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Honeywell Manuals
Controller
900U02-0100
User and installation manual
Honeywell 900U02-0100 User And Installation Manual
Process & safety controller
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Notices and Trademarks
Symbol Definitions
Table of Contents
Introduction
Purpose
Model Selection Guide
Functional Description
Figure 1 - Small Controledge HC900 Controller Configuration
Figure 2 - Expanded Controledge HC900 Controller Configuration (C50/C70 CPU Only)
Figure 3 - Single Process with Redundancies
Feature Summary
Components and Architecture
Overview
Components
Figure 4 - Configuration with Multiple Controllers
Table 1 - Descriptions of Major Components (Figure 4)
Redundant Components
Figure 5 - Redundant Configuration with Multiple I/O Racks (Star Topology)
Figure 6 Redundant Configuration with Multiple I/O Racks (Ring Topology)
Table 2 - Descriptions of Major Redundancy Components
Hardware Components
Figure 7 - Controller Rack Components
Figure 8 - Redundant Controller Rack Components
Figure 9 - I/O Expansion Rack Components
Figure 10 - Rack Options
Figure 11 - Power Supply
Figure 12 - Power Status Module (PSM)
Figure 13 - Controller Module
Figure 14 - Redundancy Switch Module
Figure 15 - Scanner 1 Module
Figure 16 - Scanner 2 Module
Figure 17 - I/O Module Terminal Block
Figure 18 - RS-232 Modem Devices
I/O Network
Figure 19 - Controledge HC900 Controller Configurations
I/O Implementation Requirements Include
Ethernet Open Connectivity Network
Figure 20 - Modular Network Structure
Figure 21 - Modbus/Tcp Framing
Figure 22 - Typical Installation Using a Cable Modem
Serial Ports
Figure 23 - Controller Serial Ports
Table 3 - Serial Port DIP Switch Settings
Figure 24 - Serial Ports DIP Switch Default Settings
Network and Security Planning
Overview
Security Checklists
Backup and Restore
Physical and Environmental Considerations
Security Updates
Network Security
Figure 25: System Architecture
Figure 26: System with Safety Peer Communication
Controledge HC900 Security Features
Figure 27: Communication from Remote Location
Notices
Pre-Installation Planning
Overview
AC Power Supply Selection for Racks with I/O
DC Power Supply
Rack Orientation and Mounting
Figure 28 - Rack Dimensions
Figure 29 - Rack Dimensions with Reserve Power Supply
Figure 30 - Vertical Spacing of Racks (All Models)
Remote Termination Panels
Environment
Heat Rise De-Ratingpage
Installation in Hazardous Location
Table 4 - Power Applied, by Module Type
Figure 31 - AC Input Module De-Rating
Figure 32 - Power Supply De-Rating
Cable/Wiring Distance Planning
Electrical Considerations
Figure 33 - Cabinet Wiring, Single Chassis
Figure 34 - Cabinet Wiring, Multiple Chassis
Figure 35 - Redundant Power Supplies each with External Fuse and Switch
Table 5 - Guidelines for Grouping Wires
Figure 36 - Master Control Relay Wiring Example
Hardware and Wiring Requirements for Safety Configuration
Figure 37 - IO-V Function Block Connections
Figure 38 - Individual Series DO Connections
Figure 39 - Common Series DO Connections
System Monitor Function Blocks
Figure 40 - Series Relay for Analog Outputs
Rack Installation
Overview
Table 6 - Installation Tools
Table 7 - Site and Equipment Preparation
Mount Racks
Table 8 - Mount Racks
Assemble Controller Rack
Table 9 - Assemble C30/C50/C70 Controller Rack
Table 10 - Assemble C75 Controller Rack
Assemble I/O Expansion Racks
Table 11 - Assemble I/O Expansion Racks
I/O Module Installation and Wiring
Overview
Module Placement in Racks
Figure 41 - I/O Module Installation
Figure 42 - Terminal Block Styles
Remote Termination Panel (RTP)
Terminal Block-To-Field (Signal) Wiring
Table 12 - Minimum Recommended Wire Sizes
Figure 43 - Signal-Wire Grounding
Figure 44 - Wire-Shield Grounding
Figure 45 - Terminal Block Jumper Installation
Removal and Insertion under Power (RIUP)
Table 13 - RIUP: Potential Hazards and Recommended Actions
I/O Module Installation Procedures
Table 14 - Connect Input/Output Wiring
I/O Terminal Block Wiring Diagrams
Table 15 - Typical Thermocouple Resistance in Ohms Per Double Foot @ 68 Degrees F
Figure 46 - RTD Inputs
Figure 47 - Universal Analog Input Wiring Diagram
Figure 48 - Examples of RTD Input Wiring
Figure 49 - Analog Input Wiring - Eight Tcs
Figure 50 - Analog Input Wiring - Eight Resistance Inputs
Figure 51 - Analog Input Wiring - Eight Rtds
Figure 52 - Analog Input Wiring - Slidewire (Position Proportion Block)
Figure 53 - 16 Point High Level Analog Input Wiring
Figure 54 - 4 Channel Analog Output Wiring Diagram
Figure 55 - 8 Channel Analog Output Wiring Diagram
Figure 56 - 16 Channel Analog Output Wiring Diagram
Figure 57 - DC Input Module Wiring Diagram
Figure 58 - DC Input Module Jumper
Figure 59 - 32 Point DC Input Module Wiring
Figure 60 - AC Input Module Wiring Diagram
Figure 61 - AC Input Module Jumper
Figure 62 - AC/DC Isolated Input Module
Figure 63 - AC/DC Isolated Input Module Wiring
Figure 64 - Contact Input Wiring Diagram
Figure 65 - DC Output Module Wiring Diagram
Figure 66 - DC Output Jumpers
Figure 67 - 32 Point DC Output Module Wiring
Figure 68 - AC Output Module Wiring Diagram
Figure 69 - AC Output Module Jumper
Figure 70 - Schematic Example: Relay Output and External Wiring
Figure 71 - Relay Output Module Wiring Diagram
Figure 72 - Relay Output Module Jumpers
Figure 73 - Pulse Counting Wiring
Figure 74 - Pulse Output Wiring
Figure 75 - Frequency Wiring
Figure 76 - Quadrature, Differential, External Power Wiring
Figure 77 - Quadrature, Single Ended, External Power Wiring
Figure 78 - Quadrature, Differential, Controledge HC900 Power Wiring
Figure 79 - Quadrature, Single Ended, Controledge HC900 Power Wiring
Figure 80: Safety UIO with Power Wiring
Table 16 - AI Channel
Figure 81 - Standard 2 Wire Transmitter with UIO
Figure 82 - Self-Powered 3-Wire Transmitter with System Ground
Table 17 - Field Wiring for Analog Output
Overview
Wiring and Cabling
Table 18 - Connect Communications Wiring and Cabling
Table 19 - Links to Controller Communication Ports
Connecting the Operator Interface to the Controller
Table 20 - Parts Needed to Make RS-485 Cable
Table 21 - Null Modem Cable Connections
Connecting the Controledge HC900 Controller to Modbus Device(S)
Operating Characteristics
Introduction
Overview
Power down / Power up
Controller Modes
Table 24 - Controller Operating Modes
Table 25 - Mode Switch Functions
Table 26 - Controller Behavior in Mode Transition
File Download/Upload Functions
Table 27 - Configuration File Downloading
Redundant Operating Characteristics
Overview
Start-Up
Modes of Operation (Figure 100)
Steady State Operations
Failover
File Download/Upload Functions
Diagnostics and Troubleshooting
Overview
External Indications of Diagnostic Information
Controller CPU Indicators
Table 29 - Controller Status LED Diagnostics
Scanner Indicators
Table 30 - LED Indications on Scanner Module
Table 31 - Scanner LED Diagnostics
I/O Module Indicators
Table 32 - LED Indications on I/O Module
Table 33 - I/O Module LED Diagnostics
Table 34 - Bad I/O Channel Diagnostics
Table 35 - LED Indications on Ethernet Switch
Analog Calibration
Overview
Removal and Replacement Procedures
Overview
Safety Considerations - PLAN AHEAD
Table 36 - Power Supply Replacement (All Except C75)
Table 37 - Controller Module Replacement
Table 38 - Scanner Module Replacement
Table 39 - RIUP: Potential Hazards and Recommended Actions
Table 40 - I/O Module Replacement
Figure 106 - Battery Life in Months
Table 41 - Installing Backup Battery (CPU Not Initialized)
Table 42 - Replacing a Backup Battery (CPU Powered))
Specifications
General Specifications (Refer to Specification Manual)
Table 43 - Controledge HC900 PV Input Types and Ranges
System Sizing and Availability Summary
Table 44 - System Size and Availability Summary
Extended Distance Configuration with Fiber Optics
Figure 107 - Extended Distance Example #1
Figure 108 - Extended Distance Example #2
Appendix - Installation of Remote Termination Panels (Rtps)
Overview
Analog Input
Relay Output
Figure 109 - Example Installation
Analog Input/Digital Input/Digital Output/Analog Output
Figure 110 - Analog Input Terminals
Figure 111 - Two-Wire Transmitter Connections with Common 24 VDC Supply
Figure 112 - Milliamp Input Connections with 250 Ohm Shunt Resistance
Figure 113 - Volt, Millivolt Input Connections
Figure 114 - Three-Wire RTD Input Connections
Figure 115 - Two-Wire RTD or Ohm Input Connections
Figure 116 - Slidewire Feedback Connections for Actuators
Figure 117 - Voltage Input Connections
Figure 118 - Current Connections with 2-Wire Transmitter
Declaration of Conformity
ATEX Certification
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Quick Links
1
Model Selection Guide
2
Figure 47 - Universal Analog Input Wiring Diagram
3
Figure 80: Safety Uio with Power Wiring
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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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This manual is also suitable for:
Controledge hc900
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