Honeywell 900U02-0100

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182 ControlEdge HC900 Process & Safety Controller User and Installation Manual Revision 10

May 2019

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

 Lead Controller automatically synchronizes the Reserve with run-time data during each

function block execution cycle

 Both the Lead and Reserve Controllers execute the function blocks in the control strategy, but

only the Lead Controller writes the physical outputs to the I/O Racks. See Figure 100.

 The Lead and Reserve controllers exchange system status to determine conditions for failover.

Figure 100 – Lead/Controller synchronization

Main Page

Notices and Trademarks2
Symbol Definitions6
Table of Contents8
Introduction15
Purpose15
Model Selection Guide16
Functional Description22
Figure 1 - Small Controledge HC900 Controller Configuration22
Figure 2 - Expanded Controledge HC900 Controller Configuration (C50/C70 CPU Only)23
Figure 3 - Single Process with Redundancies24
Feature Summary26
Components and Architecture29
Overview29
Components29
Figure 4 - Configuration with Multiple Controllers30
Table 1 - Descriptions of Major Components (Figure 4)31
Redundant Components32
Figure 5 - Redundant Configuration with Multiple I/O Racks (Star Topology)32
Figure 6 Redundant Configuration with Multiple I/O Racks (Ring Topology)33
Table 2 - Descriptions of Major Redundancy Components34
Hardware Components35
Figure 7 - Controller Rack Components35
Figure 8 - Redundant Controller Rack Components36
Figure 9 - I/O Expansion Rack Components37
Figure 10 - Rack Options38
Figure 11 - Power Supply39
Figure 12 - Power Status Module (PSM)40
Figure 13 - Controller Module41
Figure 14 - Redundancy Switch Module42
Figure 15 - Scanner 1 Module42
Figure 16 - Scanner 2 Module43
Figure 17 - I/O Module Terminal Block43
Figure 18 - RS-232 Modem Devices44
I/O Network45
Figure 19 - Controledge HC900 Controller Configurations45
I/O Implementation Requirements Include46
Ethernet Open Connectivity Network46
Figure 20 - Modular Network Structure48
Figure 21 - Modbus/Tcp Framing49
Figure 22 - Typical Installation Using a Cable Modem51
Serial Ports52
Figure 23 - Controller Serial Ports52
Table 3 - Serial Port DIP Switch Settings53
Figure 24 - Serial Ports DIP Switch Default Settings53
Network and Security Planning54
Overview54
Security Checklists54
Backup and Restore56
Physical and Environmental Considerations57
Security Updates58
Network Security58
Figure 25: System Architecture59
Figure 26: System with Safety Peer Communication61
Controledge HC900 Security Features62
Figure 27: Communication from Remote Location62
Notices63
Pre-Installation Planning64
Overview64
AC Power Supply Selection for Racks with I/O64
DC Power Supply66
Rack Orientation and Mounting66
Figure 28 - Rack Dimensions66
Figure 29 - Rack Dimensions with Reserve Power Supply67
Figure 30 - Vertical Spacing of Racks (All Models)68
Remote Termination Panels69
Environment69
Heat Rise De-Ratingpage69
Installation in Hazardous Location70
Table 4 - Power Applied, by Module Type71
Figure 31 - AC Input Module De-Rating72
Figure 32 - Power Supply De-Rating72
Cable/Wiring Distance Planning73
Electrical Considerations74
Figure 33 - Cabinet Wiring, Single Chassis75
Figure 34 - Cabinet Wiring, Multiple Chassis76
Figure 35 - Redundant Power Supplies each with External Fuse and Switch77
Table 5 - Guidelines for Grouping Wires78
Figure 36 - Master Control Relay Wiring Example80
Hardware and Wiring Requirements for Safety Configuration81
Figure 37 - IO-V Function Block Connections81
Figure 38 - Individual Series DO Connections82
Figure 39 - Common Series DO Connections82
System Monitor Function Blocks83
Figure 40 - Series Relay for Analog Outputs83
Rack Installation84
Overview84
Table 6 - Installation Tools84
Table 7 - Site and Equipment Preparation85
Mount Racks87
Table 8 - Mount Racks87
Assemble Controller Rack89
Table 9 - Assemble C30/C50/C70 Controller Rack90
Table 10 - Assemble C75 Controller Rack93
Assemble I/O Expansion Racks94
Table 11 - Assemble I/O Expansion Racks94
I/O Module Installation and Wiring96
Overview96
Module Placement in Racks96
Figure 41 - I/O Module Installation96
Figure 42 - Terminal Block Styles97
Remote Termination Panel (RTP)98
Terminal Block-To-Field (Signal) Wiring98
Table 12 - Minimum Recommended Wire Sizes98
Figure 43 - Signal-Wire Grounding99
Figure 44 - Wire-Shield Grounding99
Figure 45 - Terminal Block Jumper Installation100
Removal and Insertion under Power (RIUP)101
Table 13 - RIUP: Potential Hazards and Recommended Actions101
I/O Module Installation Procedures102
Table 14 - Connect Input/Output Wiring102
I/O Terminal Block Wiring Diagrams109
Table 15 - Typical Thermocouple Resistance in Ohms Per Double Foot @ 68 Degrees F109
Figure 46 - RTD Inputs110
Figure 47 - Universal Analog Input Wiring Diagram111
Figure 48 - Examples of RTD Input Wiring112
Figure 49 - Analog Input Wiring - Eight Tcs113
Figure 50 - Analog Input Wiring - Eight Resistance Inputs114
Figure 51 - Analog Input Wiring - Eight Rtds115
Figure 52 - Analog Input Wiring - Slidewire (Position Proportion Block)116
Figure 53 - 16 Point High Level Analog Input Wiring117
Figure 54 - 4 Channel Analog Output Wiring Diagram118
Figure 55 - 8 Channel Analog Output Wiring Diagram119
Figure 56 - 16 Channel Analog Output Wiring Diagram120
Figure 57 - DC Input Module Wiring Diagram121
Figure 58 - DC Input Module Jumper122
Figure 59 - 32 Point DC Input Module Wiring123
Figure 60 - AC Input Module Wiring Diagram124
Figure 61 - AC Input Module Jumper125
Figure 62 - AC/DC Isolated Input Module126
Figure 63 - AC/DC Isolated Input Module Wiring127
Figure 64 - Contact Input Wiring Diagram128
Figure 65 - DC Output Module Wiring Diagram130
Figure 66 - DC Output Jumpers130
Figure 67 - 32 Point DC Output Module Wiring131
Figure 68 - AC Output Module Wiring Diagram133
Figure 69 - AC Output Module Jumper133
Figure 70 - Schematic Example: Relay Output and External Wiring134
Figure 71 - Relay Output Module Wiring Diagram135
Figure 72 - Relay Output Module Jumpers136
Figure 73 - Pulse Counting Wiring137
Figure 74 - Pulse Output Wiring138
Figure 75 - Frequency Wiring138
Figure 76 - Quadrature, Differential, External Power Wiring139
Figure 77 - Quadrature, Single Ended, External Power Wiring139
Figure 78 - Quadrature, Differential, Controledge HC900 Power Wiring140
Figure 79 - Quadrature, Single Ended, Controledge HC900 Power Wiring140
Figure 80: Safety UIO with Power Wiring141
Table 16 - AI Channel143
Figure 81 - Standard 2 Wire Transmitter with UIO144
Figure 82 - Self-Powered 3-Wire Transmitter with System Ground145
Table 17 - Field Wiring for Analog Output147
Overview153
Wiring and Cabling153
Table 18 - Connect Communications Wiring and Cabling153
Table 19 - Links to Controller Communication Ports154
Connecting the Operator Interface to the Controller156
Table 20 - Parts Needed to Make RS-485 Cable157
Table 21 - Null Modem Cable Connections159
Connecting the Controledge HC900 Controller to Modbus Device(S)176
Operating Characteristics179
Introduction179
Overview179
Power down / Power up179
Controller Modes182
Table 24 - Controller Operating Modes185
Table 25 - Mode Switch Functions189
Table 26 - Controller Behavior in Mode Transition190
File Download/Upload Functions191
Table 27 - Configuration File Downloading192
Redundant Operating Characteristics193
Overview193
Start-Up193
Modes of Operation (Figure 100)193
Steady State Operations195
Failover197
File Download/Upload Functions197
Diagnostics and Troubleshooting199
Overview199
External Indications of Diagnostic Information199
Controller CPU Indicators200
Table 29 - Controller Status LED Diagnostics203
Scanner Indicators211
Table 30 - LED Indications on Scanner Module212
Table 31 - Scanner LED Diagnostics212
I/O Module Indicators216
Table 32 - LED Indications on I/O Module216
Table 33 - I/O Module LED Diagnostics217
Table 34 - Bad I/O Channel Diagnostics218
Table 35 - LED Indications on Ethernet Switch220
Analog Calibration221
Overview221
Removal and Replacement Procedures225
Overview225
Safety Considerations - PLAN AHEAD225
Table 36 - Power Supply Replacement (All Except C75)226
Table 37 - Controller Module Replacement227
Table 38 - Scanner Module Replacement228
Table 39 - RIUP: Potential Hazards and Recommended Actions229
Table 40 - I/O Module Replacement230
Figure 106 - Battery Life in Months232
Table 41 - Installing Backup Battery (CPU Not Initialized)233
Table 42 - Replacing a Backup Battery (CPU Powered))234
Specifications235
General Specifications (Refer to Specification Manual)235
Table 43 - Controledge HC900 PV Input Types and Ranges235
System Sizing and Availability Summary238
Table 44 - System Size and Availability Summary238
Extended Distance Configuration with Fiber Optics239
Figure 107 - Extended Distance Example #1239
Figure 108 - Extended Distance Example #2240
Appendix - Installation of Remote Termination Panels (Rtps)241
Overview241
Analog Input241
Relay Output241
Figure 109 - Example Installation241
Analog Input/Digital Input/Digital Output/Analog Output242
Figure 110 - Analog Input Terminals244
Figure 111 - Two-Wire Transmitter Connections with Common 24 VDC Supply244
Figure 112 - Milliamp Input Connections with 250 Ohm Shunt Resistance245
Figure 113 - Volt, Millivolt Input Connections245
Figure 114 - Three-Wire RTD Input Connections246
Figure 115 - Two-Wire RTD or Ohm Input Connections246
Figure 116 - Slidewire Feedback Connections for Actuators246
Figure 117 - Voltage Input Connections270
Figure 118 - Current Connections with 2-Wire Transmitter271
Declaration of Conformity279
ATEX Certification280

Honeywell 900U02-0100 - Page 196

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