocks HITEMP pins areturned on 7 ASYS andFSYS blocks HW OK pins areturned off 6 Scanner2 has aCPU or Memorydiagnostic 1 Associated rackmonitorblock s RACK OK pinis turned off 2 ASYS andFSYS blocks HW OK pins areturnedoff SeeCPUor MEMORYint...

Page 195: ...eslaves withthedatalink errors have anon zerodata link errorcount Theslaves experiencingthe failure aremovedtothe backgroundscan rate 1 Check baud rate 2 Check connectors 3 Check cablepolarity 4 Isolatecablingfrom electrical interference 5 If RS 232toRS 485converteris used check its power switch jumper settings andpolarity 6 Ifconfiguredas a Modbusmaster usetheslavestatusscreensto determinewhichsl...

Page 196: ...l Revision 6 21 April 2017 Scanner indicators Figure 90 LED Indicators on Scanners 1 port left 2 port right See Table 28 When the Scanner is flashing an amber Status LED after power up a power on self test error has occurred that requires scanner module replacement ...

Page 197: ...nt 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 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 of Strobes Possible Cause Scan...

Page 198: ...h is powered and it supports 100 Base T 4 Check cable shielding for proper grounding and noise immunity 5 Make sure the cables have the correct pinout 6 Cycle power to the Scanner 7 Cycle power to the switch 8 Cycle power to the controller CPU 9 Replace the expansion rack s scanner module 10 Ensure that the Scanner and Controller CPU software versions are compatible If not perform a firmware upgra...

Page 199: ...e 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 agree with those required by the configuration No action is taken Verify that the correct modules are installed for the configura...

Page 200: ...a module has a bad channel In this condition the module s status LED will not indicate the failure because the Scanner determines the condition not the module itself No action is taken Refer to the Bad I O Channel Diagnostics on page 189 to determine the nature of the problem and possible user actions 7 One of the power supplies failed No action is taken Replace the power supply ...

Page 201: ... 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 2 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 indica...

Page 202: ... 1 If expansionI O rack gotostep2 If noexpansionI O rack goto step 3 2 Check theScannerstatus LED see p 183 If it s flashing6times proceed withstep3 If it s flashingsome otherred statuscode refertoTable 29 tosolvethat problem first If it s flashinggreen themodule probablyis not requiredinthe configuration If it s not onorsteady cycle power tothescanner 3 Makesurethemoduleis the correct onefortheco...

Page 203: ...D or mV source is failing burnout checks Check terminal block connections Replace source element Replace module Under range The signal at the terminals is less than 10 below the range of the sensor Check the signal level being applied to the terminals Replace module 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 termi...

Page 204: ...eing 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 New Systems Upper LED Lower LED Link Yellow Speed Green On while the as long as electrical connection host is detected Flashes during message transactions OFF for 10Base T connections ON for 100 Base TX connections NOTE These LEDs i...

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Page 206: ...or the Ethernet 10 100 Base T Port using Designer Software A field calibration procedure consists of two parts Connecting a calibration device to each channel of an AI or AO module and 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 cali...

Page 207: ...unction compensation devices perform this operation first before performing any thermocouple calibrations However because cold junction measurement inaccuracies will be compensated in each individual thermocouple calibration cold junction calibration may be skipped After connecting the thermocouple extension wire to the terminals you must wait for the terminal temperature to stabilize If using a c...

Page 208: ...194 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 92 Terminal Board Connections for AI Calibration ...

Page 209: ...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 101 for terminal connections for 8 and 16 channel AO Figure 93 Terminal board Connections for AO Calibration ...

Page 210: ...l 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 p...

Page 211: ...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 71 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 Ensure that ...

Page 212: ...ly L1 top terminal Black USA or Brown Europe L2 N middle terminal White USA or Blue Europe 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 ...

Page 213: ...eviously saved copy of the current configuration is available If possible bring the process to a safe and orderly shutdown Table 35 Controller Module Replacement Step Action 1 If a process is currently in operation bring it to a safe and orderly shutdown 2 Using an external user supplied switch disconnect the power supply in the Controller rack from the site AC power source 3 Observe where communi...

Page 214: ...e 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 jumpe...

Page 215: ...plications at each user facility It is the responsibility of site personnel to know all potential consequences of RIUP and to take actions to prevent all adverse consequences before removing or inserting an I O module under power Table 37 provides some general guidelines for establishing appropriate procedures at a given installation Table 37 RIUP Potential Hazards and Recommended Actions Hazard S...

Page 216: ...nals 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 extract...

Page 217: ...w approximately 40 milliamps At the 4 microamp level the battery 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 hour...

Page 218: ... 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 4 The battery is retained in the holder by spring tension of the plastic holder itself Insert the negative end of the battery into the back end of the holder and press on the battery see arrow so that it snaps into the holder To ensure that the batte...

Page 219: ...ion 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 two 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...

Page 220: ...206 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Specifications General Specifications Refer to Specification manual ...

Page 221: ...stored profiles is user configurable Setpoint Scheduler Ramp type Ramp time Time units Hours or minutes Segment time 0 001 to 9999 999 hours or minutes Cycles Per segment to 999 or infinite 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 configu...

Page 222: ...1200 baud to 57 6KB Galvanically Isolated RS 485 Ports Ports per controller Two connector supplied Honeywell or Modbus RTU protocol Only one port for 1042 559 operator interface support Cable type 2 wire plus shield Belden 9271 or equivalent 1042 559 Distance from controller 2000 ft 600 m 1042 559 Power to OI 24VDC user provided at OI Unit addresses 1 to 247 Galvanically Isolated RS 485 Ports Pari...

Page 223: ...ble per device Speed 1 second fastest load dependent Peer to peer 10 100Base T via Network port Supports UDP protocol and Peer Data Exchange function blocks for peer data exchange No of Peers Controller 32 Update rate 500 ms to 5 sec selectable Peer Data Digital and Analog Signal Tags Variables up to 2240 parameters Ethernet Ethernet Network Connection 10 100 Base T RJ 45 Host Network Protocol Mod...

Page 224: ...to be approved on a case by case basis General Purpose Safety Compliant with EN61010 1 UL UL 61010 1 2nd edition CSA C22 2 No 1010 1 Hazardous Classified Location Safety FM Class I Div 2 Groups A B C D CSA Class I Div 2 Groups A B C D Class 1 Zone 2 IIC Module Temperature Classifications Module Type T Rating Module Type T Rating RedundantCPURack T6 Scanner2 T4 RedundantPSExt Rack T5 AnalogInput 8c...

Page 225: ...able 41 HC900 PV Input Types and Ranges Type Range Low Range High EU Reference Corresponding UMC800 Input type and range None n a B 18 1815 C B 40 1820 C 58 B 0 3300 F B 104 3308 F 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 200 870 C 4 J 0 1600 F J 328 1598 F 5 J 7 410 C J 0 400 C 2 J 20 770 F J 32 752 F 3 K 18 1316 C K 0 1200 C 16 K 0 2400 F K 32 2192 F 17 ...

Page 226: ... 0 1380 C PLTNL 0 1380 C 118 Platinel 32 2516 F PLTNL 32 2516 F 119 Platinel 0 750 C PLTNL 70 750 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...

Page 227: ...type and range MV 0 10 mV 0 10 88 MV 0 50 mV 0 50 92 MV 0 100 mV 0 100 95 MV 10 10 mV 10 10 89 MV 50 50 mV 50 50 93 MV 100 100 mV 100 100 96 MV 500 500 mV 500 500 98 V 0 1 V 0 1 101 V 0 2 V 0 2 103 V 0 5 V 0 5 105 V 0 10 V 0 10 108 V 1 5 V 1 5 107 V 1 1 V 1 1 102 V 2 2 V 2 2 104 V 5 5 V 5 5 106 V 10 10 V 10 10 109 Carbon 0 1250 mV n a Oxygen 30 510 mV n a ...

Page 228: ...ncluding both SAFPDE blocks PDE Blocks 32 32 32 32 Peer data exchange items including both PDE items and safety peer import items 2240 2240 2240 2240 Safety Peer Export Signals 300 300 300 300 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 capabilit...

Page 229: ...riables 2000 2000 2000 2000 Variables in a Recipe 50 50 50 50 Extended distance configuration with Fiber Optics Please refer to HC900 specification document 51 52 03 31 for more details on recommended models Also Figure 94 and Figure 95 are examples of Extended Distance configurations Figure 94 Extended Distance Example 1 ...

Page 230: ...216 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 Figure 95 Extended Distance Example 2 ...

Page 231: ...P integrates some of the typical externally connected components reducing wiring and setup time It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I O modules There are three RTP types See page 8 Analog Input 218 Relay Output 225 16 point Analog Input Digital Input Digital Output Analog Output 229 Figure 96 Exa...

Page 232: ...th the module See page 85 Connect desired cable to AI 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 AI module label onto the module connector cover Connect shield drain wire to the grounding b...

Page 233: ...itch 1 for Input 2 use Switch 2 etc If an input is not used set its DIP switch positions to OFF SW9 Volt millivolt 1 2 O N 1 2 O N 1 2 O N Ohms 1 2 O N 1 2 O N 1 2 O N 1 2 O N 1 2 O N 1 2 O N 1 2 O N RTD 1 2 O N 1 2 O N 1 2 O N Transmitter SW9 is the red power switch for 24 volt supply Module RIUP is not affected by using the RTP See page 224 for RTP internal schematic Fuses 80mA Time lag Littelfu...

Page 234: ...mitter 1 2 3 7 8 9 4 5 6 10 11 12 13 17 18 19 14 15 16 20 21 22 23 27 28 29 24 25 26 30 31 32 33 37 38 39 34 35 36 40 Transmitter 24 VDC Transmitter Transmitter Transmitter Input 1 Input 2 Input 3 Input 4 Input 5 Transmitter Input 6 Transmitter Input 7 Input 8 Note You must set switches 1 8 for transmitters Transmitter Transmitter 1 2 3 7 8 9 4 5 6 10 11 12 13 17 18 19 14 15 16 20 21 22 23 27 28 2...

Page 235: ...put 5 mA Input 6 mA Input 7 mA Input 8 Note You must set switches 1 8 for Milliamp Figure 99 Milliamp input connections with 250 ohm shunt resistance 1 2 3 7 8 9 4 5 6 10 11 12 13 17 18 19 14 15 16 20 21 22 23 27 28 29 24 25 26 30 31 32 33 37 38 39 34 35 36 40 V mV Input 1 V mV Input 2 V mV Input 3 V mV Input 4 V mV Input 5 V mV Input 6 V mV Input 7 V mV Input 8 Note You must set switches 1 8 for ...

Page 236: ...RTD Figure 101 Three wire RTD input connections 1 2 3 7 8 9 4 5 6 10 11 12 13 17 18 19 14 15 16 20 21 22 23 27 28 29 24 25 26 30 31 32 33 37 38 39 34 35 36 40 Input 1 Input 2 Input 3 Input 4 Input 6 Input 7 Input 8 2 wire RTD OHMS 2 wire RTD OHMS 2 wire RTD OHMS 2 wire RTD OHMS 2 wire RTD OHMS 2 wire RTD OHMS Input 5 2 wire RTD OHMS 2 wire RTD OHMS Note You must set switches 1 8 for Ohms Note Inst...

Page 237: ...2 3 7 8 9 4 5 6 10 11 12 13 17 18 19 14 15 16 20 21 22 23 27 28 29 24 25 26 30 31 32 33 37 38 39 34 35 36 40 Input 1 Input 2 Input 3 Input 4 Input 6 Input 7 Input 8 Slidewire Slidewire Slidewire Slidewire Slidewire Slidewire Input 5 Slidewire Slidewire R F R F F F F F F F R R R R R R Note You must set switches 1 8 for Ohms Figure 103 Slidewire feedback connections for actuators Analog Input accura...

Page 238: ...8 29 12 32 13 33 16 36 17 37 20 40 5 10 11 14 15 18 19 24 21 F1 F2 F3 F4 1 F5 F6 F7 F8 25 30 31 34 35 38 39 HC900 Terminal Block TB1 250 Ohm SW 8 2 3 23 7 28 9 250 Ohm SW 7 2 250 Ohm SW 6 2 250 Ohm SW 5 2 250 Ohm SW 4 2 250 Ohm SW 3 2 250 Ohm SW 2 2 250 Ohm SW 1 2 4 5 SW 8 1 1 2 4 5 6 7 9 10 11 12 14 15 16 17 3 8 13 18 19 20 J1 SW 7 1 SW 6 1 SW 5 1 SW 4 1 SW 3 1 SW 9 SW 2 1 SW 1 1 26 ...

Page 239: ...al High Voltage Cable assembly 5 0 meters long ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F Install relay output module label onto the module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 81 2 Mou...

Page 240: ...DO 1 LOAD NO LOAD NC LOAD NO LOAD NC LOAD NO LOAD NC LOAD NO LOAD NC LOAD NO LOAD NO LOAD NO LOAD NO ATTENTION Cable power is limited to 24 Amps per module at 60C 140 degrees F and 32 Amps at 54C 129 degrees F 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 externa...

Page 241: ...nternal schematic HC900 Terminal Block TB1 1 2 4 5 6 7 9 10 11 12 3 8 13 14 16 17 18 19 15 20 F1 SW1 F1 SW1 J1 F2 SW2 F2 SW2 F3 SW3 F3 SW3 F4 SW4 F4 SW4 F5 SW5 F5 SW5 F6 SW6 F6 SW6 F7 SW7 F7 SW7 F8 SW8 F8 SW8 1 2 3 4 5 6 7 8 15 16 17 18 9 10 19 20 12 11 14 13 6 7 9 10 8 20 19 18 17 15 14 13 12 16 11 1 2 4 5 3 ...

Page 242: ...o 8 point AI 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 ...

Page 243: ... Output Step Action 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure Mount RTP cable assembly to HC900 Controller Figure 96 Remove appropriate key tabs from terminal block to allow mating with the module See page 85 Connect desired cable to AO module at controller Choose from 900RTC L010 Remote Terminal Low Voltage Cable Assembly 1 0 meters long 900RTC ...

Page 244: ... output module Jumper open Jumper closed SW1 is not used Module RIUP is not affected by using the RTP See page 240 for RTP internal schematic 4 Connect field wiring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 LOAD LOAD LOAD LOAD AO 1 AO 2 AO 4 AO 3 LOADS ARE 0 to 750 ohm A O 1 A O 1 A O 4 A O 4 A O 2 A O 2 A O 3 A O 3 ...

Page 245: ...able 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 groundin...

Page 246: ...s 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 Remove appropriate key tabs from terminal board to allow mating with the module See page 85 Connect desired cable to 16 point DC DI module at controller Choose from 900RTC L010 Remote Terminal Low Volt...

Page 247: ... both sides of the DC power See page 240 for RTP internal schematic 4 Connect field wiring Note SDC in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 IN13 IN14 IN15 IN16 D...

Page 248: ...g 900RTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 16 point AC DI module label into module connector cover Connect shield drain wire to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 81 2 Mount RTP to DI...

Page 249: ... Step Action 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION 16 point DC Digital Output is rated at 8A per module and 1A per output Limited to 4A per group of 8 ATTENTION The RTP combines the two groups of 8 outputs into one group of 16 Mount RTP cable assembly to HC900 Controller Figure 96 Remove appropriate key tabs from terminal board to a...

Page 250: ...e 253 Connect cable to RTP 3 Set verify jumper positions as shown Jumper open Jumper closed Module Removal Insertion Under Power RIUP is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc See page 83 ATTENTION SW1 only disconnects the positive terminal not both sides of the DC power See page 240 for RTP internal schematic ...

Page 251: ...6 37 38 39 40 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 OUT8 OUT9 OUT10 OUT11 OUT12 OUT13 OUT14 OUT15 OUT16 DC Supply LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD S D C S D C D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C D O 1 D O 2 D O 9 D O 1 0 D O 5 D O 6 D C D O 3 D O 4 D O 7 D O 8 S D C S D C D C D O 1 1 D...

Page 252: ...0 Remote Terminal High Voltage Cable assembly 1 0 meters long 900RTC H025 Remote Terminal High Voltage Cable assembly 2 5 meters long 900RTC H050 Remote Terminal High Voltage Cable assembly 5 0 meters long Install 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 i...

Page 253: ... 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 OUT8 L1 L2 LOAD OUT7 LOAD OUT6 LOAD OUT5 LOAD OUT4 LOAD OUT3 LOAD OUT2 LOAD OUT1 LOAD S L 1 O U T 1 S L 1 O U T 6 S L 1 O U T 2 O U T 4 N C N C S L 1 O U T 3 S L 1 S L 1 O U T 5 S L 1 O U T 7 N C N C S L 1 O U T 8 S L 1 S L 1 L 1 S L 1 S L 1 S L 1 S L 1 S L 1 S L 1 L 2 S L 1 L 2 L 2 L 2 L 2 L 2 L 2 L 2 L 2 L 2 Note AC Outputs ar...

Page 254: ... 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 6 7 8 9 10 20 19 18 17 16 4 5 13 12 11 3 2 1 15 14 J1 J2 J3 J4 J5 1 2 3 4 5 6 7 8 9 10 19 20 13 14 15 18 17 16 11 ...

Page 255: ...le 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 81 2 Mount RTP to DIN rail Latch to rail See page 253 Connect cable to RTP ...

Page 256: ... 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 LOADS ARE 0 to 750 ohm A O 1 A O 1 A O 2 A O 2 LOAD AO 1 LOAD AO 2 LOAD AO 1 LOAD AO 2 A O 3 A O 3 A O 4 A O 4 A O 5 A O 5 A O 6 A O 6 A O 7 A O 7 A O 8 A O 8 ETC RTP A for Inputs 1 to 8 External 24VDC supply D C S D C EXT 24V RTN EXT 24V Install 24V wires as shown 22 to 10 22 to 12 24VRTN to 9 24VRTN to 11 ...

Page 257: ...ion RTP A 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 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 6 7 8 9 10 20 19 18 17 16 4 5 13 12 11 3 2 1 15 14 J1 J2 J3 J4 J5 1 2 3 4 5 6 7 8 36 35 15 16 9 10 11 14 13 12 36 35 J9 J7 J8 J6 HC...

Page 258: ...nalog 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 81 2 Mount RTPs to DIN rail Latch to rail See page 253 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 ...

Page 259: ... 24V RTN EXT 24V A O 1 0 A O 9 Install 24V wires as shown 22 to 10 22 to 12 24VRTN to 9 24VRTN to 11 16 Point Analog Input Step Action 1 ATTENTION RTP and cables are intended for permanent installation within their own enclosure ATTENTION The RTP labeled DI DO AO RTP ASSY with jumpers J2 J9 is the correct one for 16 point AI Mount RTP cable assembly to HC900 Controller Figure 96 Remove appropriate...

Page 260: ...TPs labels to distinguish them Note Inputs 9 and 10 are wired between both RTPs 3 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 83 ATTENTION SW1 opens current loop on the ground side so that RIUP of module is poss...

Page 261: ...N 8 IN 1 IN 5 IN 2 IN 3 IN 4 IN 6 IN 7 IN 8 RTP A for inputs 1 to 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 IN 1 1 IN 1 2 IN 1 3 IN 1 4 IN 1 1 IN 1 2 IN 1 5 IN 1 6 IN 1 5 IN 1 3 IN 1 4 IN 1 6 IN 1 5 IN 1 6 IN 1 5 IN 1 3 IN 1 4 IN 1 6 IN 9 IN 1 0 RTP B for inputs 9 to ...

Page 262: ...nt 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 81 2 Mount RTPs to DIN rail Latch to rail See page 253 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...

Page 263: ...OUT16 DC Supply LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD S D C S D C D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C S D C D O 1 D O 2 D O 9 D O 1 0 D O 5 D O 6 D C D O 3 D O 4 D O 7 D O 8 D C D C D C D O 1 1 D O 1 2 D O 1 3 D O 1 4 D O 1 5 D O 1 6 Install jumper wire RTP B for outputs 17 to 32 1 2 3 4 5 6 7...

Page 264: ...e assembly 2 5 meters long Install 32 point DC DI label into the module connector cover Connect both shield drain wires to the grounding bars at the base of the HC900 rack All field wiring shields must be grounded as described in the shield grounding section page 81 2 Mount RTPs to DIN rail Latch to rail See page 253 Connect cables to RTPs Cables are marked RTP A and RTP B In step 4 RTP A will be ...

Page 265: ...C S D C S D C S D C S D C S D C Install jumper wires RTP A for inputs 1 to 16 D C D C RTP B for inputs 17 to 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 IN17 IN18 IN19 IN20 IN21 IN22 IN23 IN24 IN25 IN26 IN27 IN28 IN29 IN30 IN31 IN32 IN27 IN28 IN29 IN30 IN31 IN32 DC Supply I N 1 7 I N 1 8 I N 2 5 I N 2 6 I N 2 1 I N 2 2 D C I N 1...

Page 266: ...B Position RTP A 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 6 7 8 9 10 20 19 18 17 16 4 5 13 12 11 3 2 1 15 14 J1 J2 J3 J4 J5 1 2 3 4 5 6 7 8 18 17 15 16 9 10 11 14 13 12 18 17 J9 J7 J...

Page 267: ...g 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 8 33 4 Red 34 5 White 9 21 8 Red 26 18 Green 10 27 13 Red 32 3 Blue 6 7 8 9 10 20 19 18 17 16 4 5 13 12 11 3 2 1 15 14 J1 J2 J3 J4 J5 19 20 21 22 23 24 25 26 36 35 33 34 27 28 29 32 31 30 36 35 J9 J7 J8 J6 ...

Page 268: ...e mounting rail with additional screws approx every 8 203mm to prevent twisting of the rail 2 Insert one side of DIN rail at A DIN rail A B C 3 Insert other side of DIN rail at B and push B over the rail to snap into place 4 To remove using slot screwdriver to lift C up gently plastic is fragile to disengage at B Lift up and over rail then disengage at A ...

Page 269: ...Revision 6 HC900 Process Safety Controller User and Installation Manual 255 21 April 2017 Declaration of Conformity ...

Page 270: ...256 HC900 Process Safety Controller User and Installation Manual Revision 6 21 April 2017 ATEX Certification ...

Page 271: ...ty 58 Cold Start 153 COM 1 31 Communications Installation 125 Contact Input Module Wiring 109 Controller access how to access via serial port when port settings are unknown 159 Controller Modes 156 Controller Module 28 Controller Module Diagnostics 174 Controller Name 35 Controller Rack 22 custom graphics 38 D DC Input Module Wiring 101 DC Output Module Wiring 110 Designer Software 31 Diagnostics ...

Page 272: ...188 LED Indications on I O Module 185 LED Indications on Main CPU 173 LED Indications on Scanner Module 181 LED Indicators 180 lithium battery 28 Local Area Network 35 M Master Control Relay 59 Modbus mapping structure 37 MODE switch 159 Mode Transitions 159 Model number compatibility 8 Modem 136 137 138 Module Placement 77 Module Wiring 90 mounting racks 67 N Null Modem Cable 132 O OFFLINE Mode 1...

Page 273: ...acing an I O Module 199 Replacing the Controller Module 197 Replacing the Power Supply 195 Replacing the Scanner Module 198 Reserve Power Supply 24 25 RIUP 82 194 199 Router 35 39 RS 232 131 132 RS 232 Modem 31 RS 232 Port 28 RTD Input Wiring 93 RTD Inputs 90 RTU 37 RUN Mode 156 S SCADA 37 Scanner 2 Module 24 30 Scanner Diagnostics 181 Scanner Module C50 29 scanner rack assembly 73 Serial ports 41...

Page 274: ...r contact one of the offices below ASIA PACIFIC Honeywell Process Solutions TAC hfs tac support honeywell com Australia Honeywell Limited Phone 61 7 3846 1255 FAX 61 7 3840 6481 Toll Free 1300 36 39 36 Toll Free Fax 1300 36 04 70 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Kor...

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