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Honeywell 900U02-0100 User And Installation Manual

Process & safety controller
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ControlEdge HC900
Process & Safety Controller
User and Installation Manual
Doc. No.: 51-52-25-154
Revision: 10
Date: May 2019

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Summary of Contents for Honeywell 900U02-0100

  • Page 1 ControlEdge HC900 Process & Safety Controller User and Installation Manual Doc. No.: 51-52-25-154 Revision: 10 Date: May 2019...

  • Page 2: Notices And Trademarks

    However, we assume no responsibility for its use. While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application.
  • Page 3 About This Document Abstract This document provides descriptions and procedures for the installation, operation and maintenance of the ControlEdge HC900 Controller hardware. References The following list identifies all documents that may be sources of reference for material discussed in this publication.
  • Page 5 Added “Installation in Hazardous location” section. Support and Contact Information For Europe, Asia Pacific, North and South America contact details, refer to the back page of this manual or the appropriate Honeywell Solution Support web site: Honeywell Organization WWW Address (URL) Corporate http://www.honeywell.com...

  • Page 6: Symbol Definitions

    Symbol Definitions The following table lists those symbols that may be used in this document and on the product to denote certain conditions. Symbol Definition This DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
  • Page 7 This page is intentionally left blank. Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 8: Table Of Contents

    Contents Notices and Trademarks ....................ii Symbol Definitions ..........................vi Introduction ..................... 1 1.1. Purpose ............................. 1 1.2. Model Selection Guide ......................2 1.3. Functional Description ....................... 8 1.4. Feature Summary ........................12 Components and Architecture ............... 15 2.1. Overview ..........................15 2.2.
  • Page 9 4.6. Environment..........................55 4.7. Heat Rise De-ratingpage ......................55 4.8. Installation in Hazardous Location ..................55 4.9. Cable/Wiring Distance Planning ....................58 4.10. Electrical Considerations ......................59 4.11. Hardware and wiring requirements for safety configuration ............ 66 4.12. System Monitor Function Blocks ..................... 68 Rack Installation ....................
  • Page 10 Redundant Operating Characteristics ............173 9.1. Overview ..........................173 9.2. Start-Up ..........................173 9.3. Modes of operation (Figure 100) ................... 173 9.4. Steady State Operations ....................... 175 9.5. Failover ..........................177 9.6. File Download/Upload Functions ................... 177 Diagnostics and Troubleshooting ..............179 10.1.
  • Page 11 Tables Table 1 – Descriptions of Major Components (Figure 4) ................ 17 Table 2 – Descriptions of Major Redundancy Components ..............20 Table 3 – Serial port DIP switch settings ....................39 Table 4 – Power Applied, by Module Type ..................... 56 Table 5 –...
  • Page 12 Figures Figure 1 – Small ControlEdge HC900 Controller Configuration .............. 8 Figure 2 – Expanded ControlEdge HC900 Controller Configuration (C50/C70 CPU only) ..... 9 Figure 3 – Single process with redundancies ................... 10 Figure 4 – Configuration with Multiple Controllers ................16 Figure 5 –...
  • Page 13 Figure 49 – Analog Input Wiring - Eight TCs ..................97 Figure 50 – Analog Input Wiring - Eight Resistance Inputs ..............98 Figure 51 – Analog Input Wiring - Eight RTDs ..................99 Figure 52 – Analog Input Wiring – Slidewire (Position Proportion Block) .......... 100 Figure 53 –...
  • Page 14 Figure 100 – Modes of operation on RSM .................... 174 Figure 101 – Lead/Controller synchronization ..................176 Figure 102 – LED Indicators on Controller CPUs (See Table 28)Table 28 – LED Indications on Controller CPUs ..........................180 Figure 103 – LED Indicators on Scanners—1 port (left), 2 port (right) ..........190 Figure 104 –...

  • Page 15: Introduction

    Introduction - Purpose 1. Introduction 1.1. Purpose This publication describes the installation, operation, and maintenance of the Honeywell ControlEdge HC900 Controller. This publication includes the following sections. Chapter Title Page Content Introduction Model numbers, how to verify component compatibility, function description of components, feature summary.

  • Page 16: Model Selection Guide

    Introduction 1.2. Model Selection Guide Legacy System Description Model number SIL Compatible* Racks 900R04 – 0001 4 I/O Slot Rack 900R08 – 0101 8 I/O Slot Rack 900R12 – 0101 12 I/O Slot Rack 900R08R – 0101 8 Slot Rack -Red. Power 900R12R –...
  • Page 17 Introduction Description Model number SIL Compatible* I/O Components 900TEK – 0001 Low VoltageTerminal Block (Euro style) 900TBK – 0001 Low VoltageTerminal Block (Barrier Style) 900TER – 0001 High VoltageTerminal Block (Euro style) 900TBR – 0001 High Voltage Terminal Block (Barrier Style) 900TCK –...
  • Page 18 Introduction *Reference only – For the latest Hardware and firmware revision numbers can be found at: https://www.honeywellprocess.com/library/support/Public/Downloads/ControlEdge HC900- SafetyControllerModulesRevisions.zip Operator Interface Description Model number 900 Control Station 10” Screen 900CS10 – xx 900 Control Station 15” screen 900CS15 – xx 900SDS –...
  • Page 19 Introduction SIL System Description Model Number SIL Compatible* Racks 900R04 – 0200 4 I/O Slot Rack 900R08 – 0200 8 I/O Slot Rack 900R12 – 0200 12 I/O Slot Rack 900R08R – 0200 8 Slot Rack -Red. Power 900R12R – 0200 12 Slot Rack - Red.
  • Page 20 Introduction Pulse/Freq/Quad (4chan, 1Quad) 900K01-0201 Can be used in Safety systems on the Process Worksheet ONLY. Safety Universal Input/ Output 900U02-0100 Low VoltageTerminal Block (Euro style) 900TEK-0200 Low VoltageTerminal Block (Barrier style) 900TBK-0200 High VoltageTerminal Block (Euro style) 900TER-0200 High VoltageTerminal Block (Barrier style)
  • Page 21 Introduction Scanner module.  New System (SIL and Non SIL Model Numbers)*  900C30-0460  900C50-0460  900C70-0460  900C75-0460  900S75-0460  900S50-0460  900C30S - 0460  900C50S - 0460  900C70S - 0460  900C75S-0460  900S50S - 0460 ...

  • Page 22: Functional Description

    Functional Description All Controllers The Honeywell ControlEdge HC900 Controller is an integrated loop and logic controller that is designed specifically for small-and medium-scale unit operations It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range of process control applications.

  • Page 23: Figure 2 - Expanded Controledge Hc900 Controller Configuration (C50/C70 Cpu Only)

    As indicated in Figure 3, the ControlEdge HC900 Controller includes provisions for communication via Ethernet with host systems such as the Honeywell Experion HMI and other HMI software that supports Ethernet Modbus/TCP protocol. Also, the communication structure of the ControlEdge HC900 Controller enables remote placement of input/output components, allowing significant economies in cabling and wiring.

  • Page 24: Figure 3 - Single Process With Redundancies

    Introduction Redundancy Figure 3 – Single process with redundancies ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...
  • Page 25 Introduction  Redundant CPUs - Redundancy is provided by two C75 CPUs operating in a controller rack; this rack has no I/O. A Redundancy switch module (RSM) sits between the CPUs.  Redundant CPU Power - Two power supplies, P01 one for each C75 CPU. Model numbers are 900P01-0301 and 900P01-0401.

  • Page 26: Feature Summary

    Introduction 1.4. Feature Summary Hardware  Modular rack structure; components are ordered individually as needed  CPU with Ethernet and isolated RS485 communications  Easy to assemble, modify, and expand  C30 and C30S controllers provide local I/O connections while C50/C70 and C50S/C70S Controllers provide for remote input/output rack connections over a private Ethernet-linked network ...
  • Page 27 Introduction  Ethernet 10/100 Base-T connection:  Port(s) configured to Auto Negotiate - default to half duplex  C30/C30S controller up to 5 PC hosts via Modbus/TCP protocol. C50/C50S, C70/C70S and C70R Legacy and C75/C75S (new model) support up to 10 PC hosts via Modbus/TCP protocol.

  • Page 29: Components And Architecture

    2.2. Components The Honeywell ControlEdge HC900 Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications. Some of the modules are required in all configurations. Others are optional; they are selected as appropriate to provide optional functions and/or to "size"...

  • Page 30: Figure 4 - Configuration With Multiple Controllers

    Figure 4 – Configuration with Multiple Controllers The ControlEdge HC900-expansion I/O link is a private network and the switch used for the interconnection of the ControlEdge HC900 Processor and Scanners must not be connected to any other LAN or WAN. Likewise, no devices other than the ControlEdge HC900 components should be connected to the I/O link Switch.

  • Page 31: Table 1 - Descriptions Of Major Components (Figure 4)

    USB converter is a third from the galvanically isolated RS-485 port of the party device available Controller Module using an external Honeywell from Honeywell. qualified RS-485 to USB converter. (Optional) PC link to Ethernet network, which may HMI (Human-...

  • Page 32: Redundant Components

    2.3. Redundant components Figure 5 – Redundant Configuration with multiple I/O racks (Star topology) ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 33: Figure 6 Redundant Configuration With Multiple I/O Racks (Ring Topology)

    Figure 6 Redundant Configuration with multiple I/O racks (Ring topology) The ControlEdge HC900-expansion I/O link is a private network and the switch used for the interconnection of the ControlEdge HC900 Processor and Scanners must not be connected to any other LAN or WAN.

  • Page 34: Table 2 - Descriptions Of Major Redundancy Components

    RS-485 party device available port of the Controller Module using an external from Honeywell. Honeywell qualified RS-485 to USB converter. HMI (Human- (Optional) PC link to Ethernet network, which may PC is from third-party Machine include other HMIs, other ControlEdge HC900 supplier.

  • Page 35: Hardware Components

    If the host device does not have the inherent capability to recognize a network failover, the Honeywell HWIOPC Server would be used to perform this functionality. The dual Ethernet ports will not operate in a redundant configuration through a gateway to a Host / server on another subnet.

  • Page 36: Figure 8 - Redundant Controller Rack Components

    ControlEdge HC900 Redundant Controller Rack A ControlEdge HC900 Redundant Controller is shown in the following figure. Rack Redundancy Switch Module (RSM) . Interface between Lead/Reserve controllers. Lead/Reserve controllers. Two C75 CPUs, designated “CPU-A” (left), “CPU-B” (right). Two 900P01-xxxx Power Supplies. Figure 8 –...

  • Page 37: Figure 9 - I/O Expansion Rack Components

    I/O Expansion Rack I/O expansion ("remote") racks, shown in Figure 9, are available to accommodate additional input/output modules, and/or to enable location of I/O modules close to the process and remote from the controller. For C75/C75S, all I/O is in a rack or racks separate from the controller rack. Scanner type must match controller type.

  • Page 38: Figure 10 - Rack Options

    Rack Options Racks are available in 4-slot, 8-slot, and 12-Slot versions. Racks are interchangeable between the Controller rack and an I/O expansion rack, and all three versions shown in the following figure are available for either purpose. 8 and 12 slot I/O racks can be modified with additional slots for optional Reserve Power Supply and Power Status Module.

  • Page 39: Figure 11 - Power Supply

    Power Supply The P01 Power Supply, shown in Figure 10, provides 5 Vdc and 24 Vdc to the backplane connectors in the local and remote racks. Power Supply is used in each Controller Rack, I/O expansion racks and for all rack versions (4-slot, 8-slot, and 12-Slot).

  • Page 40: Figure 12 - Power Status Module (Psm)

    Power Status Module (PSM) The Power Status Module (PSM) (Figure 12) sits between redundant power supplies on the I/O rack (see page 24). It is a status module for both power supplies and indicates which are in use, PS-1 (left) or PS-2 (right) or both (typical).

  • Page 41: Figure 13 - Controller Module

    Controller Module C30 and C30S, C50 and C50S, C70 and C70S, C75 and C75S Controllers share the same features, with exceptions noted. CPU model number (C30 and C30S, C50 and C50S , C70 and C70S, C75 and C75S). Lithium battery (battery tray), which is readily accessible for field replacement. Battery tray on Controllers C30/C30S, C50/C50S, C70/C70S, and C75/C75S.

  • Page 42: Figure 14 - Redundancy Switch Module

    Redundancy Switch Module (C75/C75S only) The Redundancy Switch Module (RSM) is shown in Figure 14. It sits between C75/C75S controllers in the redundant controller rack. Left Controller is designated “CPU-A”; right Controller is “CPU-B.” Features include: Lead/Reserve controller status indicators. Keyed switch for manual changes to controller modes or to facilitate a Manual Fail Over.

  • Page 43: Figure 16 - Scanner 2 Module

    Scanner 2 Module (S75/S75S only) 900S75, Scanner 2 Module is shown in Figure 16 The dual ports provide redundancy through the 2 CPUs. Features at the front of the module include: LED status/diagnostic indicator for scanner functions. I/O port A. Private Ethernet 10/100 Base-T Port. Connects directly to I/O port on CPU-A (or indirectly through a switch).

  • Page 44: Figure 18 - Rs-232 Modem Devices

    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 Network port.

  • Page 45: I/O Network

    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 series between a CPU and its scanners.

  • Page 46: I/O Implementation Requirements Include

    Placing the appropriate module type in each slot in each rack. The I/O expansion network uses Honeywell private protocol that optimizes I/O performance and security. The configuration and operation of the I/O expansion network is automatic, it is entirely under control of built-in private software that resides in the Controller Module and in each Scanner Module included in the ControlEdge HC900 system.
  • Page 47 Redundant Networks Honeywell Matrikon OPC Server supports redundant networks. Up to 10 connections may be distributed in any combination across the controller’s 2 network ports (E1 and E2). PC hosts may include, for example, HMI supervisory software and/or Designer Software configuration software. Redundant ports may be used in a simplex mode (non-redundant).

  • Page 48: Figure 20 - Modular Network Structure

    Figure 20 – Modular Network Structure Connection to PC Hosts For legacy systems, connection to PC hosts (for example, PCs that include HMI supervisory software and/or Designer Software configuration software) can be via Modbus/TCP as well as serial Modbus RTU over either the RS-485 or RS-232 communications ports.

  • Page 49: Figure 21 - Modbus/Tcp Framing

    The ControlEdge HC900 Controller uses either Modbus/TCP or Modbus RTU, not ASCII. The “fixed” Modbus mapping structure for the ControlEdge HC900 Controller is based on the mapping structure employed in Honeywell’s UMC800 Controller, and the function codes and methods for parameter access are also virtually identical. Modbus Maps In your controller’s configuration, certain parameters are each automatically assigned a Modbus address.
  • Page 50 OPC server/client software (various; available from Kepware and others)  : The items in this list are not sold by Honeywell. They have not all been tested and Note certified by Honeywell, and are not necessarily recommended or endorsed by Honeywell for any specific use.

  • Page 51: Figure 22 - Typical Installation Using A Cable Modem

     Using the Designer Software to configure:  Alarm Groups and Event Groups  Assignment of specific alarms to priority and e-mail enabling  E-Mail address lists  SMTP mail server IP address  Default gateway must be configured in order to send e-mail. With redundant controllers, two default gateways need to be configured;...

  • Page 52: Serial Ports

    Third party Operator Interface  Controller can be master to slaves such as  Any Honeywell Modbus device (e.g., recorders, controllers, flame safety)  Any non-Honeywell Modbus device. Only one master port at a time; can’t have both serial ports as master ports.

  • Page 53: Table 3 - Serial Port Dip Switch Settings

    Setting serial ports S1 and S2 to RS-232 or galvanically isolated RS-485 For legacy systems, S1serial port default setting is RS-232; S2 serial port default setting is RS-485. Each port can be set to RS-232 or RS-485 (not shown). For new systems, the serial ports S1 and S2 are galvanically isolated RS-485 unterminated (See Table 3 below).

  • Page 54: Network And Security Planning

    3. Network and Security Planning 3.1. Overview This document contains networking and security-related information applicable to ControlEdge HC900 process & safety controller. It provides information about the recommendations to assist you in planning, setting up, and maintaining a secure environment for your system Assumptions and prerequisites This guide is primarily intended for engineers, system administrators, and other technical staff who are responsible for planning the configuration and maintenance of a ControlEdge HC900 system.
  • Page 55 Unauthorized external access This threat includes intrusion into the process control system from the business network and possibly an intranet or the Internet. Unauthorized external access can result in the following:  Loss of system availability  Incorrect execution of controls causing damage to the plant, or theft or contamination of product ...

  • Page 56: Backup And Restore

    Protecting ControlEdge HC900 system components This section lists the steps you can take towards securing your ControlEdge HC900 system. PC installed with HC Designer Protection measure  Take steps to implement and enforce physical security.  Enable the worksheet protection and enforce a strong password policy. ...

  • Page 57: Physical And Environmental Considerations

    3.4. Physical and Environmental Considerations The physical security of a process control network is particularly important. If the hardware is rendered inoperable, the entire system (and hence the plant) is rendered inoperable. Protecting against unauthorized system access External media drives can enable anyone to bypass Windows security and gain access to your system. If there is an easy access to a computer, and it has a floppy disk or CD drive, it can be booted from an alternative operating system.

  • Page 58: Security Updates

    Microsoft releases a range of security updates and other operating system and software updates. Note that only Honeywell-qualified Microsoft updates are supported. Therefore, you must wait until Honeywell has validated Microsoft updates before installing them. It is also recommended that you implement a controlled system for the distribution of all updates.

  • Page 59: Figure 25: System Architecture

    Figure 25: System architecture Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 60 At level 1 network, ControlEdge HC900 controller and Scanners connect to one switch, and it is the most critical network in the system as a failure or loss of service on this network can result in loss of control. At level 2 network, Engineering Workstation, third party devices, HMI, and SCADA connect to the switched of this level.

  • Page 61: Figure 26: System With Safety Peer Communication

    Recommended network topology with safety peer communication In the ControlEdge HC900 system where safety peer communication is required, it is recommended to have separate peer communication network and add port filtering of peer protocol (UDP port 502) on host communication switch. This ensures that the safety peer communication network is separate from the host network communication.

  • Page 62: Controledge Hc900 Security Features

    Communication from Remote location It is not recommended to connect a ControlEdge HC900 controller installed in a remote location to the public network. The communication to ControlEdge HC900 controller installed in a remote location is recommended to be on a private leased line or secured by setting up VPN device external to the ControlEdge HC900.

  • Page 63: Notices

    Submit the requested information to Honeywell using one of the following methods: • Send an email to security@honeywell.com. • Contact your local Honeywell Technical Assistance Center (TAC) listed in the “Support” section of this document. Support For support, contact your local Honeywell Process Solutions Customer Contact Center (CCC). To find your local CCC visit the website, https://honeywellprocess.com/en-US/contact-us/customer-support-...

  • Page 64: Pre-Installation Planning

    4. Pre-Installation Planning 4.1. Overview Methodical pre-planning of an installation will preclude false starts and errors that can cause costly hardware re-configuration and/or poor system performance. Factors to consider in your pre-installation planning include:  C75 CPU requires 900P01 power supplies, C70R CPU requires 900P02 power supplies. ...
  • Page 65 Enter Calculate 5V current Calculate 24V current Current @ Current @ Module type Quantity 24 V ( D = A * B ) ( E = A * C ) 820 mA 0 mA legacy. 1100 mA Controller (C30 and C30S) New.

  • Page 66: Dc Power Supply

    Complete columns A, D and E above. 1. Is column D total 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-xxxx. 4.

  • Page 67: Figure 29 - Rack Dimensions With Reserve Power Supply

    Figure 29 – Rack Dimensions with reserve power supply Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 68: Figure 30 - Vertical Spacing Of Racks (All Models)

    Figure 30 – Vertical Spacing of Racks (all models) ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 69: Remote Termination Panels

    Controller rack, I/O Racks, and the 900CS Control Station manufactured by Honeywell must be mounted in approved furniture designed for industrial applications. Consideration should be given to the installation so that the potential for the build-up of static electricity is minimized or eliminated.

  • Page 70: Installation In Hazardous Location

    1. Control Edge HC900 devices are for rack mounting in a suitable protective enclosure, in accordance with the Honeywell’s instruction, subject to acceptance by the local authority having jurisdiction. 2. All the HC900 Models mentioned are Equipment Class I, Pollution Degree 2, Installation Category II, Continuous operation.

  • Page 71: Table 4 - Power Applied, By Module Type

    Table 4 – Power Applied, by Module Type Module ControlEdge Field Power Total Power HC900 Hardware (Watts) (Watts) Power (Watts) Controller C30 and C30S Controller C50 and C50S Controller C70 and C70S Controller C75 and C75S Redundancy switch module (RSM) Power Status Module (PSM) Scanner 1 Port (S50/S50S) Scanner 2 Port (S75/S75S)

  • Page 72: Figure 31 - Ac Input Module De-Rating

    Figure 31 – AC Input Module de-Rating Figure 32 – Power Supply de-Rating ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 73: Cable/Wiring Distance Planning

     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. Maximum of 2 switches between each CPU’s I/O port and all I/O racks.

  • Page 74: Electrical Considerations

    Straight-through cable assembly Cable left end 10Base-T / 100Base-T Cable right end Signal Description Left to right Left to right Wire color/pin number Wire color/pin number white/orange/1 Tx + white/orange/1 Orange/2 Tx - Orange/2 white/green/3 Rx + white/green/3 Blue/4 Unused Blue/4 white/blue/5 Unused...

  • Page 75: Figure 33 - Cabinet Wiring, Single Chassis

    Figure 33 – Cabinet Wiring, Single Chassis Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 76: Figure 34 - Cabinet Wiring, Multiple Chassis

    Figure 34 – Cabinet Wiring, Multiple Chassis ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 77: Figure 35 - Redundant Power Supplies Each With External Fuse And Switch

    For P01 power supply use 3.0A, slow-blow for 115VAC operation; 2.5A, slow-blow for 230VAC operation. For P02 power supply, use 2.5A, slow-blow for 115VAC operation; 2.0A, slow-blow for 230VAC operation. For P24 power supply use 7.0A slow-blow. Figure 35 – Redundant power supplies each with external fuse and switch Revision 10 ControlEdge HC900 Process &...

  • Page 78: Table 5 - Guidelines For Grouping Wires

    CE Conformity Electrical noise produces undesirable effects in measurements and control circuits. Digital equipment is especially sensitive to the effects of electrical noise. You should use the following methods to reduce these effects:  Supplementary bonding of the controller enclosure to a local ground, using a No. 12 (4 mm copper conductor, is recommended.
  • Page 79 Master Control Relay A Master Control Relay (MCR) structure is a safety mechanism for shutting down the process control system in emergency conditions. This mechanism, which is hard-wired (provided and installed by the User) can include several Emergency Stop switches., strategically located near process equipment. An example of an MCR structure is given in Figure 36.

  • Page 80: Figure 36 - Master Control Relay Wiring Example

    Figure 36 – Master Control Relay Wiring Example ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 81: Hardware And Wiring Requirements For Safety Configuration

    4.11. Hardware and wiring requirements for safety configuration For the function blocks for safety a special hardware configuration and wiring is required. Below high level diagram explains the wiring concept for using the validation function blocks. Figure 37 - IO-V function block connections Figure 38, Figure 39, and Figure 40 demonstrate the connection of a series output relay’s normally OPEN contact to protect against outputs that are stuck “ON”.

  • Page 82: Figure 38 - Individual Series Do Connections

    +24VDC +24VDC Sourcing 110/220 DO-32 Relay Output 900H32 900H01 Relay Output 900H01 DI-16 900G02 Relay Output DI-16 OR DI-32 Relay Output 900H01 900G02 900G32 900H01 DO-8 OR DI-32 900H03 900G32 DI-16 900G03 900G04 9.5 V >= VALID HIGH <= 32.0 V 0.0 V >= VALID LOW <= 3.5 V +24VDC +24VDC...

  • Page 83: System Monitor Function Blocks

    Figure 40 – Series Relay for Analog Outputs 4.12. System Monitor Function Blocks The ControlEdge 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: ...

  • Page 84: Rack Installation

    5. Rack Installation 5.1. Overview This section contains procedures for installing one or more ControlEdge HC900 Controllers. It is recommended that the information in this section be reviewed before beginning the installation. Familiarity with the overall procedure will help to prevent errors and will promote efficiency in general. ABS installations require additional protection from the environment and must be installed in a grounded metal enclosure.

  • Page 85: Table 7 - Site And Equipment Preparation

    Equipment Preparation A checklist for site preparation is given in Table 7. Table 7 – Site and Equipment Preparation Step Procedure Reference Verify that sufficient numbers of the following items  Section on Pre-Installation are on hand: Planning.  Racks (4-, 8- and 12-slot) ...
  • Page 86 Step Procedure Reference Install (or verify correct installation of) enclosures for Mount Racks ControlEdge HC900 Controllers and ancillary Table 8 – Mount Rack equipment:  Mounting rails or flat-panels  (for cabinet with multiple ControlEdge HC900 Chassis):  grounding bus ...

  • Page 87: Mount Racks

    5.2. Mount Racks Rack assembly information is given in Table 8. Table 8 – Mount Racks Step Procedure Comments/References Mount the Rack in the For dimensions of the pattern for drilling holes, refer to the enclosure as follows. diagram below. ...
  • Page 88 Step Procedure Comments/References Aluminum grounding bars for I/O module wiring are optional. They can be mounted at top, at bottom, or at top and bottom of the rack, as indicated at right. If grounding bars are included, attach them with two M3 screws (supplied with grounding bars in plastic bag).

  • Page 89: Assemble Controller Rack

    5.3. Assemble Controller Rack C30/C50/C70 Controller Rack assembly information is given in Table 9. C75 Controller Rack assembly information is given in Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 90: Table 9 - Assemble C30/C50/C70 Controller Rack

    Table 10. Table 9 – Assemble C30/C50/C70 Controller Rack Step Procedure Comments/References Carefully place the Power Supply in the leftmost slot in the Rack, ensuring that the connector at the back seats properly. Insert a slot screwdriver in the slots at the top and bottom of the power supply cover while pulling backward to open the cover.
  • Page 91 Step Procedure Comments/References Ensure that wiring to the Power Supply is ATTENTION! disconnected from the site source, and then connect AC Do not connect PE Ground (Green) Wire wiring to the power supply as directly to terminal on Power Supply. shown at right.
  • Page 92 Step Procedure Comments/References Ensure that AC power to the rack is disconnected. Set controller module’s communication ports to desired settings (page 38). Carefully place the Controller Module in the rack, immediately to the right of the Power Supply. Fasten it in place with two captured screws at top and bottom.

  • Page 93: Table 10 - Assemble C75 Controller Rack

    Table 10 – Assemble C75 Controller Rack Step Procedure Comments/References Carefully place the Power Supplies in the slots in the Rack, ensuring that the connector at the back seats properly. See Table 9 steps 1 and 2 for power supply wiring details.

  • Page 94: Assemble I/O Expansion Racks

    5.4. Assemble I/O Expansion Racks I/O Expansion Rack assembly information is given in Table 11. Table 11 – Assemble I/O Expansion Racks Step Procedure Comments/References Insert power supply into left-most slot If using redundant power, your I/O rack will contain a second in the I/O rack.
  • Page 95 Step Procedure Comments/References Set scanner address for the I/O rack using the Scanner Module DIP switches on SW3 (shown at right). For C50/C70, use addresses 1-11. For C75, use addresses 1-12. Scheme 1 (upto 5 racks): DIP switches 6-8 must be OFF. Only one DIP switch may be ON: DIP switch 1 ON = Scanner 1 DIP switch 2 ON = Scanner 2...

  • Page 96: I/O Module Installation And Wiring

    6. I/O Module Installation and Wiring 6.1. Overview This section contains descriptions of and procedures for installing I/O Modules in controller racks (C30/C30S, C50/C50S, C70/C70S, models) and in I/O expansion racks (S50/S50S, S75/S75S only). 6.2. Module Placement in Racks Each input or output module is placed in an I/O slot in a rack as shown in Figure 41. Each “slot”...

  • Page 97: Figure 42 - Terminal Block Styles

    Terminal Block Styles The terminal block is available in the barrier style, shown at left in Figure 42, and the Euro style, shown at right. Not shown: A Euro style with 36 connections is also available for certain high capacity modules. Terminal blocks have an embossed numbering “key”...

  • Page 98: Remote Termination Panel (Rtp)

    6.3. Remote Termination Panel (RTP) The optional Remote Termination Panel (RTP) provides an easy way to connect the ControlEdge HC900 controller to the field wiring. The RTP integrates some of the typical externally connected components, reducing wiring and setup time. It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I/O modules.

  • Page 99: Figure 43 - Signal-Wire Grounding

    Signal Grounding The shield for each input should be grounded at the grounding bar (optional) at the top or bottom of each rack as indicated in Figure 44. For low- frequency noise rejection, I/O wiring shields should be grounded only at the controller end. For high-frequency noise rejection, shields should be grounded at the controller and at the field device.

  • Page 100: Figure 45 - Terminal Block Jumper Installation

    Terminal Block Jumper Combs Two styles of terminal block jumper combs are available for use with the barrier-style terminal blocks: ten-position and two position, see Figure 45. The ten-position jumpers are used with AC output modules to inter-connect L1 (AC Hot) of all channels. The two-position jumpers are used to connect Common (DC negative or AC neutral) for the DC input module, the DC Output Module, and the AC...

  • Page 101: Removal And Insertion Under Power (Riup)

    6.5. Removal and Insertion Under Power (RIUP) Read and understand all of the following information regarding RIUP before attempting to remove and/or replace any I/O module, particularly in a system that is actively controlling a process. In legacy systems, all of the I/O Module types in the ControlEdge HC900 Controller System include the Removal and Insertion Under Power (RIUP) feature.

  • Page 102: I/O Module Installation Procedures

    6.6. I/O Module Installation Procedures Table 14 – Connect Input/Output Wiring Step Procedure Comments Reference Using Rack #, Slot #, Channel # data from 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.
  • Page 103 Step Procedure Comments Reference (Optional): Install jumper combs into designated Barrier style Terminal Blocks, to reduce the wiring required to supply power: Two-position jumper for the DC Input Module and/or on the DC Output Module. Ten-position jumper for the AC Output Module. Five-position jumper (10- position jumper cut in half) for a Relay Output...
  • Page 104 Step Procedure Comments Reference NOTE: In the diagram below, the white cut-outs represent the cut-outs on the modules that cont accommodate tabs on the Terminal Block. That is, all key-tabs that line up with the white cut- ’d 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.
  • Page 105 Step Procedure Comments Reference If installing High Level 16 channel Analog Input module, set its SW1 and SW2 DIP switches to ON. This connects an internal 250 ohm resistor. A small slotted screwdriver or paperclip works well; avoid using pencils. If installing 8- or 16-channel Analog Output module, set its DIP switch as follows.
  • Page 106 Step Procedure Comments Reference If installing a PFQ module, set its Input 1, Input 2 and Index DIP switches to differential or single ended mode. Inputs mode need not match index mode. See below for switch positions. Switch location on PFQ module: Settings (using Input 1 as example) Single ended (factory setting): 1 and 2 (SINGLE) = ON, 3 and 4 (DIFF) = OFF...
  • Page 107 Step Procedure Comments Reference 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 Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 108 Step Procedure Comments Reference Install I/O modules in racks. Be sure to follow placement guidelines under Heat Rise De-rating page 55. Install I/O module, install appropriate terminal block. Note: The Filler Block Cover looks much like an I/O Terminal In each slot location not occupied by an I/O Block assembly, except that it does not include the wire module, install a Filler...

  • Page 109: I/O Terminal Block Wiring Diagrams

    6.7. I/O Terminal Block Wiring Diagrams Universal Analog Input Module Wiring The Universal Analog Input Module has eight inputs, which can include any combination of the following input types: RTD, TC, Ohms, Millivolt, Volt, or Milliamp. Figure 47 shows wiring examples of each of the analog input types.

  • Page 110: Figure 46 - Rtd Inputs

    Figure 46 to Figure 50 show examples of RTD input wiring (2-wire and 3-wire RTDs). Four-wire RTD inputs are not available. Figure 46 – RTD Inputs OHMs Inputs Ohms inputs are wired similar to 2-wire RTD inputs. That is, they require a current source, and thus must use one of the I current sources.

  • Page 111: Figure 47 - Universal Analog Input Wiring Diagram

    Failure to comply with these instructions could result in death or serious injury. Figure 47 – Universal Analog Input Wiring Diagram Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 112: Figure 48 - Examples Of Rtd Input Wiring

    Figure 48 – Examples of RTD Input Wiring ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 113: Figure 49 - Analog Input Wiring - Eight Tcs

    Figure 49 – Analog Input Wiring - Eight TCs Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 114: Figure 50 - Analog Input Wiring - Eight Resistance Inputs

    Figure 50 – Analog Input Wiring - Eight Resistance Inputs ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 115: Figure 51 - Analog Input Wiring - Eight Rtds

    Resistance Temperature Device Inputs Figure 51 – Analog Input Wiring - Eight RTDs Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 116: Figure 52 - Analog Input Wiring - Slidewire (Position Proportion Block)

    Slidewires Figure 52 – Analog Input Wiring – Slidewire (Position Proportion Block) ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 117: Figure 53 - 16 Point High Level Analog Input Wiring

    16 point High Level Analog Input Wiring (Figure 53) Be sure to set the module DIP switches for voltage or current mode. See page 89. This requires Low Voltage Euro style 36-terminal terminal block. Note: Unused input channel shall not be left open for 900A16-0102 IO module Figure 53 –...

  • Page 118: Figure 54 - 4 Channel Analog Output Wiring Diagram

    4 channel Analog Output Module Wiring An example of Analog Output Module wiring is shown in Figure 54. 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 ControlEdge HC900 Process & Safety Controller Safety Manual for additional details.

  • Page 119: Figure 55 - 8 Channel Analog Output Wiring Diagram

    8 and 16 channel Analog Output Module Wiring Hazardous voltages exist at terminal blocks. AO8 and AO16 modules require at least one channel to be configured prior 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.

  • Page 120: Figure 56 - 16 Channel Analog Output Wiring Diagram

    OUT 1+ OUT 2+ OUT 1 - OUT 2- OUT 3+ OUT 4+ OUT 3- OUT 4- OUT 5+ OUT 6+ OUT 5- OUT 6- OUT 7+ OUT 8+ OUT 7- OUT 8- OUT 9+ OUT 10+ OUT 9- OUT 10- OUT 11+ OUT 12+ OUT 11-...

  • Page 121: Figure 57 - Dc Input Module Wiring Diagram

    DC Input Module Wiring The DC Input Module has sixteen inputs, in two groups of eight inputs per group. The groups are isolated from each other; inputs are non-isolated within each group. An example of Digital Input Module wiring is shown in Figure 57. Specifications for this module and for other modules are given in the Specifications manual.

  • Page 122: Figure 58 - Dc Input Module Jumper

    Figure 58 – DC Input Module Jumper ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 123: Figure 59 - 32 Point Dc Input Module Wiring

    32 point DC Input Module Wiring The 32-point DC Digital Input module (Figure 59) provides two groups of 16 inputs, each with a pair of terminals for connection to common. DC power applied between the common terminal and an input cause the input to turn ON.

  • Page 124: Figure 60 - Ac Input Module Wiring Diagram

    AC Input Module Wiring The AC Input Module has sixteen inputs. An example of AC Input Module wiring is shown in Figure 60. Specifications for this module and for other modules are given in the Specifications section of this manual. Common Terminals Two common terminals are provided for each group of eight inputs.

  • Page 125: Figure 61 - Ac Input Module Jumper

    Figure 61 – AC Input Module Jumper Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 126: Figure 62 - Ac/Dc Isolated Input Module

    AC/DC Isolated Input Module Wiring The AC/DC Input Module has sixteen isolated inputs. An example of AC Input and DC input Module wiring is shown in Figure 62 and Figure 63. Specifications for this module and for other modules are given in the Specifications manual.

  • Page 127: Figure 63 - Ac/Dc Isolated Input Module Wiring

    IN 1 IN 1 IN 2 IN 2 IN 1 IN 1 IN 2 IN 2 IN 3 IN 3 IN 4 IN 4 IN 3 IN 3 IN 4 IN 4 IN 5 IN 5 120/240Vac 120/240Vac IN 6 IN 6 IN 5 IN 5...

  • Page 128: Figure 64 - Contact Input Wiring Diagram

    Contact Input Module Wiring The Contact Input Module has sixteen inputs in one group. An example of Contact Input wiring is shown in Figure 64. SIL applications require an external blocking diode used to insure inputs are protected from ground faults. See ControlEdge HC900 Process & Safety Controller Safety Manual for additional details. Specifications for the Contact Input Module and other modules are given in the Specifications manual.
  • Page 129 DC Output Module Wiring The DC Output Module provides 16 current-sinking outputs in two groups of eight points per group. The two groups are isolated from each other; outputs are non-isolated within each group. Current sinking means that a positive voltage potential is continuously applied to one side of each DC output load, and the negative side of the load is switched internally in the module.

  • Page 130: Figure 65 - Dc Output Module Wiring Diagram

    Figure 65 – DC Output Module Wiring Diagram Figure 66 – DC Output Jumpers ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 131: Figure 67 - 32 Point Dc Output Module Wiring

    32 point DC Output Wiring The DC digital Output module provides 32 externally powered outputs in 2 groups of 16 (Figure 67). The outputs are high side switching (current sourcing) type. Over-current protection is provided for each channel, in 4 groups of 8 channels. In case of short circuit for any output channel, that whole group of 8 is switched off.
  • Page 132 AC Output Module Wiring The AC Output Module provides eight output circuits. Each output is isolated from the other outputs. An example of AC output wiring is shown in Figure 68. 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.

  • Page 133: Figure 68 - Ac Output Module Wiring Diagram

    Figure 68 – AC Output Module Wiring Diagram Figure 69 – AC Output Module Jumper Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 134: Figure 70 - Schematic Example: Relay Output And External Wiring

    Relay Output Module Wiring The Relay Output Module provides eight individually isolated, electromechanical relay outputs. Four of the outputs are Form-C, and the other four are Form-A. A schematic showing the relationship of individual Form-A relays and Form-C relays to external (user) connections is given in Figure 70. SIL applications require an external series relay used to ensure outputs achieve failsafe action.

  • Page 135: Figure 71 - Relay Output Module Wiring Diagram

    Note: specified relay life is 1,000,000 cycles. For applications requiring constant cycling of output, Honeywell recommends using a solid-state AC or DC output module. Required Output Fusing Outputs are not fused in the Relay module. Install a fuse for each output at the field device that is appropriate for the load and the wire used.

  • Page 136: Figure 72 - Relay Output Module Jumpers

    Figure 72 – Relay Output Module Jumpers ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 137: Figure 73 - Pulse Counting Wiring

    Pulse/Frequency/Quadrature Module Wiring (Figure 73 through Figure 79) The 4 Channel Pulse/Frequency/Quadrature Module provides four different functionalities in the form of Pulse Input, Frequency measurement, Quadrature encoder input and Pulse Output. Each of the 4 channels can be configured for any one of these four functionalities; with the exception that quadrature encoder input (A and B pulses) can be applied to only Channels 1 and 2 respectively.

  • Page 138: Figure 74 - Pulse Output Wiring

    Figure 74 – Pulse Output Wiring Figure 75 – Frequency Wiring ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 139: Figure 76 - Quadrature, Differential, External Power Wiring

    Figure 76 – Quadrature, Differential, External Power Wiring Figure 77 – Quadrature, Single Ended, External Power Wiring Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 140: Figure 78 - Quadrature, Differential, Controledge Hc900 Power Wiring

    Figure 78 – Quadrature, Differential, ControlEdge HC900 Power Wiring Figure 79 – Quadrature, Single Ended, ControlEdge HC900 Power Wiring ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 141: Figure 80: Safety Uio With Power Wiring

    Safety Universal Input/ Output (16 Pts) Module Wiring It is 16 Channel safety universal I/O module, and each channel can be configured for AI, DI and DO. AO type can configured for channel 9 to 16. The channels on Safety UIO are source type. UIO Terminal Block Connections Ch 1 +...
  • Page 142 In Figure 80, each power supply source supplies power to the whole module. If redundant power supply is provided, the UIO module still can work in case of failure on one power source. At least one power supply is required, otherwise UIO module cannot work and "External power" error is reported.

  • Page 143: Table 16 - Ai Channel

    NAMUR devices • Devices that supply current, which is not first supplied by the external 24 V to the device. For example, a device that creates current (even if referenced to Honeywell ground). Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual...

  • Page 144: Figure 81 - Standard 2 Wire Transmitter With Uio

    Standard 2-wire transmitter with UIO Figure 81 - Standard 2 Wire Transmitter with UIO ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 145: Figure 82 - Self-Powered 3-Wire Transmitter With System Ground

    Self-powered 3-wire transmitter with Sink Type Input This can be applied to any channels from 1 through 16. The UIO cahannel will be connected to Sink type transmitter +Ve terminal. The below figure shows the simple wiring diagram for connecting UIO to 3-wire transmitter. The device must reference its 'DCS-side' common to ControlEdge 900 common.
  • Page 146 Self-powered 4-wire transmitter sinking type transmitter with UIO This wiring method can be applied to any of the channels 1 through 16. Figure 83 - Self-powered 4-wire sinking type transmitter with UIO UIO does not support the following input types: ...

  • Page 147: Table 17 - Field Wiring For Analog Output

    Field wiring for Analog Output The UIO can drive 4-20mA. See the following table for AO specification: Table 17 - Field wiring for analog output Parameter Specification Output Type 4-20 mA current loop Output Channels 8 Maximum per module (with line monitoring) Assignable to channels 9 to 16 Output Ripple =<...
  • Page 148 Figure 84 - Field wiring for analog output Field wiring for Digital Input (Dry Contact) A UIO channel configured as a Digital Input. See the following table for DI specification: Parameter Specification Open Voltage Short Circuit Current 7 mA 15 kΩ > 0.1 W Open Contact 5 kΩ...
  • Page 149 See the following wiring diagram of the UIO channel configuration. Figure 85 - UIO channel configuration Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 150 Ω When the DI channel is configured with open wire detection (OWD), a 15k shunt resistor required in the field near the switch contact as displayed in the following figure. A 15K shunt resistor and a 7.5K series resistor are required closed to the contact in field side. Refer to the following block diagram of this channel configuration, and a field wiring example.
  • Page 151 Figure 86: Safety UIO_DO channel configuration Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 153: Overview

    I/O Module Installation and Wiring - Overview 7. Communications Installation 7.1. Overview This section contains descriptions, procedures and recommendations for installing communications systems and components. 7.2. Wiring and cabling Table 18 – Connect Communications Wiring and Cabling Step Procedure Comments/Reference Determine requirements for communications links.

  • Page 154: Table 19 - Links To Controller Communication Ports

    Step Procedure Comments/Reference Set IP addresses and Default IP addresses: subnet masks. C30/C50: 192.168.1.254 and Subnet Mask of 255.255.255.0. C70/C75: E1: 192.168.1.254, E2: 192.168.2.254. Must be on different subnets. Links to controller communication ports Refer to Table 19 and the figure in Step 2 above. Port availability depends on Controller model. Table 19 –...
  • Page 155 E110/100 Base-T Host, Peer, and Shielded CAT5 cable, RJ45 connector on Host, Default IP address is RJ45 Internet Devices up to 100 meters. Peer, or Internet Device 192.168.1.254 E210/100 Base-T Host, Peer, and Shielded CAT5 cable, RJ45 connector on Host, Default IP address is RJ45 Internet Devices...

  • Page 156: Connecting The Operator Interface To The Controller

    C75 CPU A’s I/O port to 2 or more I/O racks Shielded Ethernet No foreign messaging 100Base-T CAT5 cable with RJ- approved unmanaged permitted 45 connectors switch. From this unmanaged switch to each Scanner 2’s I/O A port. One (1) additional unmanaged switch may be used, for a total of 2 unmanaged switches...

  • Page 157: Table 20 - Parts Needed To Make Rs-485 Cable

    Table 20 – Parts needed to make RS-485 Cable Part # Quantity Description Belden #9271 (or equivalent), Variable Commercially available communication with 120 ohm resistors (2,000 cable feet Maximum) Belden #9182 (or equivalent), with 150 ohm resistors (4, 000 feet maximum) 10-terminal connector (Supplied with the operator interface) Phoenix #1840379 (or...
  • Page 158 A. Direct Serial RS-232 Connection (Legacy Controllers) Figure 87 – A Direct Serial RS-232 Connection ATTENTION: Always observe the wiring/cabling guidelines on page 58. Step Procedure Prepare a null modem cable. Refer to RS-232 Converter Direct Link to PC Configuration Tool (page 143) for specific instructions on the null modem cable.

  • Page 159: Table 21 - Null Modem Cable Connections

    RS-232 Direct Link to PC Configuration Tool (Legacy Controllers) The Controller can be connected directly to the PC, in which case a Null Modem Cable is required. The Null Modem Cable can be ordered from Honeywell (Part# 50004820-501). Cable connections are shown in Table 21.
  • Page 160 RS-232 Remote Connection to PC Configuration Tool (Legacy Controllers) The Controller can also be connected remotely by a set of modems, which are available from third-party suppliers. A Null Modem Cable is used between the Controller and the modem, shown in Figure 88 and shown in Table 21.
  • Page 161 ATTENTION: Always observe the wiring/cabling guidelines on page 58. Step Procedure Connect a modem to the ControlEdge HC900 controller for a list of approved modems, their settings, and the connection specifics. On the PC, check on the Utilities Worksheet in the HC Designer software to see if the PC modem is properly installed.
  • Page 162 Modem requirements Most commercially available modems can be used with the ControlEdge HC900 Controller. The modem must have the following capabilities:  RS-232 interface  Auto answer  Can operate at 1200, 2400, 4800, 9600, 19200, 38400, 57600 baud; recommended 9600 or 19200 or 38400 baud, 8 data bits, 1 stop bit, and no parity ...
  • Page 163 Modem configuration Before connecting a modem to the controller’s RS-232 port (marked “CONFIGURATION”), the modem must be configured with the following settings:  Baud Rate = 1200, 2400, 4800, 9600, 19200, 38400, 57600 (Must match Baud Rate configured in ControlEdge HC900 Controller) ...
  • Page 164 Modem configuration examples Below are procedures for setting up the following commercially available modems:  3Com US Robotics 56K Data/Fax External Modem  Zoom 56K Dual Mode External Modem (page 150)  Best Data 56SX Data Fax External Modem (page 151) ...
  • Page 165 Step Action Key in the following command string: AT Y0 Then, press the ENTER key. The modem should respond with OK. Key in the following command string: AT &B1 Then, press the ENTER key. The modem should respond with OK. Key-in the following command string: AT E0 Q1 &W0 The Modem will not respond.
  • Page 166 Zoom 56K Dual Mode External Modem Step Action Connect the modem to a PC. If your PC’s RS-232 port has a 25-pin connector, use a DB-25 male to DB-25 female RS-232 cable. If your PC’s RS-232 port has a 9-pin connector, use a DB-25 male to DB-9 female modem cable.
  • Page 167 Best Data 56SX Data Fax External Modem Step Action Connect the modem to a PC. If your PC’s RS-232 port has a 2- pin connector, use a DB-9 male to DB-25 female modem cable. If your PC’s RS-232 port has a 9-pin connector, use a DB-9 male to DB-9 female RS-232 cable.
  • Page 168 SixNet VT-MODEM Industrial External Modem Step Action Connect the modem to a PC. If your PC’s RS-232 port has a 25 pin connector, use a DB-9 male to DB-25 female modem cable. If your RS-232 port has a 9 pin connector, use a DB-9 male to DB-9 female RS-232cable.
  • Page 169 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 90 and Table 22. Figure 90 – Dual Networks ATTENTION: Always observe the wiring/cabling guidelines on page 58. Revision 10 ControlEdge HC900 Process &...
  • Page 170 Table 22 – Dual Network connections in Figure 90 Key No. Connection/Description Connect CPU-A E1 port to Ethernet switch (3a) Connect CPU-B E1 port to Ethernet switch (3a) Connect Ethernet switch (3a) to PC Ethernet port Connect CPU-A E2 port to Ethernet switch (3b) Connect CPU-B E2 port to Ethernet switch (3b) Connect Ethernet switch (3b) to Ethernet port Ethernet switch or router/firewall for CPU-A E1 port...
  • Page 171 Table 23 – Dual network connections Step Procedure Make sure the PC has 2 Ethernet NICs (Network Interface Cards) installed and enabled. Connect Ethernet 10/100 Base-T straight or crossover cables to the ControlEdge HC900 controller’s E1 and E2 ports. Connect the other end of the cables to the PC’s Ethernet ports. On the PC, use the Utilities Worksheet in the Designer software to connect to the controller over Ethernet.
  • Page 172 Step Procedure Select the Set Controller’s Network Parameters button. Using the wizard (bottom radio button), select the PC port to be used, then set the controller’s new network parameters including IP address, Subnet Mask (if other than the default), and Default Gateway IP address (if required, otherwise use default).
  • Page 173 C. Direct Ethernet Connection to one ControlEdge HC900 controller ATTENTION: Always observe the wiring/cabling guidelines on page 58. Step Procedure Make sure the PC has an Ethernet NIC (Network Interface Card) installed and enabled. Connect an Ethernet 10/100 Base-T crossover cable to the ControlEdge HC900 controller’s Open Ethernet RJ-45 port (top RJ-45 port).
  • Page 174 Step Procedure You may change the controller’s IP address and related network parameters from its default using the Utilities Worksheet in the HC Designer software. This may be done using either the RS-232 serial port (legacy systems) via a null modem cable connection or the Ethernet connection from the PC to the controller.
  • Page 175 Step Procedure Select the Set Controller’s Network Parameters button. Using the wizard (bottom radio button), select the PC COM port to be used, then set the controller’s new network parameters including IP address, Subnet Mask, and Default Gateway (if required). See your IT network administrator for proper entries.

  • Page 176: Connecting The Controledge Hc900 Controller To Modbus Device(S)

    7.5. Connecting the ControlEdge HC900 Controller to Modbus device(s) RS-485 Modbus connections Use Designer software to configure the controller’s galvanically isolated RS-485 port as a master or slave. Install resistor as shown for terminated devices except ControlEdge HC900. For terminating ControlEdge HC900, do not install resistor.
  • Page 177 If the RS-485 network to slave devices is intermittent or fails completely over short durations and recovers after the controller is power cycled, use an external isolator with additional port biasing. See Figure 93. Note: Legacy Controllers do not provide biasing. Figure 93 - RS-485 Modbus slave wiring with isolation Revision 10 ControlEdge HC900 Process &...
  • Page 178 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 94 shows recommended installation procedure for using an external isolator and additional port bias.

  • Page 179: Operating Characteristics

    8. Operating Characteristics 8.1. Introduction This section applies to all controllers, that is, non-redundant and redundant. For operating characteristics that unique to redundant controllers, see Redundant Operating Characteristics on page 173. This section provides insights into system functioning that are useful in configuration, in installation /commissioning tasks, and in normal and abnormal operation.
  • Page 180 Warm Start A Warm Start is a restart of the control strategy using dynamic data that is stored in battery backed RAM to allow control action to resume exactly as it was before the restart. In the Warm Start procedure (flowcharted in the main flow of Figure 95), diagnostic testing proves the integrity of the hardware, software, and configuration database resulting in an automatic Warm Start of process control.
  • Page 181 Cold Start A Cold Start clears the data in battery backed RAM, turns all outputs off, transfers the configuration file from flash memory to RAM and reinitializes all dynamic data. The Cold Start procedure is flowcharted in Figure 96. The controller initiates the Cold Start procedure: ...

  • Page 182: Controller Modes

    Execution sequence  The type of control functions executed during a scan is determined by the system configuration.  Controller configurations contain a series of algorithms in the form of function blocks that get executed in a fixed sequence. The first 100 function blocks are pre-assigned by the system to handle communication tasks, alarm processing, system monitoring functions, etc.
  • Page 183 Table 25, and the procedures that the controller performs in transitions between modes are described in Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 184 Table 26. PROGRAM Mode In the PROGRAM Mode, active control processing is suspended. This mode is used for safe execution of utility functions such as configuration download and calibration of analog inputs and outputs. All outputs are Off. RUN Mode The Run Mode is used for normal operation of the controller;...

  • Page 185: Table 24 - Controller Operating Modes

    OFFLINE Mode The OFFLINE Mode can be entered only from the RUN Mode, and is intended primarily for performing AI calibration. CAUTION Because Function Blocks are not processed and outputs are Frozen in this mode, inputs (that is, process values) can vary from the values that existed when the OFFLINE Mode was entered.
  • Page 186 Mode Name Functions in selected mode OFFLINE IO scanning (Controller and Expander Racks) is performed, but function blocks are not executed, and all outputs (digital and analog) are Frozen (see Note 2) at the states they were in when the OFFLINE mode was selected. Monitoring of Diagnostics (local and expanded racks) Detection of I/O Modules Other functions permitted:...
  • Page 187 Table 25. The effects on controller operation for each mode transition are described in Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 188 Table 26. Figure 97 – Mode Switches: Controller (left), RSM (right) ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 189: Table 25 - Mode Switch Functions

    Program) operation. Mode cannot be changed at any operator interface. While in PROG position the S1 serial port is set to Honeywell ELN protocol. This temporarily overrides the configured settings for S1 port. With your PC’s serial com port connected to S1, use Designer Software’s Utilities to view any setting of any controller port (such as...

  • Page 190: Table 26 - Controller Behavior In Mode Transition

    Table 26 – Controller Behavior in Mode Transition Initial Mode New Mode Controller Behavior PROGRAM Validate configuration database. Reset all I/O scanners. Upon startup, initiate Cold Start sequence. Diagnostic: Identify and configure all I/O racks and modules. (All output modules are configured with Failsafe values. Any modules not included in the configuration are configured with default values, which cause outputs to be Off.) While in transition, all output modules are Off;...

  • Page 191: File Download/Upload Functions

    8.5. File Download/Upload Functions The following is a general description of file transfers between the controller and computer devices external to the controller. CAUTION Performing download procedures incorrectly could cause loss of control in an operating process or loss of data and program files in a controller. Refer to the appropriate User's Manuals for download/upload procedures.

  • Page 192: Table 27 - Configuration File Downloading

    Configuration Download Configuration files include the items indicated in Table 27. Downloading of some items is mode dependent. That is, downloading of some file types is not permitted in the Run mode or in the Offline mode. Table 27 – Configuration file downloading Downloading of Permitted When Controller is in .

  • Page 193: Redundant Operating Characteristics

    9. Redundant Operating Characteristics 9.1. Overview This section describes operating characteristics specific to redundant controllers. In a redundant ControlEdge HC900 system, the Lead Controller performs all primary tasks including interfacing with remote I/O racks, communicating with a local HMI, exchanging data with peer controllers, interfacing with Modbus slave devices, and communicating with a Host PC application.
  • Page 194 Figure 99 – Modes of operation on RSM RUN Mode (Locked) In the Run mode, the controller performs all control and communication tasks needed for steady-state operation. On-line configuration edits and configuration changes are inhibited. SIL application must operate in this position. SIL requirements may not occur in other operational modes. This RUN-locked mode is the Safety mode for Safety controllers and the proper normal operational mode for all controllers.

  • Page 195: Steady State Operations

    9.4. Steady State Operations  Lead Controller issues polls to I/O Racks for inputs  Both Lead and Reserve read I/O responses from I/O Racks  Lead and Reserve both execute function blocks in the control strategy  Only the Lead Controller writes physical outputs to the I/O Racks ...
  • Page 196 Lead/Reserve controller synchronization  Lead Controller automatically synchronizes the Reserve with the configuration database  During download of a configuration from a Host to the Lead  During process operation to bring a Reserve Controller from the Unavailable state to the On- Line state ...

  • Page 197: Failover

    9.5. Failover Automatic Failover  Triggered on any of the following conditions of the Lead Controller:  Loss of communications with I/O Rack(s)  Processor exception conditions  Error conditions that occur in the following areas will not cause a failover: ...
  • Page 198 This page is intentionally left blank. ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 199: Diagnostics And Troubleshooting

    Diagnostics and Troubleshooting Diagnostics and Troubleshooting 10.1. Overview The ControlEdge HC900 system incorporates a comprehensive set of diagnostic tools that test hardware and software operation. Diagnostic software elements are contained in each system component. The diagnostic elements that are executed at any given time depend on operating conditions such as current operating mode and the current status of hardware and software.

  • Page 200: Controller Cpu Indicators

    10.3. Controller CPU indicators Figure 101 – LED Indicators on Controller CPUs (See Table 28) ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...
  • Page 201 Table 28 – LED Indications on Controller CPUs Figure LED State/Color Description model item All models Controller Status No power. Solid Red Failed Blinking Yellow Failed Blinking Red (Diagnostic Code; refer to Table 29.) Solid Green PROGRAM Mode Blinking Green RUN Mode Solid Yellow OFFLINE Mode/while Flash RAM...
  • Page 202 Table 29. Hazardous voltages exist in the equipment enclosure.  Identify and avoid contact with voltage sources.  Disconnect power before servicing. (More than one switch may be required to disconnect all power.) Failure to comply with these instructions could result in death or serious injury. ControlEdge HC900 Process &...

  • Page 203: Table 29 - Controller Status Led Diagnostics

    Table 29 – Controller Status LED Diagnostics Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication RAM or ROM failed Executes an infinite loop that Cycle power Not available Not available on power-up.
  • Page 204 Replace the CPU board. This diagnostic will cause the in the “Reserve failure, see CPU  HWOK pins of the AYSY and Undefined Contact Honeywell Personnel. Diagnostics in FSYS blocks to be turned off. instruction error Diagnostics” the “Reserve display.
  • Page 205 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication One of the The exception vector was exception vectors automatically corrected in the controller’s RAM and the located in RAM became corrupted.
  • Page 206 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication If the lead’s If the lead’s The Real-time On power-up, time and date is Use HCDesigner, HCUtilities, or Clock (RTC) is not...
  • Page 207 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication See “Rack One of the following Associated blocks set their fail Locate the Scanner 2 that has a See the Diagnostics”...
  • Page 208 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication High temperature Associated AI blocks that are condition in a configured as T/Cs set their fail Scanner 2 rack has pin on, their warn pin off, and been detected.
  • Page 209 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication ASYS and FSYS blocks’ HW   8 or 9 If 8 flashes, the S1 Check baud rate serial port is OK pins are turned off.
  • Page 210 Number Possible Causes Lead and/or Reserve User Action Honeywell OI HCDesigner/HC of Red Controller Action(s) Indication Utilities Strobes Indication If the lead’s If the lead’s Ethernet port tests E1 or E2 port diagnostic is set Replace CPU module. failed during power- to FAILED.

  • Page 211: Scanner Indicators

    10.4. Scanner indicators Figure 102 – LED Indicators on Scanners—1 port (left), 2 port (right) 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. Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 212: Table 30 - Led Indications On Scanner Module

    Table 30 – LED Indications on Scanner Module Figure LED State/Color Description 102 item Scanner Status No power Solid Red Failed Blinking Red (Diagnostic Code; refer to Table 31 - Scanner LED Diagnostics.) Solid Green Startup Mode Blinking Green Scan Mode 10/100 Base-T port XMT (upper LED) Green (On/Off)
  • Page 213  Data abort error properly isolated from  Software interrupt external noise sources.  Undefined instruction error Upgrade scanner firmware Replace scanner module Contact Honeywell Personnel. Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 214 Number Possible Cause Scanner Action User Action Strobes One of the exception vectors The vector is restored to the proper located in RAM became value and the Scanner continues to corrupted. operate normally. Flash failed to burn properly The boot code is the only software Perform a code download.
  • Page 215 Number Possible Cause Scanner Action User Action Strobes An AI module’s CJ No action is taken. Improve ventilation to rack temperature reading is Replace AI module indicating a thermal problem. The scanner determines this problem not the AI module; therefore, the module’s status LED will not indicate this diagnostic.

  • Page 216: I/O Module Indicators

    10.5. I/O Module Indicators Figure 103 – I/O Module LED indicators Table 32 – LED Indications on I/O Module Figure 103 item LED State/Color Description Module Status No power. Solid Red Hardware failure Blinking Red Diagnostic Code; refer to Table 33 –...

  • Page 217: Table 33 - I/O Module Led Diagnostics

    I/O Module Diagnostic Indication To indicate the type of diagnostic failure, the module’s status LED is flashed red with a number of quick strobes followed by a long off time. Table 33 outlines the potential module diagnostics. Hazardous voltages exist at terminal blocks. AO8 and AO16 modules require at least one channel to be configured prior to a cold start for the module to work properly.

  • Page 218: Table 34 - Bad I/O Channel Diagnostics

    Table 34 – Bad I/O Channel Diagnostics Channel Failure message Description User Action Type indicated on Honeywell OI or Honeywell HCDesigner/Utilities function block monitor The sensor – T/C, RTD, or mV source -- is Check terminal block Burnout Failure connections failing burnout checks.
  • Page 219 Channel Failure message Description User Action Type indicated on Honeywell OI or Honeywell HCDesigner/Utilities function block monitor Check the signal level being Failing to convert When attempting to take a reading, the applied to the terminals. ADC fails. This could result if the incoming signal is either too large or small.

  • Page 220: Table 35 - Led Indications On Ethernet Switch

    Ethernet Switch indicators Table 35 – LED Indications on Ethernet Switch LED State/Color Description 10/100 Base-T port Legacy XMT (upper LED) Green (On/Off) On while a message is being sent from the Main CPU; otherwise Off. On while the Main CPU is receiving a message. LINK (lower LED) Green (On/Off) Remains On as long as host is present;...

  • Page 221: Analog Calibration

    Analog Calibration 11.1. Overview All calibration data for Analog Input Modules and Analog Output Modules is stored in non-volatile memory in the I/O modules. Calibration data is stored for each channel of each AI or AO module. Calibration data for each channel can be either: ...
  • Page 222  If you plan on calibrating the 2 cold junction compensation devices, perform this operation first before performing any thermocouple calibrations. However, because cold junction measurement inaccuracies will be compensated in each individual thermocouple calibration, cold junction calibration may be skipped. ...
  • Page 223 Figure 104 – Terminal Board Connections for AI Calibration Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 224 Analog Output Calibration Analog output modules have essentially one output type. A diagram of a precision ammeter connected to the terminals of a 4-channel Analog Output module is given in Figure 105. The specifications of the meter must be consistent with calibration requirements. See page 103 for terminal connections for 8 and 16 channel AO.

  • Page 225: Removal And Replacement Procedures

    Removal and Replacement Procedures 12.1. Overview This section contains procedures for removing and replacing the active components of a ControlEdge HC900 Controller. It also includes recommendations, suggestions, and hints as they apply to the circumstances under which the procedures are used. 12.2.

  • Page 226: Table 36 - Power Supply Replacement (All Except C75)

    EXPLOSION HAZARD Class 1, Division 2 Installations  SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS i, DIVISION 2. EXPLOSION HAZARD Class 1, Division 2 Installations  Do not DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS known not to BE HAZARDOUS. Replacing the Power Supply The power supply for the ControlEdge HC900 Controller is available in two models and is used in the local (controller) rack and in the remote (I/O expansion) racks, in 4-, 8-, and 12-module sizes.

  • Page 227: Table 37 - Controller Module Replacement

    Replacing the Controller Module Removing and replacing the Controller Module requires that that the source of AC power is removed from the rack. Removing power from the Controller rack has the following consequences:  All control action stops  All power to all I/O modules in the rack is lost; hence all control outputs to the process are lost. Because external power connected to terminal boards (from or to field devices) will still be present, it is essential that field devices are maintained in a safe condition during replacement procedures.

  • Page 228: Table 38 - Scanner Module Replacement

    Replacing the Scanner Module Removing and replacing the Scanner Module from an I/O expansion rack (C50, C70, C75 CPU controllers only) requires that the source of AC power is removed from the rack. Removing power from the Expansion rack has the following consequences: ...

  • Page 229: Table 39 - Riup: Potential Hazards And Recommended Actions

    All of the I/O Module types in the ControlEdge HC900 Controller System include the Removal and Insertion Under Power (RIUP) feature. That is, while the rack is powered, any of the I/O Modules can be removed or inserted:  With no physical damage to the module, to the rack, or to other modules in the rack ...

  • Page 230: Table 40 - I/O Module Replacement

    Table 40 – I/O Module Replacement Step Action Removal or Insertion Under Power of an I/O module is an option, but if operating circumstances permit, disconnecting power from the rack is the preferred option. Plan and develop an action sequence before beginning the replacement procedure. Primary considerations include: When replacing I/O module, the voltages to the modules must be disconnected at the field device before removing the terminal block from the module.
  • Page 231 Battery Installation/Replacement Advisory Regarding Battery Installation Memory for the CPU in the Controller Module includes:  Volatile memory (SDRAM) and  Non-volatile memory (Flash) Only volatile memory requires battery backup. Care during Installation HC900 controller comes with an insulator tab which keeps the front battery disconnected from the controller during the transportation.

  • Page 232: Figure 106 - Battery Life In Months

    Figure 106 – Battery Life in Months Note: The above graph is assuming,  Honeywell supplied batteries are New when installed  Initialization sequence is followed as described in above paragraph Installing the backup battery when the CPU is not initialized will cause undue battery drain.

  • Page 233: Table 41 - Installing Backup Battery (Cpu Not Initialized)

    Battery Installation Procedures Table 41 – Installing Backup Battery (CPU not initialized) Step Action Improper application of site power can cause damage to equipment. Ensure that the controller rack is ready and safe for application of AC power. Apply site AC power to the Power Supply that is associated with the controller Module. Press the latch on the battery cover (1) to release the battery holder, and pull on the handle (2) to remove the battery holder.

  • Page 234: Table 42 - Replacing A Backup Battery (Cpu Powered))

    Battery Replacement Procedures Table 42 – Replacing a Backup Battery (CPU Powered)) Step Action If the battery is removed from the Controller Module when AC power is not applied, the content of RAM will be lost. Before beginning this procedure, upload and SAVE a copy of the configuration, or ensure that a previously saved copy of the current configuration is available.

  • Page 235: Specifications

    Specifications 13.1. General Specifications (Refer to Specification manual) Table 43 - ControlEdge HC900 PV Input Types and Ranges Type Range Range High (Reference): Corresponding UMC800 Input type and range None 1815 40 1820 C 58 3300 104 3308 F 59 -270 1000 -454...
  • Page 236 Type Range Range High (Reference): Corresponding UMC800 Input type and range W_W26 2320 W_W26 -20 2320 C 52 W_W26 4200 W_W26 -4 4208 F 53 W5W26 2316 W5W26 -20 2320 C 54 W5W26 4200 W5W26 -4 4208 F 55 W5W26 1227 W5W26 2240...
  • Page 237 Type Range Range High (Reference): Corresponding UMC800 Input type and range 0 10 V -1 1 V -2 2 V -5 5 V -10 10 Carbon 1250 Oxygen Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 238: System Sizing And Availability Summary

    13.2. System Sizing and Availability Summary Table 44 – System Size and Availability Summary Specification Combined Analog and Digital I/O 384 points 4608 points 4608 points 4608 points Analog Inputs 142 points 2304 points 2304 points 2304 points Analog Outputs 40 points 400 points 400 points...

  • Page 239: Extended Distance Configuration With Fiber Optics

    Specification Variables 2000 2000 6144* 6144* Variables in a Recipe *-Applicable only for version 6.6 and above 13.3. Extended distance configuration with Fiber Optics Please refer to ControlEdge HC900 specification document (51-52-03-31) for more details on recommended models. Also Figure 107 and Figure 108 are examples of Extended Distance configurations.

  • Page 240: Figure 108 - Extended Distance Example #2

    Figure 108 – Extended Distance Example #2 ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...

  • Page 241: Appendix - Installation Of Remote Termination Panels (Rtps)

    Appendix - Installation of Remote Termination Panels (RTPs) 14.1. Overview The Remote Termination Panel (RTP) provides an easy way to connect the ControlEdge HC900 controller to the field wiring. The RTP integrates some of the typical externally connected components, reducing wiring and setup time. It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I/O modules.

  • Page 242: Analog Input/Digital Input/Digital Output/Analog Output

    14.2. Analog Input 8 Point Analog Input Step Action ATTENTION: RTP is not for use with thermocouples. ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109). ...
  • Page 243 8 Point Analog Input Step Action Set DIP switch positions SW1 through SW8. Set each input’s DIP switch positions according to the input type. For Input n use Switch n. For example, for Input 1 use Switch 1, for Input 2 use Switch 2, etc. If an input is not used, set its DIP switch positions to OFF. Fuses: 80mA Time lag Littelfuse part # 37400800410 UL/CSA approved...

  • Page 244: Figure 110 - Analog Input Terminals

    8 Point Analog Input Step Action Connect field wiring. Refer to Figure 110 through Figure 116 for field wiring. Any input type can be wired to any of the 8 inputs. After wiring, double-check DIP switches settings for each input type (Step 3). 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 power...

  • Page 245: Figure 112 - Milliamp Input Connections With 250 Ohm Shunt Resistance

    Note: You must set Note: You must set switches 1- 8 for Milliamp. switches 1- 8 for Milliamp. Input 5 Input 5 Input 3 Input 3 Input 7 Input 7 Input 1 Input 1 Input 4 Input 4 Input 6 Input 6 Input 2 Input 2...

  • Page 246: Figure 114 - Three-Wire Rtd Input Connections

    8 Point Analog Input Step Action Figure 114 – Three-wire RTD input connections Input 5 Input 5 Input 7 Input 7 2 wire 2 wire 2 wire 2 wire Note: Note: RTD/OHMS RTD/OHMS RTD/OHMS RTD/OHMS You must set switches 1- 8 You must set switches 1- 8 for Ohms for Ohms...
  • Page 247 Analog Input accuracy specification Range AI Module Accuracy RTP + Cable Accuracy AI Module + RTP Accuracy 0.1% of Range 0.04% Range (0.357C) 0.14% of Range 100 Plat. RTD 0.1% of Range 0.12% Range (0.824C) 0.22% of Range JIS RTD 0.1% of Range 0.57% Range (1.540C) 0.67% of Range...
  • Page 248 Analog Input RTP Internal schematic HC900 Terminal Block SW 1(2) 250 Ohm SW 2 (2) 250 Ohm SW 3 (2) 250 Ohm SW 4 (2) 250 Ohm SW 5 (2) 250 Ohm SW 6 (2) 250 Ohm SW 7 (2) 250 Ohm SW 8 (2) 250 Ohm...
  • Page 249 14.3. Relay Output Relay Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109).  Remove appropriate key tabs from terminal block to allow mating with the module. See page 87. ...
  • Page 250 Relay Output Step Action Connect field wiring. 10 11 12 13 14 15 16 17 18 19 20 ATTENTION  Cable power is limited to 24 Amps per module at 60C (140 degrees F) and 32 Amps at 54C (129 degrees F). ...
  • Page 251 Relay Output RTP Internal schematic HC900 Terminal Block Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 252 RTP Cable wire positions and colors (applies to 8 point AI and Relay Output) Twisted Pair Number ControlEdge HC900 Module TB RTP J1 Plug Connector Color Position Black Black White Black Green Black Blue Black Yellow Black Brown Black Orange White Green Blue...
  • Page 253 4 Point Analog Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109).  Remove appropriate key tabs from terminal block to allow mating with the module. See page 87. ...
  • Page 254 4 Point Analog Output Step Action Connect field wiring. LOADS ARE 0 to 750 ohm 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 16 Point Contact Digital Input Step Action...
  • Page 255 16 Point Contact Digital Input Step Action Set jumper positions as shown for the 16 point contact digital input module. Jumper open Jumper closed SW1 is not used. Module RIUP is not affected by using the RTP. See page 246 for RTP internal schematic. Connect field wiring.
  • Page 256 16 Point DC Digital Input Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. ATTENTION: The RTP combines the two groups of 8 inputs into one group of 16. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109). ...
  • Page 257 16 Point DC Digital Input Step Action 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). 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 Install jumper wires DC Supply...
  • Page 258 16 Point AC Digital Input Step Action Mount RTP to DIN rail.  Latch to rail. See page 258.  Connect cable to RTP 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.
  • Page 259 16 Point AC Digital Input Step Action Connect field wiring. Note: S-L1 in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open (0). 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 Install jumper wires 16 Point DC Digital Output...
  • Page 260 16 Point DC Digital Output Step Action Mount RTP to DIN rail.  Latch to rail. See page 258.  Connect cable to RTP 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.
  • Page 261 16 Point DC Digital Output Step Action 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). 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 Install jumper wire DC Supply...
  • Page 262 8 Point AC Digital Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. ATTENTION: 8 point AC Output is limited to maximum of 2A per output for any VAC, 6A per RTP for 240VAC, 8A per RTP for 120VAC.
  • Page 263 8 Point AC Digital Output Step Action Connect field wiring. CAUTION: S-L1 terminals in the wiring figure below are live when switch SW1 is on (1). 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 Note: AC Outputs are individually fused in the module, but adding a fuse here protects the wiring.
  • Page 264 16 Point Safety Universal Input/Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. ATTENTION: Mount RTP cable assembly to 900 Platform (Figure 109).  Remove appropriate key tabs from terminal block to allow mating with the module. See ControlEdge or HC900 Hybrid Controller Installation and User guides for details.
  • Page 265 16 Point Safety Universal Input/Output Step Action Connect field wiring. For more information on channel type wiring see Field wiring in appendix of ControlEdge HC900 Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 266 RTP Cable wire positions and colors (Applies to 4 AO, 16 DI, 16 DO, 8 DO, 16 UIO) Twisted Pair Number ControlEdge HC900 Module TB RTP J1 Plug Connector Color Position Black Black White Black Green Black Blue Black Yellow Black Brown Black...
  • Page 267 RTP A Cable wire positions and colors (for cable assembly drawing, applies to 8 AO) Twisted Pair Number of ControlEdge HC900 Module TB RTP A J1 Plug Connector Color Cable A Position Black Black White Black Green Black Blue Black Yellow Black Brown...
  • Page 268 16 Point Analog Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109).  Remove appropriate key tabs from terminal board to allow mating with the module. See page 87. ...
  • Page 269 16 Point Analog Output Step Action Connect field wiring. LOADS ARE 0 to 750 ohm ETC. 9 10 11 12 13 14 15 16 17 18 19 20 RTP A for Outputs 1 to 8, 9+ and 10+ 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 9 10 11 12 13 14 15 16 17 18 19 20 RTP B for Outputs 11 to 16, 9- and 10-)

  • Page 270: Figure 117 - Voltage Input Connections

    16 Point Analog Input Step Action Mount RTPs to DIN rail.  Latch to rail. See page 258.  Connect cables to RTPs. Cables are marked “RTP A” and “RTP B.” In step 4, RTP A will be wired to Inputs 1-10, RTP B to Inputs 9-16.

  • Page 271: Figure 118 - Current Connections With 2-Wire Transmitter

    16 Point Analog Input Step Action Figure 118 - Current connections with 2-wire transmitter Not shown: recommended external current loop fuses. Additionally, on RTP A connect the following terminals: 3-22, 4-23, 7-24, 8-25, 15-26, 16-27, 19-29, 20-30 On RTP B connect the following terminals: 1-22, 2-23, 5-24, 6-25, 13-26, 14-27, 17-28, 18-29 Revision 10 ControlEdge HC900 Process &...
  • Page 272 32 Point DC Digital Output Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. ATTENTION: 32 point DC Digital Output is limited to 6A per RTP and 0.5A per output. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109). ...
  • Page 273 32 Point DC Digital Output Step Action Connect field wiring. 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 RTP A for outputs 1 to 16 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 Install jumper wire...
  • Page 274 32 Point DC Digital Input Step Action ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. Mount RTP cable assembly to ControlEdge HC900 Controller (Figure 109).  Remove appropriate key tabs from terminal board to allow mating with the module. See page 87. ...
  • Page 275 32 Point DC Digital Input Step Action Connect field wiring. 9 10 11 12 13 14 15 16 17 18 19 20 RTP A for inputs 1 to 16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Install jumper wires DC Supply 9 10 11 12 13 14 15 16 17 18 19 20...
  • Page 276 RTP A Cable wire positions and colors (for cable assembly drawing, applies to 16 AI, 32 DI, 32 DO) Twisted Pair Number of ControlEdge HC900 Module TB RTP A J1 Plug Connector Color Cable A Position Black Black White Black Green Black Blue...
  • Page 277 RTP B Cable wire positions and colors (for cable assembly drawing, applies to 16 AI, 32 DI, 32 DO) Twisted Pair Number of ControlEdge HC900 Module TB RTP B J1 Plug Connector Color Cable B Position Black Black White Black Green Black Blue...
  • Page 278 Latch/Unlatch RTP to rail Step Action Mounting screws must be installed at each end of the mounting rail; with additional screws approx. every 8"(203mm) to prevent twisting of the rail. Insert one side of DIN rail at A. DIN rail Insert other side of DIN rail at B, and push B over the rail to snap into place.

  • Page 279: Declaration Of Conformity

    Declaration of Conformity Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...

  • Page 280: Atex Certification

    ATEX Certification HC900 Process & Safety Controller User and Installation Manual Revision 10 May 2019...
  • Page 281 This page has been intentionally left blank Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 282 INDEX AC Input Module Wiring ..........108 DC Input Module Wiring ..........105 AC Input terminal block ............ 25 DC Output Module Wiring ..........113 AC Output Module Wiring ..........116 DC Power Supply .............. 52 AC Power Supply Selection for racks with I/O ....50 Declaration of Conformity ..........
  • Page 283 MODE switch ..............168 Mode Transitions ............168 I/O channel numbers ............81 Model number I/O Expansion Network (C50 CPU only) ......31 compatibility ..............7 I/O Expansion Network (C70R) ......... 32 Modem ............146, 147, 148 I/O expansion port ............28, 29 Module Placement ............
  • Page 284 RAM ................163 Serial port Redundancy Switch Module (RSM) ..... 11, 22, 28 accessing ........See Controller access Redundant Serial Ports ............... 38 2 systems w/PC supervision ........156 service provider ..............37 C70R controller module..........27 shielded twisted pair ............63 components..............
  • Page 285 Fax: (86-21) 6237-2826 Singapore Honeywell Pte Ltd. Phone: +(65) 6580 3278 Fax: +(65) 6445-3033 South Korea Honeywell Korea Co Ltd Phone: +(822) 799 6114 Fax: +(822) 792 9015 Revision 10 ControlEdge HC900 Process & Safety Controller User and Installation Manual May 2019...
  • Page 286 For more information To learn more about ControlEdge HC900 Controller, visit www.honeywellprocess.com Or contact your Honeywell Account Manager Process Solutions Honeywell 1250 W Sam Houston Pkwy S Houston, TX 77042 Honeywell Control Systems Ltd Honeywell House, Skimped Hill Lane Bracknell, England, RG12 1EB...

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