Honeywell 900U02-0100

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

May 2019

RTP A Cable wire positions and colors (for cable assembly drawing, applies to 16 AI, 32

DI, 32 DO)

Twisted Pair Number of

Cable A

ControlEdge HC900 Module TB

Position

RTP A J1 Plug Connector

Color

Black

Red

Black

White

Black

Green

Black

Blue

Black

Yellow

Black

Brown

Black

Orange

Red

White

Red

Green

Red

Blue

J2 J3

J9 J7

HC900

Terminal

Block

RTP A

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 276

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