Honeywell HC900 Installation And User Manual
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Honeywell HC900 Installation And User Manual

Honeywell hc900 hybrid controller installation and user guide
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See also: Reference Manual , User Manual
HC900 Hybrid Controller
Installation and User Guide
Doc. No.:
51-52-25-107
Revision:
5
Date:
9/03
Industrial Measurement and Control

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Summary of Contents for Honeywell HC900

  • Page 1 HC900 Hybrid Controller Installation and User Guide Doc. No.: 51-52-25-107 Revision: Date: 9/03 Industrial Measurement and Control...
  • Page 2 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 HC900 Hybrid Controller hardware. References The following list identifies all documents that may be sources of reference for material discussed in this publication. HC900 Hybrid Controller Technical Overview Specification...

  • Page 4: Symbol Definitions

    Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements. Definition HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 5: Table Of Contents

    Module Placement in Racks...57 Remote Termination Panel (RTP) ...59 Terminal Block-to-Field (Signal) Wiring...59 Removal and Insertion Under Power (RIUP) ...62 I/O Installation Procedures ...63 I/O Terminal Block Wiring Diagrams ...68 Revision 5 9/03 Contents HC900 Hybrid Controller Installation and User Guide...
  • Page 6 Communications Installation ... 85 Overview...85 Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software88 RS-485 Link to Operator Interface ...100 Connecting the HC900 Controller to Modbus device(s)...105 Operating Characteristics... 107 Introduction...107 Overview...107 Power Down / Power Up ...107 Controller Modes ...110...
  • Page 7 Appendix B Installation of Remote Termination Panels (RTPs) ... 183 Overview...183 Analog Input ...184 Relay Output...191 Digital Input/Digital Output/Analog Output...194 RTP Cable wire positions and colors ...204 Latch/Unlatch RTP to rail...205 Index Sales and Service Declaration of CE Conformity Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...
  • Page 8 Table 35 - I/O Module Replacement ...151 Table 36 - Installing Backup Battery (CPU not initialized)...153 Table 37 - Replacing a Backup Battery (CPU Powered)) ...154 Table 38 - HC900 PV Input Types and Ranges...171 viii HC900 Hybrid Controller Installation and User Guide...
  • Page 9 Figures Figure 1 – Small HC900 Controller Configuration ...2 Figure 2 – Expanded HC900 Controller Configuration (C50 CPU only)...2 Figure 3 - Configuration with Multiple Controllers ...6 Figure 4 - Controller Rack Components...8 Figure 5 - I/O Expander Rack Components (C50 CPU only)...8 Figure 6 - Rack Options...9...
  • Page 10 Figure 63 Milliamp input connections with 250 ohm shunt resistance ...187 Figure 64 Volt, millivolt input connections...187 Figure 65 Three-wire RTD input connections ...188 Figure 66 Two-wire RTD or ohm input connections...188 Figure 67 Slidewire feedback connections for actuators ...189 HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 11: Introduction

    Provides guidelines for installing RS-232, RS-485, and Ethernet cabling and Installation associated components. Controller Operating Characteristics of the HC900 Hybrid Controller as they relate to configuration of a Characteristics control strategy, and to operation of an installed and running system. Diagnostics and...

  • Page 12: Functional Description

    Ethernet links to expand the dimensions of control over a wider range of unit processes, as indicated in Figure 2. Figure 2 – Expanded HC900 Controller Configuration (C50 CPU only) Figure 1 – Small HC900 Controller Configuration HC900 Hybrid Controller Installation and User Guide...

  • Page 13: Feature Summary

    The HC900 Controller design enables users and OEMs who are adept in system integration to assemble a system that fits a broad range of requirements. Any configuration can be readily modified or expanded as requirements dictate. In initial configuration and in subsequent modifications, the HC900 Controller affords an optimum balance of performance and economy.
  • Page 14 Alarms/Events Up to 240 Alarms (20 groups of 12) Up to 64 Events E-Mail notification of Alarms and Events to up to three addresses per controller, by alarm priority (1-5) HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 15: Components And Architecture

    Components and Architecture Overview This section provides a description of each of the major components that can be included in an HC900 Controller physical configuration, and indicates some of the methods by which they can be combined. Components The Honeywell HC900 Hybrid Controller includes a set of hardware modules that can be combined and configured as required for a wide range of small to medium process control applications.

  • Page 16: Figure 3 - Configuration With Multiple Controllers

    Components and Architecture - Components Figure 3 - Configuration with Multiple Controllers HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 17: Table 1 - Descriptions Of Major Components (Figure 3)

    RS-232 port on any (one) Controller module. Includes Honeywell Hybrid Control Designer (configuration software). (Optional) PC link to Ethernet network, which may include other HMIs, other HC900 Controllers, and other networks (including Internet). Typically includes HMI operating software. May also include Hybrid Control Designer (configuration tool and utility software).

  • Page 18: Hardware Components

    Hardware Components This section contains general descriptions of each of the major components of the HC900 system. For environmental specifications, refer to the section on Pre-Installation Planning. HC900 Controller Rack An HC900 Controller ("local rack") is shown in Figure 4. As indicated in this figure, the Controller Rack includes: 1.

  • Page 19: Figure 6 - Rack Options

    3. Wiring label 4. Grounding lug (Reference; lug is not part of Power Supply; it is staked to bottom of Rack.) Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide Figure 6 - Rack Options Figure 7 – Power Supply...

  • Page 20: Figure 8 - Controller Module

    2 - RS-232 Port; interface to the PC configuration tool, external modem, or Modbus device 3 - Mode switch (Program Lock, Run/Program, Run Lock) 4 - RS-485 Port for Honeywell Operator Interface or Modbus device 5 - Ethernet 10BaseT Port; interface to peer controllers, HMIs, and other networks 6 –...

  • Page 21: Figure 10 - I/O Module Terminal Blocks

    Figure 10) and the Barrier style (on the right). For more information on I/O modules and associated terminal blocks, refer to the section in this manual on Input/Output Installation and Wiring. Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide Figure 10 - I/O Module Terminal Blocks...

  • Page 22: Figure 11 - Rs232 Modem Devices

    PC. The PC can be located remote from the Controller by using Modems and telephone links. Modems and suitable cabling are available from third-party vendors. HC900 Hybrid Controller Installation and User Guide Figure 11 - RS232 Modem Devices Revision 5 9/03...

  • Page 23: Ethernet Devices/Considerations

    Ethernet device requirements vary with specific applications. Regarding intended use, however, they fall into two categories: • Components of the Ethernet Open Connectivity Network, which links an HC900 Hybrid Controller to Peers, to HMI Supervisory Stations, and to other Ethernet 10Base-T devices that support TCP/IP.

  • Page 24: Ethernet Open Connectivity Network

    Controller Module and in each Scanner Module included in the HC900 system. The controller examines the control strategy stored in its memory, verifies that the physical configuration (Rack Numbers, and I/O Module type- by Module Number) matches the stored control strategy, and establishes communication with each of the I/O modules in each of the I/O racks.

  • Page 25: Figure 13 - Modular Network Structure

    Hybrid Controller Function Block User Guide for additional information.) An illustration of HC900 Controller Peer-to-Peer on a Local Area Network (LAN) is given in Figure 13. Typically, a Router is used for interconnection to another network (LAN, WAN, or other).

  • Page 26: Figure 14 - Modbus/Tcp Framing

    Controller-to-HMI communications. The Hybrid Control Designer configuration package, which is supplied by Honeywell, is ready for use as soon as it is installed. This package uses a subset of Modbus function codes that provide for very efficient and secure configuration transactions.
  • Page 27 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 certified Note by Honeywell, and are not necessarily recommended or endorsed by Honeywell for any specific use.

  • Page 28: Figure 15 - Typical Installation Using A Cable Modem

    E-Mail Communications The HC900 Controller includes e-mail software that enables communication of Alarms and Events to up to three Internet addresses. Implementing this feature consists of: • Using the Hybrid Control Designer to configure: − Alarm Groups and Event Groups −...

  • Page 29: Serial Ports (Rs232 And Rs485)

    Controller can act as Modbus master or slave through either port. • Controller can be master to slaves such as • Honeywell Operator Interface (1040, 559). Must be on 485 port. Will not work on 232 port with − 232/485 converter. Honeywell HC Designer PC software −...

  • Page 30: Figure 16 Serial Port Configurations 1 - 6

    Protocol Protocol RS-232 RS-232 RS 485 RS 485 ELN protocol ELN protocol Figure 16 Serial Port Configurations 1 - 6 HC900 Hybrid Controller Installation and User Guide 3rd Party HMI Modbus Master Modbus Modbus Slave Slave Protocol Protocol 2000 Ft...

  • Page 31: Figure 17 Serial Port Configurations 7 - 11

    ELN Slave or Modbus Slave Modbus Slave Protocol Protocol ELN protocol ELN protocol Figure 17 Serial Port Configurations 7 – 11 HC900 Hybrid Controller Installation and User Guide Modbus Slaves Honeywell Honeywell RS232 to RS485 Converter Modbus Modbus Master Master Protocol...

  • Page 32: Networking Basics Reference

    Some protocols operate in one layer of the OSI model, while others operate in more than one layer. For example, Transport Control Protocol/Internet Protocol (TCP/IP) is commonly on the Internet and is used in private networks such as an HC900 Controller LAN. TCP HC900 Hybrid Controller Installation and User Guide...
  • Page 33 Layer 3, IP operates at Layer 2, and Ethernet itself includes protocols that operate at Layers 1 and 2. Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...

  • Page 34: Glossary Of Networking Terms

    A glossary of networking terms is given in Table 5. Each term entry and description in this table is included as an element of a language bridge between users of an HC900 Controller network and personnel who are employed to implement the construction of the network. This glossary is not represented as complete and sufficient for implementing a network.

  • Page 35: Table 3 - Open System Interconnection Model

    Windows Client, Novell Client32) PC Software (e.g., Windows NT/2000, Novell NetWare) Software (e.g., Modbus/TCP) NIC drivers Cable, NICs HC900 Hybrid Controller Installation and User Guide Protocols Network components (examples) affected (examples) Networking software packages in PC hosts SMTP Modbus drivers...

  • Page 36: Table 4 - Networking Device Types

    HC900 controller and/or protocol port number). Gateway A PC set up to inter-connect two disparate network models at any combination of layers of the OSI Model. Table 4 - Networking Device Types Description HC900 Hybrid Controller Installation and User Guide Notes Revision 5 9/03...

  • Page 37: Table 5- Glossary Of Networking Terms

    A programming standard that connects databases and web browsers. Examples are Thin Ethernet (RG-58/AU or RG48/CU) and Thick Ethernet (RG-8) with BNC connectors. Coaxial cable was commonly used for earlier networks; Twisted-Pair is popular in current use. HC900 Hybrid Controller Installation and User Guide Comments...
  • Page 38 Runs in a DHCP server, which assigns an IP address to each node that connects to the network. (Can not be used in a an HC900 LAN.) An Internet system (resident in a Web Browser) that resolves domain names to IP addresses. (For example, Http://www.yahoo.com resolves to...
  • Page 39 Access to the Internet is governed by a world-wide set of rules. IP (Internet Protocol) addresses are assigned by Internet Corporation for Assigned Names and Numbers(ICANN) HC900 Hybrid Controller Installation and User Guide Comments...
  • Page 40 Unique code “burned" into firmware by the device manufacturer. (Also see AUI, MDI, MAC) Physical connector at cable end (e.g., RJ-45 plug on Ethernet CAT 5 cable.) (Also see AUI, MAU) HC900 Hybrid Controller Installation and User Guide Comments Revision 5 9/03...
  • Page 41 Advised judgment is recommended. The NIC is plugged into one of the PC’s expansion slots. It includes the hardware and software (OSI Layer 1 and Layer 2) required for connecting the PC to the network. HC900 Hybrid Controller Installation and User Guide Comments...
  • Page 42 A Repeater can extend the distance over which a message can be transported, but it also expands the time for transport. HC900 Hybrid Controller Installation and User Guide Comments Revision 5 9/03...
  • Page 43 - operates at the Transport Layer of the OSI Model. - manages connections between computers. (Also see User Datagram Protocol [UDP]). Internet Protocol (IP): - operates at the Network Layer (one step below TCP) - defines how data is addressed (source/destination) HC900 Hybrid Controller Installation and User Guide Comments...
  • Page 44 Provides access to multiple IP subnets at a physical location. Remote access via a secure (encrypted) “tunnel” though the Internet. Typically, a network that includes several LANs at different geographical locations, interconnected using common carrier transmission services. HC900 Hybrid Controller Installation and User Guide Comments Revision 5 9/03...
  • Page 45 Pre-Installation Planning - Networking Basics Reference Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 46: Pre-Installation Planning

    Equipment placement, particularly if the locations of field devices warrant the use of separate and/or • remote IO hardware. Selection and placement of ancillary equipment such as equipment enclosures, conduits, and raceways • for wiring and cabling. Pre-Installation Planning HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 47: Power Supply Selection

    @ 5 V in mA @ 24 V in mA Yes/No Yes/No Yes/No HC900 Hybrid Controller Installation and User Guide mA Sub. Tot mA Sub. Tot ( D = A * B ) ( E = A * C )

  • Page 48: Environment

    Environment Environmental Operating Limits The environmental conditions required for operating the HC900 Hybrid Controller are listed Table 6. Table 6 - Operating Limits and Installation Guidelines Condition Ambient Temperature Relative Humidity Vibration Frequency Acceleration Mechanical Shock Acceleration Duration Electromagnetic Interference (EMI) and...

  • Page 49: Orientation Of Rack Mounting

    The HC900 Controller must be mounted in suitable equipment enclosures. That is, all components such as the Controller rack, IO Expander Racks, and the Operator Interface manufactured by Honeywell must be mounted in approved furniture designed for industrial applications. Orientation of Rack Mounting Racks must be mounted as indicated in illustrations throughout this manual, so as to provide for vertical airflow through the racks.

  • Page 50: Figure 18 - Ac Input Module De-Rating

    Pre-Installation Planning - Heat Rise De-rating Figure 18 - AC Input Module de-Rating Figure 19 - Power Supply De-rating HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 51: Equipment Placement Considerations

    Factors that determine where equipment should be located within the site include at least the following: Environmental conditions (see above). • Wiring/cabling characteristics. The HC900 Controller includes (optional) I/O expansion racks (C50 • CPU only), which provide options regarding methods of connecting field devices into the system. That is, the length of I/O wiring can be reduced significantly by locating I/O expansion racks remote from the Controller rack, but close to process equipment.

  • Page 52: Electrical Considerations

    Electrical Considerations The HC900 Controller should be mounted in an appropriate metal enclosure. A diagram that shows recommended wiring practice for the cabinet enclosure is given in Figure 20 - Cabinet Wiring, Single Chassis, and Figure 21 - Cabinet Wiring, Multiple Chassis.

  • Page 53: Figure 20 - Cabinet Wiring, Single Chassis

    Pre-Installation Planning - Electrical Considerations Figure 20 - Cabinet Wiring, Single Chassis Figure 21 - Cabinet Wiring, Multiple Chassis Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 54: Table 8 - Guidelines For Grouping Wires

    Input signal wire (thermocouple, 4 mA to 20 mA, etc.) 4-20 mA output signal wiring Slidewire feedback circuit wiring Low voltage alarm relay output wiring Low voltage wiring to solid state type control circuits HC900 Hybrid Controller Installation and User Guide ) copper Revision 5 9/03...
  • Page 55 System Monitor Function Blocks The HC900 Controller includes function blocks that enable the user to monitor the status of system functions. When constructing a control configuration, add the following function blocks to the control strategy: • ASYS - System Monitor •...

  • Page 56: Figure 22 - Master Control Relay Wiring Example

    Pre-Installation Planning - Electrical Considerations Figure 22 - Master Control Relay Wiring Example HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 57: Figure 23 - Rack Dimensions

    Vertical spacing of racks, which is required for rack ventilation and for routing wires, is shown in Figure 24. Figure 23 - Rack Dimensions Figure 24 - Vertical Spacing of Racks Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...
  • Page 58 Time and effort spent at the beginning of a project is quickly recovered in the efficient execution of each planning and installation procedure. To reduce the burden of documenting an HC900 Controller installation, several data-collection aids are given in Appendix A of this manual. These include: sample diagrams ("maps") of site facilities and of networking systems...

  • Page 59: Installation Guide

    Overview This section contains procedures for installing one or more HC900 Controllers. It is recommended that the Site Plan Documentation, completed as a part of Pre-Installation Planning, is used as a primary data source and checklist while performing these procedures.

  • Page 60: Table 10 - Site And Equipment Preparation

    Sheet metal screws, steel #10 or M4, for mounting racks in enclosures (4 screws for 4-slot racks, 8 screws for 8- or 12-slot racks) Install (or verify correct installation of) enclosures for HC900 Controllers and ancillary equipment: • Mounting rails or flat-panels •...
  • Page 61 Arrange and organize items to be installed at or near enclosures, and use the Site Plan Documentation as a checklist to verify readiness for installation. Revision 5 9/03 Procedure HC900 Hybrid Controller Installation and User Guide Reference I/O Module Installation section in this manual.

  • Page 62: Table 11 - Install Hc900 Controller Components

    Drill and tap for # 10 (or M4) screws. • Remove the rack from the enclosure. Table 11 - Install HC900 Controller Components For dimensions of the pattern for drilling holes, refer to the diagram below. CAUTION: When drilling holes, prevent metal flakes from falling into the rack, or onto any surface within the electrical cabinet.
  • Page 63 Fasten the screws (captured in the face of the power supply) into the tabs at top and bottom of the rack. Revision 5 9/03 Comments/References HC900 Hybrid Controller Installation and User Guide...
  • Page 64 Comments/References Do not connect PE Ground (Green) Wire directly to terminal on Power Supply. HC900 Hybrid Controller Installation and User Guide ATTENTION! Revision 5 9/03...
  • Page 65 Install under power after the controller configuration is complete. (For more information, refer to Battery Installation/Replacement, page 152.) Revision 5 9/03 Comments/References HC900 Hybrid Controller Installation and User Guide...
  • Page 66 Then, for each expansion rack, insert the Scanner Module immediately to the right of the Power Supply, and secure it in place with the two captured screws in the faceplate. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 67: I/O Module Installation And Wiring

    Always tighten both terminal block screws before applying field power to the module. • Do not apply energized ("live") field wiring to an input/output module that is not installed in one of the racks in the HC900 Controller. • Do not operate the controller without a Protective Earth connection.

  • Page 68: Figure 26 - Terminal Block Styles

    Use of documentation aids in Appendix A will facilitate correct use of labels. HC900 Hybrid Controller Installation and User Guide Figure 26 - Terminal Block Styles...

  • Page 69: Remote Termination Panel (Rtp)

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

  • Page 70: Figure 27 - Signal-Wire Grounding

    I/O module. HC900 Hybrid Controller Installation and User Guide Figure 27 - Signal-Wire Grounding Figure 28 - Wire-Shield Grounding Revision 5...

  • Page 71: Figure 29 - Terminal Block Jumper Installation

    V+ terminals on the DC Output Module. Refer to the wiring information on each module, given in this section of this manual. Revision 5 9/03 Figure 29 - Terminal Block Jumper Installation HC900 Hybrid Controller Installation and User Guide...

  • Page 72: Removal And Insertion Under Power (Riup)

    I/O module, particularly in a system that is actively controlling a process. All of the I/O Module types in the HC900 Controller System include the Removal and Insertion Under Power (RIUP) feature. That is, while the rack is powered, any of the I/O Modules can be removed or inserted: •...

  • Page 73: I/O Installation Procedures

    Five-position jumper (10- position jumper cut in half) for a Relay Output Module. Revision 5 9/03 Table 14 - Connect Input/Output Wiring Comments Refer to terminal block wiring diagrams for specific information. HC900 Hybrid Controller Installation and User Guide Reference...
  • Page 74 I/O Module, break off the "key-tabs" in the pattern that identifies each module type. (For a diagram of each key-tab pattern, use the I/O Modules and/or the diagram shown below. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...
  • Page 75 The orientation of the diagrams below corresponds to the picture of the terminal block, shown in the previous picture. Revision 5 9/03 Comments Diagrams for I/O Module Key-Tabs HC900 Hybrid Controller Installation and User Guide Reference...
  • Page 76 Form a bend in each wire to provide strain relief, and secure the wire bundle with the tie. Comments Barrier Terminal Block Euro Terminal Block HC900 Hybrid Controller Installation and User Guide Reference Revision 5 9/03...
  • Page 77 (screw terminals). The Filler Block mounts in the same manner as a Terminal Block (with captured screws at top and bottom). Blank labels are provided for mounting in the hinged door. HC900 Hybrid Controller Installation and User Guide Reference...

  • Page 78: I/O Terminal Block Wiring Diagrams

    Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. 1 & 1 & 2) is also used HC900 Hybrid Controller Installation and User Guide Figure 30 - RTD Inputs Revision 5 9/03...

  • Page 79: Figure 31 - Universal Analog Input Wiring Diagram

    I/O Module Installation and Wiring - I/O Terminal Block Wiring Diagrams Figure 31 - Universal Analog Input Wiring Diagram Figure 32 - Examples of RTD Input Wiring Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 80: Figure 33 - Analog Input Wiring - Eight Tcs

    I/O Module Installation and Wiring - I/O Terminal Block Wiring Diagrams Figure 33 - Analog Input Wiring - Eight TCs Figure 34 - Analog Input Wiring - Eight Resistance Inputs HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 81: Figure 35 - Analog Input Wiring - Eight Rtds

    IN 7 + IN 7 + IN 7- IN 7 - & 8 IN 8 + IN 8 - HC900 Hybrid Controller Installation and User Guide 1 & 2 IN 2 + IN 2 - & 4 IN 4+ IN 4- &...

  • Page 82: Figure 37 - Analog Output Wiring Diagram

    Using switches at field devices, disconnect the field wiring form power sources before servicing. Failure to comply with these instructions could result in death or serious injury. Figure 37 - Analog Output Wiring Diagram HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 83: Figure 38 - Dc Input Module Wiring Diagram

    IN 12 IN 13 IN 14 IN 15 IN 16 Fuse Figure 38 - DC Input Module Wiring Diagram HC900 Hybrid Controller Installation and User Guide IN 2 IN 4 IN 6 IN 8 IN 10 IN 12 IN 14...

  • Page 84: Figure 39 - Dc Input Module Jumper

    I/O Module Installation and Wiring - I/O Terminal Block Wiring Diagrams Figure 39 - DC Input Module Jumper HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 85: Figure 40 - Ac Input Module Wiring Diagram

    Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. Revision 5 9/03 Figure 40 - AC Input Module Wiring Diagram HC900 Hybrid Controller Installation and User Guide...

  • Page 86: Figure 41 - Ac Input Module Jumper

    I/O Module Installation and Wiring - I/O Terminal Block Wiring Diagrams Figure 41 - AC Input Module Jumper HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 87: Figure 42 - Contact Input Wiring Diagram

    Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. Revision 5 9/03 Figure 42 - Contact Input Wiring Diagram HC900 Hybrid Controller Installation and User Guide...
  • Page 88 Hazardous voltages exist at terminal blocks. • Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 89: Figure 43 - Dc Output Module Wiring Diagram

    Revision 5 9/03 Figure 43 - DC Output Module Wiring Diagram Figure 44 - DC Output Jumpers HC900 Hybrid Controller Installation and User Guide...
  • Page 90 Hazardous voltages exist at terminal blocks. • Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 91: Figure 45 - Ac Output Module Wiring Diagram

    Revision 5 9/03 Figure 45 - AC Output Module Wiring Diagram Figure 46 - AC Output Module Jumper HC900 Hybrid Controller Installation and User Guide...

  • Page 92: Figure 47 - Schematic Example: Relay Output And External Wiring

    A ten-position jumper comb, available for the AC Output Module, can be cut in half and used as shown in Figure 49 to reduce the number of wires required to connect the Relay Output Module to AC Neutral or to DC Common. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 93: Figure 48 - Relay Output Module Wiring Diagram

    Using switches at field devices, disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. Figure 48 - Relay Output Module Wiring Diagram Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 94: Figure 49 - Relay Output Module Jumpers

    I/O Module Installation and Wiring - I/O Terminal Block Wiring Diagrams Figure 49 - Relay Output Module Jumpers HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 95: Communications Installation

    Connect communications cabling as indicated by the site cabling diagram. (The Ethernet port for the expansion rack is only present for Model C50) For Modbus connections, see page 105. Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03 Comments Reference...
  • Page 96 A crossover cable is required for PC to Controller connection; otherwise, straight cable.) HC900 Hybrid Controller Installation and User Guide Reference Data For Wiring details of Null Modem cable, 9- pin Male/Female connector, see Figure 50 - Null Modem Cable Construction.
  • Page 97 Rack #2 (no Controller and hub, other racks on I/O and hub-to-hub. Expander Link) Shielded CAT5E RJ45 connector on Hub straight cable between controller and expansion rack and hub to expansion racks. HC900 Hybrid Controller Installation and User Guide Reference Data...
  • Page 98 Connecting the HC900 Controller to a PC with the Hybrid Control Designer Software To establish communications between the HC900 controller and the Hybrid Control (HC) Designer configuration software use any of the following methods: A. Direct Serial RS-232 connection •...
  • Page 99 Connect one end of the null modem cable to the HC900 controller’s RS-232 configuration port. Connect the other end to an available serial port (COM1 through COM8) on your PC. Refer to RS- 232 Direct Link to PC Configuration Tool (page 90) for specific instructions on the null modem cable.

  • Page 100: Table 17 - Pc Cable Pinouts

    The Controller can be connected directly to the PC, in which case a Null Modem Cable is required. The Null Modem cable is available from Honeywell (Part # 51404755-501) or from third-party suppliers, or can be fabricated by the user. The Null Modem construction is shown in Figure 50 - Null Modem Cable Construction.

  • Page 101: Figure 51 - Rs-232 Remote Access Via Modems

    All functions of the Hybrid Control Designer configuration tool can be performed over this link. Remote access functions include on-line monitoring, configuration upload and download, and firmware upgrade. Revision 5 9/03 Figure 51 - RS-232 Remote Access via Modems HC900 Hybrid Controller Installation and User Guide...
  • Page 102 Set up the phone book in the HC Designer software. This list includes the phone numbers for each of the HC900 controllers that can be connected using a modem. The phone book can be accessed from the Main Menu (View | Phone Book) or from the Utilities Worksheet by selecting the modem port as the current port.

  • Page 103: Modem Requirements

    Modem requirements Most commercially available modems can be used with the HC900 Controller. The modem must have the following capabilities: RS-232 interface • Auto answer • Can operate at 9600 or 19200 or 38400 baud, 8 data bits, 1 stop bit, and no parity •...

  • Page 104: Modem Configuration

    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 = 9600, 19200, or 38400 (Must match Baud Rate configured in HC900 Controller) • Parity = None •...
  • Page 105 Run a serial communication port program such as Hyperterminal. Within the communication program, select the port to which the modem is connected. Configure the port to these settings: baud rate = 9600, 19200, 38400, 57600 (Must match Baud Rate configured in HC900 Controller) data bits = 8...
  • Page 106 Set the modem switches to the following: Switch Setting Connect the modem to the RS-232 port of the HC900 using a DB-25 male to DB-9 male RS-232 cable. Connect the modem to a telephone jack. Power up the modem and the HC900 Controller.
  • Page 107 Then, press the ENTER key. The Modem will not respond. Power down the modem and disconnect it from the PC. Connect the modem to the RS-232 port of the HC900 Controller using a DB-25 male to DB-9 male RS-232 cable.
  • Page 108 The Modem will not respond. Power down the modem and disconnect it from the PC. Connect the modem’s serial cable to the RS-232 port of the HC900 using a DB-9 male to DB-9 male RS-232 cable. Connect the modem to a telephone jack.
  • Page 109 The Modem will not respond. Power down the modem and disconnect it from the PC. Connect the modem to the RS-232 port of the HC900 Controller using a DB-9 male to DB-9 male modem cable. Connect the modem to a telephone jack.

  • Page 110: Rs-485 Link To Operator Interface

    Phoenix #1840379 (or equivalent) 047260 089037 Table 18 - Parts needed for RS-485 Cabling Quantity Variable HC900 Hybrid Controller Installation and User Guide Description Commercially available communication cable 10-terminal connector (Supplied with the operator interface) connector (3-pin) (Supplied with the...
  • Page 111 On the PC, use the Utilities Worksheet in the HC Designer software to connect to the controller over Ethernet. Every HC900 controller is shipped with the default IP address of 192.168.1.254 and Subnet Mask of 255.255.255.0. You can use these network parameters initially for testing or configuration use.
  • Page 112 Subnet Mask (if other than the default), and Default Gateway IP address (if required, otherwise use default). Refer to the HC900 Hybrid Control Designer User’s Guide or its respective on-line help, Utilities Worksheet - Set Controller’s Network Parameters, for further details on this step.
  • Page 113 Consult your IT department or network administrator for allocating IP addresses to the controllers if required. You will need to set each controller’s IP address prior to network connection since every HC900 controller is shipped with the default IP address of 192.168.1.254. Placing multiple controllers on the same network before they have been given unique IP addresses will cause problems.
  • Page 114 Setting Up the Controller Network Parameters See the HC900 Hybrid Control Designer Users Guide, Doc. # 51-52-25-110 or respective HC Designer Help Files for setting up following network parameters: IP Address, Subnet Mask (optional), Default Gateway IP Address (optional) •...

  • Page 115: Connecting The Hc900 Controller To Modbus Device(S)

    Connecting the HC900 Controller to Modbus device(s) RS-485 Modbus connections Using the master and slave(s) RS-485 ports of the controller and other device(s), connect as shown. Master Shield TX/RX- 120 ohm TX/RX+ Use HC Designer software to configure the controller’s RS-485 port as a master or slave.
  • Page 116 Operating Characteristics - Connecting the HC900 Controller to Modbus device(s) HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 117: Operating Characteristics

    Diagnostics section in this user manual. Overview The HC900 Controller components begin operation as soon as power is applied, and continue until power is removed. The operation of the system varies according to the following interacting factors: Power transitions: Power DOWN / Power UP •...

  • Page 118: Figure 52 - Warm Start Operation

    Mode switch on the controller, or by exiting the Program mode at an operator interface.) When initiated by the user (after download with Cold Start selected, or any transition from PROGAM • Mode to RUN Mode.) Figure 52 - Warm Start Operation HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 119: Figure 53 - Cold Start Operation

    Operating Characteristics - Power Down / Power Up Figure 53 - Cold Start Operation Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 120: Controller Modes

    Controller Modes The HC900 Controller includes three operating modes. The purpose of each mode is described immediately below, and salient characteristics of each are described in Table 19. The functions of the Mode Switch are described in Table 20, and the procedures that the controller performs in transitions between modes are described in Table 21.

  • Page 121: Table 19 - Controller Operating Modes

    Time Proportional Output (TPO): Same duty cycle as in last active state • TPSC Outputs: digital outputs are Off to freeze the motor position. • Analog output: same current as previous (last active current level) Revision 5 9/03 Table 19 - Controller Operating Modes HC900 Hybrid Controller Installation and User Guide...

  • Page 122: Table 20 - Mode Switch Functions

    PROGRAM, RUN, or OFFLINE. OFFLINE None (locked in In this position, the Controller is locked in the Program) PROGRAM mode of operation. Mode can not be changed at any operator interface. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 123: Table 21 - Controller Behavior In Mode Transition

    Freeze output module channels. Freeze Force LED indications on all output modules. Function Block execution starts immediately. Any calibration process that was in progress is immediately aborted, and the results are discarded. HC900 Hybrid Controller Installation and User Guide...

  • Page 124: Software Download/Upload Functions

    Pathways for file transactions between the controller and computer devices external to the controller are shown in Figure 54. Figure 54 - Pathways for Upload/Download Transactions HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 125: Table 22 - Configuration File Downloading

    For details of uploading configuration items, refer to Hybrid Control Designer and Operator Interface manuals. Revision 5 9/03 Table 22 - Configuration file downloading Permitted When Controller is in . . . PROGRAM Mode HC900 Hybrid Controller Installation and User Guide RUN Mode OFFLINE Mode Yes/No (Note 1)
  • Page 126 Operating Characteristics - Software Download/Upload Functions HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 127: Diagnostics And Troubleshooting

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

  • Page 128: Figure 55 - Led Indicators

    Diagnostics and Troubleshooting - External Indications of Diagnostic Information Figure 55 - LED Indicators HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 129: Table 23 - Led Indications On Main Cpu

    Green (On/Off) On when another 10Base-T PHY is present on the link NOTE: These LEDs indicate activity on the communication port, they are controlled by hardware (PHY chip), not by software. HC900 Hybrid Controller Installation and User Guide Indicates Condition:...

  • Page 130: Table 24 - Led Indications On Scanner Module

    For Inputs, indicates On or Off status of the field input even if Forced to the opposite state. For Outputs, indicates On or Off status of the output including if Forced. HC900 Hybrid Controller Installation and User Guide Indicates Condition: Indicates Condition: Revision 5...

  • Page 131: User Interface

    LED. Communications and control are disabled. A block has an output None that is forced. HC900 Hybrid Controller Installation and User Guide Indicates Condition: User Action 1. Cycle power 2. Replace CPU 3. Replace rack 1. Cycle power 2.
  • Page 132 See PREFETCH exception occurred for ABORT. an unknown reason. Bad Instruction See PREFETCH Detected ABORT HC900 Hybrid Controller Installation and User Guide User Action Download a valid configuration. Replace CPU. running ceases. This forces the modules into failsafe. 1. Configure one of the ASYS and FSYS ports as a master.
  • Page 133 Bad date and time See NOT PROGRAMMED. RTC failed to program See NOT PROGRAMMED. Unable to read RTC See NOT PROGRAMMED. HC900 Hybrid Controller Installation and User Guide User Action See PREFETCH ABORT. See PREFETCH ABORT. See WATCHDOG Replace battery. monitor block’s RACK OK pin is turned off.
  • Page 134 Refer to MODULE NO modules that are in its COMM diagnostic for SPI backplane. further details. HC900 Hybrid Controller Installation and User Guide User Action 1. Check connections 2. Access the Comm port diagnostics screen 3. Replace CPU 1.
  • Page 135 MODULE NO COMM. compatible with the scanner module. Refer to MODULE NO COMM diagnostic for further details. HC900 Hybrid Controller Installation and User Guide User Action 1. Verify that the expansion rack should be in the configuration 2. Verify that the...
  • Page 136 2. Associated blocks set 3. Associated rack 4. Associated rack 5. ASYS block’s HW OK HC900 Hybrid Controller Installation and User Guide User Action 1. Improve ventilation that are configured as to rack T/Cs set their fail pin 2.
  • Page 137 Module is reporting a See WRONG MODULE. diagnostic condition. See Table 28 - Bad Module Diagnostics. HC900 Hybrid Controller Installation and User Guide User Action Action is based on the IODIAG indication. If IODIAG is not MODULE ERROR,...
  • Page 138 DLL errors. 2. Depending on the 3. Associated rack's COM 4. Rack 1 COM Port HC900 Hybrid Controller Installation and User Guide User Action 1. Use the OI or Hybrid block’s RACK OK pin is Control Designer turned off.
  • Page 139 2. All rack monitor block 3. All modules in the 4. ASYS block’s HW OK 5. The statuses for the HC900 Hybrid Controller Installation and User Guide User Action Replace main-CPU XIO PORT DIAG are module set to HWFAIL, and COMPORT DIAG is set to FAIL.
  • Page 140 2. Rack 1 monitor block’s 3. ASYS block’s HW OK 4. If configured as a HC900 Hybrid Controller Installation and User Guide User Action 1. Check baud rate COMPORT DIAG is set 2. Check connectors to FAILED.
  • Page 141 DHCP and IP address SEE NETWORK SETUP are not configured ERROR Ethernet port tests failed during power- HC900 Hybrid Controller Installation and User Guide User Action Replace CPU module COMPORT DIAG is set to FAILED. RACK OK pin is turned off.
  • Page 142 SEE NETWORK SETUP are not configured ERROR Ethernet port tests SEE NETWORK SETUP failed during power- ERROR HC900 Hybrid Controller Installation and User Guide User Action At host, determine COMPORT DIAG is set which message is to WARNING. causing the exception code and fix.

  • Page 143: Table 28 - Bad Module Diagnostics

    √ √ √ √ √ √ HC900 Hybrid Controller Installation and User Guide # of User Action Strobes 1. If expansion rack(C50 CPU only), check communication link connection to main CPU 2. Remove the module and check for a bent pin, then reinsert the module.

  • Page 144: Table 29 - Bad Channel Diagnostics

    Channel The board indicates that the channel is Failure failing to output the correct value. Table 29 - Bad Channel Diagnostics HC900 Hybrid Controller Installation and User Guide User Action Check terminal block connections Replace source element Replace card.

  • Page 145: Table 30 - Scanner Diagnostics

    Communications and module scanning are disabled. Does no scanning of modules. Modules remain in their failsafe state. HC900 Hybrid Controller Installation and User Guide User Action 1. Cycle power 2. Replace scanner 3. Replace rack 1. Cycle power 2. Replace scanner 3.
  • Page 146 Does no scanning of modules. Modules remain in their failsafe state. HC900 Hybrid Controller Installation and User Guide User Action 1. Verify that the jumpers on the scanner are setup for the correct rack address. 2. Check that cable is connected to expansion rack(C50 CPU only).
  • Page 147 Does no scanning of modules. Modules remain in their failsafe state. HC900 Hybrid Controller Installation and User Guide User Action 1. Cycle power to the scanner 2. Upgrade scanner software 3. Replace scanner module 4. Contact Honeywell Personnel.
  • Page 148 No action is taken. No action is taken. No action is taken. No action is taken No action is taken. HC900 Hybrid Controller Installation and User Guide User Action 1. Improve ventilation to rack 2. Replace AI module 1. Verify configuration 2.
  • Page 149 Diagnostics and Troubleshooting - User Interface Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 150: Analog Calibration

    Only trained and authorized personnel should perform the procedures in this section. Failure to comply could result in death or serious injury. ATTENTION For calibration procedures, refer to the Operator Interface manual or Hybrid Control Designer manual. Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03 Analog Calibration...

  • Page 151: Analog Input Calibration

    The calibration device(s) must have the following precision characteristics: TC, mVolts, Volts inputs: 1 microvolt resolution • Ohms, RTD inputs: .01 ohm resolution • 4-20mA inputs: 4 microamp resolution • Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...

  • Page 152: Figure 56 - Terminal Board Connections For Ai Calibration

    Copper wire T/C extension wire Millivolt Ice Point Source Reference Copper wire T/C extension wire HC900 Hybrid Controller Installation and User Guide IN 1+ IN 1 - 1 & 2 IN 2 + IN 2 - IN 3+ IN 3- 3 &...

  • Page 153: Figure 57 - Terminal Board Connections For Ao Calibration

    A diagram of a precision ammeter connected to the terminals of an Analog Output module is given in Figure 57. The specifications of the meter must be consistent with calibration requirements. Figure 57 - Terminal board Connections for AO Calibration Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...
  • Page 154 - Overview HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 155: Removal And Replacement Procedures

    All of the input/output modules available for use in the HC900 Controller have a RIUP designation. That is, they can be Removed and Inserted Under Power, where "power" refers to DC power at the backplane of the rack. (It does not refer to power for field wiring at the terminal board associated with the I/O module, which must be disconnected (using a user-supplied switch) at the field device before removing or inserting the module.

  • Page 156: Table 31 - Power Supply Replacement

    Replacing the Power Supply The power supply for the HC900 Hybrid Controller is available in two models and is used in the local (controller) rack and in the remote (I/O expansion) racks(C50 CPU only), in 4-, 8-, and 12-module sizes.
  • Page 157 Using a meter and the test points on the face of the power supply, ensure that voltages (measured on the backplane) are within specifications. Revision 5 9/03 Action HC900 Hybrid Controller Installation and User Guide...

  • Page 158: Table 32 - Controller Module Replacement

    Download the configuration. Set the Real-Time Clock. If all status indications are green, power may be restored to the I/O modules per the application's procedures. Table 32 - Controller Module Replacement Action HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 159: Table 33 - Scanner Module Replacement

    Controller Module with which it is connected. Check status indications at the Scanner Module, at the Controller Module, and at the OI. Revision 5 9/03 Table 33 - Scanner Module Replacement Action HC900 Hybrid Controller Installation and User Guide...

  • Page 160: Table 34 - Riup: Potential Hazards And Recommended Actions

    I/O module, particularly in a system that is actively controlling a process. All of the I/O Module types in the HC900 Controller System include the Removal and Insertion Under Power (RIUP) feature. That is, while the rack is powered, any of the I/O Modules can be removed or...

  • Page 161: Table 35 - I/O Module Replacement

    If the rack was powered-down for the procedure, restore power to the rack. Re-connect signals to field devices. Revision 5 9/03 Table 35 - I/O Module Replacement Action - Each signal at each of the terminals for an I/O HC900 Hybrid Controller Installation and User Guide...

  • Page 162: Battery Installation/Replacement

    60 hours. Installing the backup battery when the CPU is not initialized will cause undue battery drain. Do not install or replace the backup battery until after site power is applied. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 163: Table 36 - Installing Backup Battery (Cpu Not Initialized)

    (front) end of the battery. While maintaining proper orientation (battery toward the left), slide the battery holder into the slot in the Controller Module until it snaps into place. Revision 5 9/03 Action HC900 Hybrid Controller Installation and User Guide...

  • Page 164: Table 37 - Replacing A Backup Battery (Cpu Powered))

    While maintaining proper orientation (battery toward the left), slide the battery holder into the slot in the Controller Module until it snaps into place. Action If the battery is removed from the Controller Module when AC power is not HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 165: Controller Components And Modules

    Full Document set on CD Full document set, hard copy - Engish Software HC Designer Config. Software CD Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide NUMBER 900R04 - 0001 900R08 - 0001 900R12 - 0001 900P01 -0001...

  • Page 166: Specifications

    Voltage: Universal power, 90 to 264 Vac, 47 to 63Hz Controller Rack Rating: 130VA @ 264VAC, typical 110VA @ 115VAC In-rush current: 7 amps peak-to-peak for 150 ms at 240 Vac Variable; depends on I/O Module complement. Description HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 167: Controller Module Design

    • connects to any Modbus slave or master device • connects to the Operator Interface (up to 2000 feet, using Belden 9271 or equivalent) • connects to any Modbus slave or master device HC900 Hybrid Controller Installation and User Guide...

  • Page 168: Scanner Module Design

    - Receives power (5 Vdc and 24 Vdc) from power supply - Serial Peripheral Interface (SPI) for I/O Modules in Local Rack - diagnostic sensing for I/O slots in this rack Description HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 169: Rack Design

    Mounting holes are in standardized patterns, as shown in the diagram below. 12-slot racks only 0.263 6.90 Key: inches 6.04 Revision 5 9/03 Description 8-slot racks only All racks 3.02 6.23 HC900 Hybrid Controller Installation and User Guide Reference Center for Drilled Holes at Top of Rack 6.375 3.02 6.04...

  • Page 170: Input Output System: Common Features

    HC900. Two types are available: 20-connector barrier strip or 20-connector "Euro" style. Both styles fit any type of I/O module available for the HC900 System. Blocks have color code: red block, with tin plating on terminals for higher voltages, and black with gold plating for lower voltages. Coding system applies to both block types.

  • Page 171: Analog Input, Analog Output Modules: Common Features

    Humidity = 45% to 55% RH non-condensing Line voltage = Nominal ± 1 % Source resistance = ohm Series mode and common mode = 0 V Frequency = Nominal ± 1 % ±0.01% of full scale/°C One per card HC900 Hybrid Controller Installation and User Guide...
  • Page 172 Stored in non-volatile memory. Data is stored in non-volatile memory Redundant Factory Calibration Individual Channel Field Calibration Monitoring of Factory Calibration, Field Calibration, 24 Vdc supply, and configuration. Stored in non-volatile memory. HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 173: Analog Output Modules

    Individual Channel Field Calibration Timeout causes outputs to be forced to configured values. Monitoring of Factory Calibration, Field Calibration, Configuration, and +24 Vdc power supply. Feedback to CPU that indicates output current flowing. HC900 Hybrid Controller Installation and User Guide...

  • Page 174: Digital Input Modules; Common Features

    5360 Ohms nominal 2.0 mA min., ON: 1000 Ohms, Max OFF: 150 K ohms, Min OFF to ON: 4ms max; 2ms nominal ON to OFF: 6ms max; 5ms nominal 2.6 mA HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 175: Dc Input Module

    6.9 mA @ 24Vdc nominal 3.5 mA 1.5 mA 230 mA maximum for 5 Vdc; (no 24 Vdc power) OFF to ON: 4 ms maximum; 2 ms nominal ON to OFF: 4 ms maximum; 2 ms nominal HC900 Hybrid Controller Installation and User Guide...

  • Page 176: Ac Input Module

    Green - Good Yellow - at least one output is Forced Red - Fault Via light pipes at front of card for each digital output point green indicates On, logic side HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 177: Dc Output Module

    1 A per point, 8 A max. per card, resistive load 0.15 mA @ 32 Vdc 4 A for 10 ms 0.0 mA 426 mA @ 5 V Off to On: 10 ms On to Off: 5 ms Electronic limiting HC900 Hybrid Controller Installation and User Guide...

  • Page 178: Ac Output Module

    Off to On: 2 ms + 1/2 cycle On to Off: 2 ms + 1/2 cycle Replaceable; Wickmann part #3741315041. 3.15 Amp time lag fuse with UL/CSA approval for 250 VAC HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 179: Relay Output Module

    Form-C: 4 Electro-mechanical relay 120/250 Vac, 30 Vdc 4 A @ 250 Vac, 30 Vdc resistive load 1 mA @ 350 Vdc 0 mA 140 mA @ 5 V 100 mA @ 24 V HC900 Hybrid Controller Installation and User Guide...

  • Page 180: Environmental And Operating Conditions

    14 Hz to 250 Hz— acceleration 1 g 100 V to 240 V (24 V optional) 50/60 Hz 110 VA typical 115VAC HC900 Hybrid Controller Installation and User Guide Extreme Transportation and Storage 32 to 140 –40 to 151 0 to 60 –40 to 66...

  • Page 181: Table 38 - Hc900 Pv Input Types And Ranges

    When using the Hybrid Control Designer configuration software to convert UMC800 configuration files to HC900 configuration files, the HC900 range to the left of the UMC800 data will be used by the conversion program. There may also be UMC800 ranges that are not supported by the HC900 Controller. For these ranges the conversion process will default the range data to a null, not-programmed, range.
  • Page 182 Cu10 -20 250 C 84 Cu10 37.8 Ohms 1000 2000 Ohms 4000 HC900 Hybrid Controller Installation and User Guide (Reference): Corresponding UMC800 Input type and range 0 1380 C 118 0 100 C 72 -4 482 F 85 0 200 0 2000...
  • Page 183 -10 10 mV -50 50 mV –100 100 mV –500 500 0 10 V -1 1 V -2 2 V -5 5 V -10 10 1250 HC900 Hybrid Controller Installation and User Guide (Reference): Corresponding UMC800 Input type and range...
  • Page 184 4 max. 20 max. 8 max. 2 max. 2000 Model C30 – 34,000 Model C50 – 168,000 64 max. 1500 44,000 Model C30 – 192 points Model C50 – 512 points HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...
  • Page 185 Specifications - Environmental and Operating Conditions Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 186: Appendix A Site Planning Documentation Aids

    I/O module in each controller, and for each peer network to be installed at the user's site. The data collected on these sheets will be very useful in performing and coordinating installation and software configuration tasks. Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03 Appendix A...

  • Page 187: Figure 58 - Example Site Map - Equipment Placement

    Appendix A Site Planning Documentation Aids - Overview • Figure 58 - Example Site Map - Equipment Placement Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 188: Figure 59 - Example Network System Diagram

    Site Planning Documentation Aids - Overview Figure 59 - Example Network System Diagram HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...
  • Page 189 Appendix A Site Planning Documentation Aids - Overview HC900 Controller Configurator Revision 5 HC900 Hybrid Controller Installation and User Guide 9/03...

  • Page 190: I/O Module Configurator

    Contact Input; DCO = DC Digital Output; ACO = DC Digital Output; RO = Relay Output. Jumper Comb: specify: none ( - ), 2-position (2), or 10-position (10) |_|_|_| . |_|_|_| . |_|_|_| Subnet Mask |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| (up to 16 ASCII char's) HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...

  • Page 191: I/O Module Channel Assignment Configurator

    To specify rack, encircle appropriate number. Revision 5 9/03 Site Planning Documentation Aids - I/O Module Channel Assignment Configurator Alias Name Slot # Module Type ____ Tagname HC900 Hybrid Controller Installation and User Guide |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Slot # Module Type ____ Tagname Tagname...

  • Page 192: Peer Network Configurator

    Alias Name Subnet Mask Alias Name Subnet Mask Alias Name Subnet Mask HC900 Hybrid Controller Installation and User Guide |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_|_| . |_|_|_| . |_|_|_| . |_|_|_| |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_|_| . |_|_|_| . |_|_|_| . |_|_|_| |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_|_| . |_|_|_| . |_|_|_| . |_|_|_| |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_|_| .

  • Page 193: Appendix B Installation Of Remote Termination Panels (Rtps)

    Appendix B Installation of Remote Termination Panels (RTPs) Overview The Remote Termination Panel (RTP) provides an easy way to connect the HC900 controller to the field wiring. The RTP integrates some of the typical externally connected components, reducing wiring and setup time.

  • Page 194: Analog Input

    Install AI module label onto the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 195 Refer to Figure 61 through Figure 67 for field wiring. Any input type can be wired to any of the 8 inputs. After wiring, double check DIP switches are set correctly for each input type (Step 3). Revision 5 9/03 Action Ohms: RTD: HC900 Hybrid Controller Installation and User Guide Fuses: 80mA Time lag Wickmann part #3740080041 UL/CSA approved Transmitter:...

  • Page 196: Figure 61 Analog Input Terminal And Dip Switch Designations

    Transmitter Transmitter Input 2 Input 2 Input 2 Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter HC900 Hybrid Controller Installation and User Guide Input 5 Input 5 Input 5 Input 7 Input 7 Input 7 Input 4 Input 4 Input 4 Transmitter...

  • Page 197: Figure 63 Milliamp Input Connections With 250 Ohm Shunt Resistance

    V, mV Input 3 Input 3 Input 1 Input 1 Input 2 Input 2 Figure 64 Volt, millivolt input connections HC900 Hybrid Controller Installation and User Guide Input 5 Input 5 Input 7 Input 7 Input 6 Input 6 V, mV...

  • Page 198: Figure 65 Three-Wire Rtd Input Connections

    Input 2 Input 2 Input 4 Input 4 Input 3 Input 3 Figure 66 Two-wire RTD or ohm input connections HC900 Hybrid Controller Installation and User Guide Input 5 Input 5 Input 7 Input 7 3 wire 3 wire 3 wire...

  • Page 199: Figure 67 Slidewire Feedback Connections For Actuators

    Figure 67 Slidewire feedback connections for actuators RTP + Cable Accuracy ±0.04% Range (0.357°C) ±0.12% Range (0.824°C) ±0.57% Range (1.540°C) ±0.07% Range (0.140Ω) ±0.04% Range (0.004mV) HC900 Hybrid Controller Installation and User Guide Input 5 Input 5 Input 7 Input 7 Slidewire Slidewire...
  • Page 200 SW 7 (2) SW 8 (2) 250 Ohm 250 Ohm 250 Ohm 250 Ohm 250 Ohm 250 Ohm 250 Ohm 250 Ohm 8(1) 7(1) 6(1) 5(1) 4(1) 3(1) 2(1) HC900 Hybrid Controller Installation and User Guide 1(1) SW 9 Revision 5 9/03...

  • Page 201: Relay Output

    Install relay output module label onto the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 202 Cable power is limited to 24 Amps per module at 60C (140 degrees F) and 32 Amps at 54C (129 degrees F). Action 10 11 12 13 14 15 16 17 18 19 20 HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...
  • Page 203 Relay Output RTP Internal schematic HC900 Terminal Block Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...

  • Page 204: Digital Input/Digital Output/Analog Output

    Install AO module label onto the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 205 Install DI module label into the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 206 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Action 9 10 11 12 13 14 15 16 17 18 19 20 HC900 Hybrid Controller Installation and User Guide Jumper open Jumper closed...
  • Page 207 Install DC DI module label into the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 208 Install AC DI module label into module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 209 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Revision 5 9/03 Action 9 10 11 12 13 14 15 16 17 18 19 20 HC900 Hybrid Controller Installation and User Guide Jumper open Jumper closed...
  • Page 210 Install DC DO label into the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 211 Install AC DO label into the module connector cover. • Connect shield drain wire to the grounding bars at the base of the HC900 rack. All field-wiring shields must be grounded as described in the shield grounding section (page 60).
  • Page 212 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Action 9 10 11 12 13 14 15 16 17 18 19 20 HC900 Hybrid Controller Installation and User Guide Jumper open Jumper closed...
  • Page 213 Digital Input/Digital Output/Analog Output RTP Internal schematic HC900 Terminal Block Revision 5 9/03 HC900 Hybrid Controller Installation and User Guide...

  • Page 214: Rtp Cable Wire Positions And Colors

    RTP Cable wire positions and colors Twisted Pair Number HC900 Module TB Position HC900 Hybrid Controller Installation and User Guide RTP J1 Plug Connector Color Black Black White Black Green Black Blue Black Yellow Black Brown Black Orange White Green...

  • Page 215: Latch/Unlatch Rtp To Rail

    Insert other side of DIN rail at B, and push B over the rail to snap into place. To remove, using slot screwdriver to lift C up gently (plastic is fragile) to disengage at B. Lift up and over rail, then disengage at A. Revision 5 9/03 Action DIN rail HC900 Hybrid Controller Installation and User Guide...
  • Page 216 Appendix B Installation of Remote Termination Panels (RTPs) - Latch/Unlatch RTP to rail HC900 Hybrid Controller Installation and User Guide Revision 5 9/03...
  • Page 217 I/O implementation, 14 I/O Installation Procedures, 63 I/O Module Diagnostics, 133 I/O Module Installation, 57 I/O numbering assignments, 14 I/O slot, 57 I/O wiring shields, 60 Information Technology, 22 Input/Output Modules, 11 Installation Tools, 49 HC900 Hybrid Controller Installation and User Guide...
  • Page 218 OFFLINE Mode, 110 OHMs Inputs, 68 OPC, 16 OPC server/client software, 17 Open Modbus/TCP protocol, 16 Operating Characteristics, 107 HC900 Hybrid Controller Installation and User Guide Operating Modes, 107 Orientation of Rack Mounting, 39 OSI Model, 22 —P— Parallel processing, 3...
  • Page 219 Terminal Block Colors, 58 Terminal Block Styles, 58 test-points, 54 The Fix, 17 transmission delays, 42 Revision 4 HC900 Hybrid Controller Installation and User Guide 5/03 —U— UDP, 14 Universal Analog Input Wiring, 69 uplink port, 13 User Datagram Protocol, 14 —V—...

  • Page 221: Sales And Service

    For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor, contact one of the offices below. ARGENTINA CANADA Honeywell S.A.I.C. Honeywell Limited Belgrano 1156 The Honeywell Centre Buenos Aires 300 Yorkland Blvd. Argentina Toronto, Ontario Tel. : 54 1 383 9290 M2j 1s1...
  • Page 228 Industrial Measurement and Control Honeywell 1100 Virginia Drive Fort Washington, PA 19034 www.honeywell.com/imc 51-52-25-107 Rev. 5 0903 Printed in USA...

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