Honeywell HC900 User Manuals

Table of Contents

• Introduction

  1
• Purpose

  1
• Functional Description

  2
• Functional Description

  2
• Feature Summary

  3
• Components and Architecture

  5
• Overview

  5
• Components

  5
• Hardware Components

  8
• Ethernet Devices/Considerations

  13
• Serial Ports (RS232 and RS485)

  19
• Networking Basics Reference

  22
• Pre-Installation Planning

  36
• Overview

  36
• Power Supply Selection

  37
• Environment

  38
• Orientation of Rack Mounting

  39
• Heat Rise De-rating

  39
• Equipment Placement Considerations

  41
• Electrical Considerations

  42
• Installation Guide

  49
• Overview

  49
• I/O Module Installation and Wiring

  57
• Overview

  57
• 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
• Communications Installation

  85
• Overview

  85
• 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
• Software Download/Upload Functions

  114
• Diagnostics and Troubleshooting

  117
• Overview

  117
• External Indications of Diagnostic Information

  117
• User Interface

  121
• Analog Calibration

  140
• Overview

  140
• Removal and Replacement Procedures

  145
• Overview

  145
• Safety Considerations - PLAN AHEAD!

  145
• Controller Components and modules

  155
• Specifications

  156
• HC900 Hybrid Controller Design

  156
• Controller Module Design

  157
• Scanner Module Design

  158
• Rack Design

  159
• Input Output System: Common Features

  160
• Analog Input, Analog Output Modules: Common Features

  161
• Analog Input Module

  161
• Analog Output Modules

  163
• Digital Input Modules; Common Features

  164
• Contact Input Module

  164
• DC Input Module

  165
• AC Input Module

  166
• Features Common to all Output Modules

  166
• DC Output Module

  167
• AC Output Module

  168
• Relay Output Module

  169
• Environmental and Operating Conditions

  170
• Appendix A Site Planning Documentation Aids

  176
• Overview

  176
• I/O Module Configurator

  180
• I/O Module Channel Assignment Configurator

  181
• Peer Network Configurator

  182
• 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
• Table 1 – Descriptions of Major Components (Figure 3)

  7
• Table 2 Simultaneous serial port configurations

  19
• Table 3 - Open System Interconnection Model

  25
• Table 4 - Networking Device Types

  26
• Table 5- Glossary of Networking Terms

  27
• Table 6 - Operating Limits and Installation Guidelines

  38
• Table 7 - Power Applied, by Module Type

  39
• Table 8 - Guidelines for Grouping Wires

  44
• Table 9 - Installation Tools

  49
• Table 10 - Site and Equipment Preparation

  50
• Table 11 - Install HC900 Controller Components

  52
• Table 12 - Minimum Recommended Wire Sizes

  59
• Table 13 - RIUP: Potential Hazards and Recommended Actions

  62
• Table 14 - Connect Input/Output Wiring

  63
• Table 15 - Connect Communications Wiring and Cabling

  85
• Table 16 - Links to Controller Communication Ports

  86
• Table 17 - PC Cable Pinouts

  90
• Table 18 - Parts needed for RS-485 Cabling

  100
• Table 19 - Controller Operating Modes

  111
• Table 20 - Mode Switch Functions

  112
• Table 21 - Controller Behavior in Mode Transition

  113
• Table 22 - Configuration file downloading

  115
• Table 23 - LED Indications on Main CPU

  119
• Table 24 - LED Indications on Scanner Module

  120
• Table 25 - LED Indications on I/O Module

  120
• Table 26 - LED Indications on Ethernet Hub

  121
• Table 27 - Controller Module Diagnostics

  121
• Table 28 - Bad Module Diagnostics

  133
• Table 29 - Bad Channel Diagnostics

  134
• Table 30 - Scanner Diagnostics

  135
• Table 31 - Power Supply Replacement

  146
• Table 32 - Controller Module Replacement

  148
• Table 33 - Scanner Module Replacement

  149
• Table 34 - RIUP: Potential Hazards and Recommended Actions

  150
• 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
• 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
• Figure 7 – Power Supply

  9
• Figure 8 - Controller Module

  10
• Figure 9 - Scanner Module

  10
• Figure 10 - I/O Module Terminal Blocks

  11
• Figure 11 - RS232 Modem Devices

  12
• Figure 12 – HC900 Controller Configurations

  13
• Figure 13 - Modular Network Structure

  15
• Figure 14 - Modbus/TCP Framing

  16
• Figure 15 - Typical installation using a Cable Modem

  18
• Figure 16 Serial Port Configurations 1 - 6

  20
• Figure 17 Serial Port Configurations 7 – 11

  21
• Figure 18 - AC Input Module de-Rating

  40
• Figure 19 - Power Supply De-rating

  40
• Figure 20 - Cabinet Wiring, Single Chassis

  43
• Figure 21 - Cabinet Wiring, Multiple Chassis

  43
• Figure 22 - Master Control Relay Wiring Example

  46
• Figure 23 - Rack Dimensions

  47
• Figure 24 - Vertical Spacing of Racks

  47
• Figure 25 - I/O Module Installation

  57
• Figure 26 - Terminal Block Styles

  58
• Figure 27 - Signal-Wire Grounding

  60
• Figure 28 - Wire-Shield Grounding

  60
• Figure 29 - Terminal Block Jumper Installation

  61
• Figure 30 - RTD Inputs

  68
• Figure 31 - Universal Analog Input Wiring Diagram

  69
• Figure 32 - Examples of RTD Input Wiring

  69
• Figure 33 - Analog Input Wiring - Eight TCs

  70
• Figure 34 - Analog Input Wiring - Eight Resistance Inputs

  70
• Figure 35 - Analog Input Wiring - Eight RTDs

  71
• Figure 36 Analog Input Wiring – Slidewire (Position Proportion Block)

  71
• Figure 37 - Analog Output Wiring Diagram

  72
• Figure 38 - DC Input Module Wiring Diagram

  73
• Figure 39 - DC Input Module Jumper

  74
• Figure 40 - AC Input Module Wiring Diagram

  75
• Figure 41 - AC Input Module Jumper

  76
• Figure 42 - Contact Input Wiring Diagram

  77
• Figure 43 - DC Output Module Wiring Diagram

  79
• Figure 44 - DC Output Jumpers

  79
• Figure 45 - AC Output Module Wiring Diagram

  81
• Figure 46 - AC Output Module Jumper

  81
• Figure 47 - Schematic Example: Relay Output and External Wiring

  82
• Figure 48 - Relay Output Module Wiring Diagram

  83
• Figure 49 - Relay Output Module Jumpers

  84
• Figure 50 - Null Modem Cable Construction

  90
• Figure 51 - RS-232 Remote Access via Modems

  91
• Figure 52 - Warm Start Operation

  108
• Figure 53 - Cold Start Operation

  109
• Figure 54 - Pathways for Upload/Download Transactions

  114
• Figure 55 - LED Indicators

  118
• Figure 56 - Terminal Board Connections for AI Calibration

  142
• Figure 57 - Terminal board Connections for AO Calibration

  143
• Figure 58 - Example Site Map - Equipment Placement

  177
• Figure 59 - Example Network System Diagram

  178
• Figure 60 Example installation

  183
• Figure 61 Analog input terminal and DIP switch designations

  186
• Figure 62 Two–wire transmitter connections with common 24 VDC supply

  186
• 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