Honeywell Experion PKS User manual

EXPERION PKS
RELEASE 515
ControlNet Installation Guide
EPDOC-XX25-en-515A
November 2019

Disclaimer
This document contains Honeywell proprietary information. Information contained herein is to be used
solely for the purpose submitted, and no part of this document or its contents shall be reproduced,
published, or disclosed to a third party without the express permission of Honeywell International Sàrl.
While this information is presented in good faith and believed to be accurate, Honeywell disclaims the
implied warranties of merchantability and fitness for a purpose and makes no express warranties
except as may be stated in its written agreement with and for its customer.
In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The
information and specifications in this document are subject to change without notice.
Copyright 2019 - Honeywell International Sàrl
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Contents 3
Chapter 1 - About This Document 6
1.1 Revision History 6
Chapter 2 - System Cabling and Wiring Installation 7
2.1 Experion system cabling and wiring 7
2.1.1 LAN (TCP/IP - Ethernet) 8
2.1.2 ControlNet Network 8
2.1.3 Field Wiring 8
2.1.4 Power and ground 8
2.2 Before You Begin 9
2.2.1 Planning 9
2.2.2 Obtain Documentation 9
2.2.3 General Installation Checklist 9
2.2.4 Conduct environmental checks 9
Chapter 3 - ControlNet PCIC Card Installation 10
3.1 About the ControlNet PCIC Card 10
3.1.1 Compliance to European Union Directives 11
3.1.2 Component handling guidelines 12
3.1.3 About PCIC card drivers 12
3.2 Installing the PCIC Card 12
3.2.1 Prerequisites 12
3.2.2 Accessing the expansion slots 13
3.2.3 Inserting the PCIC card 13
Chapter 4 - ControlNet Network Component Installation 14
4.1 Preparing to Install ControlNet Components 14
4.1.1 Prepare for installation 14
4.1.2 Components 14
4.1.3 Agency approval 14
4.1.4 Planning 14
4.1.5 ESD/EMI Immunity 15
4.2 About Mounting Taps 15
4.2.1 Mounting dimensions for taps 15
4.2.2 Mounting taps 17
4.2.3 Identifying drop-cables 19
4.3 Installing Repeaters 20
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4.3.1 Mounting dimensions for repeaters 20
4.3.2 Mounting your repeater 21
4.3.3 Grounding your repeater 21
4.3.4 Connecting ControlNet cables to your repeater 22
4.3.5 Connecting power and relay circuitry 22
Chapter 5 - Building ControlNet Trunk Cables 25
5.1 Preparing to Build ControlNet Trunk Cabling 25
5.1.1 Materials needed 25
5.1.2 Tools needed 25
5.1.3 Bulk cable testing 26
5.1.4 Adjusting the cutting blades 26
5.1.5 Reversing and replacing the cutting blades 28
5.1.6 Changing the memory-blade holder 30
5.2 About Installing cable connectors 31
5.2.1 Stripping the cable 31
5.2.2 Testing stripped cable for electrical shorts and continuity 36
5.2.3 Attaching connectors to the cable 37
5.2.4 Testing finished cables 40
Chapter 6 - Testing ControlNet Trunk Cables 41
6.1 Preparing to Test ControlNet Trunk Cables 41
6.1.1 Before you begin 41
6.1.2 When to use these tests 41
6.2 Testing using an Ohmmeter 41
6.2.1 Testing for electrical shorts and continuity using an ohmmeter 41
6.3 Testing using a Time Domain Reflectometer (TDR) 43
6.3.1 To test each length of cable 44
Chapter 7 - ControlNet Cable Installation 50
7.1 Preparing to Install ControlNet Cabling 50
7.1.1 Before you begin 50
7.1.2 Pre-built cables 50
7.2 Installing Trunk Cable 51
7.2.1 Wiring external to enclosures 51
7.2.2 Wiring inside enclosures 52
7.3 Connecting and Terminating Cables 52
7.3.1 Connecting trunk cable sections to taps 52
7.3.2 Terminating cable segments 53
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7.3.3 Connecting ControlNet devices 54
7.3.4 Connecting to repeaters 55
7.3.5 Connecting to ControlNet Interface modules 57
7.3.6 Connecting to the Server ControlNet Interface module for the PC 58
7.3.7 Connecting Tap Dummy Loads 59
Chapter 8 - Appendix A 61
8.1 CSA Hazardous Location Approval 61
8.1.1 CSA Certification 61
8.1.2 Temperature Ratings 62
8.1.3 Notices 62
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ABOUT THIS DOCUMENT
This document provides guidelines and procedures for installing ControlNet network components and
making and testing ControlNet cables.
1.1 Revision History
Revision Date Description
A November 2019 Initial release of the document.
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CHAPTER
1

SYSTEM CABLING AND WIRING
INSTALLATION
lExperion system cabling and wiring
lBefore You Begin
2.1 Experion system cabling and wiring
Your Experion system's cable and wiring requirements can be broken down into four basic categories:
Ethernet Plant Information Network (PIN), Supervisory ControlNet Network, I/O ControlNet Network,
and Field Wiring, as illustrated in Figure1.
Figure 2.1 Experion system topology
lLAN (TCP/IP - Ethernet)
lControlNet Network
lField Wiring
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CHAPTER
2

lPower and ground
2.1.1 LAN (TCP/IP - Ethernet)
Your Experion system uses a local area network (LAN, see figure) for server-to-station and station-to-
server communications. This network may also provide links to other higher order networks and
communication systems.
Installation of the LAN used by the Experion system is NOT included in the procedures provided by this
guide.
For information concerning the installation of the cables and network hardware associated with LAN
networks, please refer to your site documentation; network supplier provided documentation, or any of
the many books on this subject.
2.1.2 ControlNet Network
Your Experion system's ControlNet networks (see figure) are often thought of in terms of supervisory
and I/O level. These terms identify the purpose of each level. However, these two levels are physically
identical in their hardware, configuration, and communications needs.
Installation of the ControlNet network is defined and described in the procedures provided by this
guide. To begin installing your ControlNet network, refer to Before You Begin in this guide.
2.1.3 Field Wiring
As with any control system, field wiring (see figure), in all its forms, provides the vital link between the
I/O modules and the process-connected sensing, measurement and control devices.
Installation of field wiring is NOT included in the procedures provided by this guide.
For information concerning:
lPin outs of Experion chassis I/O modules, refer to the Experion Control Hardware Installation Guide .
lStandard rules, considerations and planning, refer to the Control Hardware Planning Guide .
lSpecific field-device wiring requirements, refer to your site documentation or that provided by the
device manufacturer.
2.1.4 Power and ground
Your Experion system requires power and ground to be provided to the servers, stations, and controller
and I/O chassis. Individual field devices may also require power and ground connections.
Installation of power and ground, outside of that required by your ControlNet network itself, is NOT
included in the procedures provided by this guide.
For information concerning power and ground requirements and installation of:
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Chapter 2 - System Cabling and Wiring Installation

Chapter 2 - System Cabling and Wiring Installation
lServers and stations of your Experion system, refer to your site documentation and that provided by
the computer's manufacturer.
lStandard rules, considerations and planning, refer to the Control Hardware Planning Guide .
lSpecific field-device wiring requirements, refer to your site documentation or that provided by the
device manufacturer.
lControlNet modules, refer to the Experion Control Hardware Installation Guide .
lControlNet network and components, excluding ControlNet modules, refer to the following topics in
this guide.
oPreparing to Install ControlNet Components
About Mounting TapsInstalling Repeaters
oBuilding ControlNet Trunk CablesInstalling Trunk Cable
oConnecting and Terminating Cables
2.2 Before You Begin
2.2.1 Planning
All planning activities should be completed before you begin installing cable and wiring.
For more information concerning planning activities, refer to your site documentation and the Control
Hardware Planning Guide:
2.2.2 Obtain Documentation
Before installing any Experion cabling or wiring, obtain all available and pertinent documentation. This
should include all documentation supplied by Honeywell, your site's engineering documentation, and
that from any additional third party suppliers whose products are involved in this installation.
Additionally, you should obtain any applicable regulatory documentation that applies to your
installation.
2.2.3 General Installation Checklist
Regardless of your specific case, consider the following installation checklist:
lCarefully review all available Honeywell and site engineering documentation, paying close
attention to cautionary notes.
lInstall your Experion system in accordance with the current edition of the National Electric Code
ANSI/NFPA 70, the Canadian Electrical Code, and other regulatory agencies governing your
particular application.
lUse technically qualified personnel to install and service your Experion system and components.
2.2.4 Conduct environmental checks
Using the Control Hardware Planning Guide and the Experion specifications available online, be sure
that all environmental guidelines and requirements have been taken into consideration before installing
your ControlNet network.
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CONTROLNET PCIC CARD INSTALLATION
lAbout the ControlNet PCIC Card
lInstalling the PCIC Card
3.1 About the ControlNet PCIC Card
The Peripheral Component Interconnect communication (PCIC) interface card lets a PCI Local bus
compatible computer communicate directly with other ControlNet products.
Figure 3.1 Front View
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CHAPTER
3

Figure 3.2 Component Side View
lCompliance to European Union Directives
lComponent handling guidelines
lAbout PCIC card drivers
3.1.1 Compliance to European Union Directives
This product has the CE mark (on its packaging) and is approved for installation within the European
Union and EEA regions. It has been designed and tested to meet the following directives.
Directive Description
EMC This product is tested to meet Council Directive 89/ 336/ EEC
Electromagnetic Compatibility (EMC) and the following standards, in whole
or in part, documented in a technical construction file:
lEN 50081- 2EMC - Generic Emission Standard, Part 2 - Industrial
Environment
lEN 50082- 2EMC - Generic Immunity Standard, Part 2 - Industrial
Environment
This product is intended for use in an industrial environment.
Low
Voltage
This product is tested to meet Council Directive 73/ 23/ EEC Low Voltage, by
applying the safety requirements of EN 61131- 2 Programmable Controllers,
Part 2 - Equipment Requirements and Tests.
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Chapter 3 - ControlNet PCIC Card Installation

Chapter 3 - ControlNet PCIC Card Installation
3.1.2 Component handling guidelines
NOTE
Electrostatic discharge
ESD
The PCIC card uses CMOS technology,
which is highly sensitive to electrostatic
discharge (ESD). ESD may be present
whenever you are handling the card. Handling
a card without any ESD protection can cause
internal circuit damage that may not be
apparent during installation or initial use.
Follow these guidelines when you handle a
card:
lTouch a grounded object to discharge
static potential,
lWear an approved wrist-strap grounding
device,
lDo not touch the connector pins,
lDo not touch circuit components on the
card,
lIf available, use a static safe workstation,
lWhen not in use, keep the card in its static
shield box or bag.
ATTENTION
Remember, a computer with ac power disconnected is not a grounded object.
3.1.3 About PCIC card drivers
The following releases of Rockwell Software's RSLinx include the device drivers for the PCIC card:
lRSLinx 2. 1 Service Pack 2 and later
lRSLinx 2. 2 and later
Refer to online Help in RSLinx for information on configuring the driver for the PCIC card. For more
information about RSLinx, visit, http://www.software.rockwell.com.
3.2 Installing the PCIC Card
3.2.1 Prerequisites
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lBe sure you know how to install hardware in your computer. And, have the computer's
documentation available for reference.
lBe sure you have installed the operating system for your computer and configured your options.
lBe sure you are wearing a grounding wrist strap before you handle the card.
lBe sure you have a Phillips-head and flat-head screwdriver on hand.
3.2.2 Accessing the expansion slots
1. Use the following procedure to access the PCI local bus expansion slots in your computer. Refer to
the computer manufacturer's documentation for details, if required.
2. Turn OFF the power switch to remove power from the computer.
3. Remove the computer's cover.
lSelect a vacant PCI local bus expansion slot.
lRemove the slot's expansion cover on the back (rear bracket) of the computer.
4. Go to the next section Inserting the PCIC card .
3.2.3 Inserting the PCIC card
1. Use the following procedure to insert the PCIC card into the computer's PCI local bus expansion
slot.
2. Insert the PCIC card into the edge connector for the selected slot.
3. Install the expansion slot screw to secure the card in its slot.
4. Turn ON the power switch and wait for the computer to power up.
lIf the computer powers up correctly, go to Step 4.
lIf the computer hang ups, you probably have a memory or I/O conflict. Remove all other cards
and try again. If the computer still hangs up, call our Technical Assistance Center.
5. Replace the computer's cover.
6. Connect the ControlNet network to the PCIC card connectors. See the section Connecting to the
Server ControlNet Interface module for the PC in this document for details.
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Chapter 3 - ControlNet PCIC Card Installation

CONTROLNET NETWORK COMPONENT
INSTALLATION
lPreparing to Install ControlNet Components
lAbout Mounting Taps
lInstalling Repeaters
4.1 Preparing to Install ControlNet Components
4.1.1 Prepare for installation
Before you begin to install your ControlNet networks, please review Control Hardware Planning Guide
to ensure that all pre-installation planning and activities have been considered.
4.1.2 Components
For a listing of the components associated with the ControlNet network, refer to the Control Hardware
Planning Guide .
4.1.3 Agency approval
For a listing of agency approvals, and specific details concerning these approvals, refer to the Experion
specifications.
4.1.4 Planning
All ControlNet network planning activities should be completed before you begin installation.
For more information concerning planning activities, refer to your site documentation and the following
topics in ControlNet Configuration section of the Planning Guide .
l Planning Overview
l Planning Your Link and Segment Configurations
l Connecting Your Links and Segments
l Planning Your Physical Media
l Planning for Your Cable Connectors
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CHAPTER
4

l Planning for Your Taps
l Planning Your Nodes
l Planning for Terminators
l Planning Your ControlNet Addressing
4.1.5 ESD/EMI Immunity
For more information concerning ESD/EMI Immunity planning, guidelines, and practices, refer to:
l Planning for Static Electricity Minimization
l Planning for Interference Minimization
l Planning Raceway Layouts
l Planning for Bonding and Grounding
l Planning for Power Distribution
l Suppressing Power Surges
l Planning Enclosure Lighting
l Avoiding Unintentional Momentary Turn-on of Outputs
4.2 About Mounting Taps
The following general rules should be applied when mounting taps:
lThere is no minimum trunk cable length requirement between taps. Adjacent taps can be connected
(without a trunk cable at all) using a barrel connector (TC-MC3BNC).
lMake sure the mounting location is convenient for your cable routing.
lMake sure the mounting location does not cause any cable bend-radii to exceed the limits given in
Installing Trunk Cable.
lDo not mount the tap in a position that routes the drop-cable or trunk-cable over any ac power
terminals on nearby modules.
For more details on selecting where to mount taps, refer to the Control Hardware Planning Guide .
lMounting dimensions for taps
lMounting taps
lIdentifying drop-cables
4.2.1 Mounting dimensions for taps
T-tap
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Chapter 4 - ControlNet Network Component Installation

Chapter 4 - ControlNet Network Component Installation
Y-tap
Universal Mounting Bracket
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4.2.2 Mounting taps
You can mount your ControlNet taps (Y-tap and T-tap):
lto a universal mounting bracket (included with the tap), and then mount the tap and bracket as an
assembly
lthrough the body holes in the tap using:
lscrews and flat washers
la tie wrap
ATTENTION
When using the Through-body-hole mounting method to attach taps, the mounting surface may
be conductive and/or grounded because of the electrical isolation provided by the body holes.
Once you have mounted your taps, you can discard any unused universal mounting brackets.
CAUTION
Do not allow any metal portions of the tap, such as the universal mounting bracket screws or
connectors, to contact any conductive material. This contact could cause noise on the network.
To mount the taps
1. If you are using:
lthe through-body-hole mounting method, go to Step 4.
la universal mounting bracket, go to Step 2.
2. Align the bracket with the mounting holes on the tap.
3. Using the screws provided, attach the tap to the universal mounting bracket.
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Chapter 4 - ControlNet Network Component Installation

Chapter 4 - ControlNet Network Component Installation
4. Mount the tap and bracket (if used) to a suitable fixture using the appropriate method.
DIN Rail Mounting
Flat Surface Mounting
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Through Body Hole Mounting
CAUTION
Do not over-tighten the screws. Doing so can damage the tap. Applied torque should be
0.2-0.4 N•M (1-2 ft-lbs.).
4.2.3 Identifying drop-cables
ATTENTION
If you have not already done so, this is a good time to apply identification to your drop-cables. For
more information regarding drop-cable identification, refer to the Planning Guide, ControlNet
Configuration, Planning Your Taps, Planning for drop-cable identification
Identifying the drop-cables from the taps you install makes locating system parts and troubleshooting
the system much easier. Drop-cable labels are included with each tap kit.
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Chapter 4 - ControlNet Network Component Installation

Chapter 4 - ControlNet Network Component Installation
To identify the drop-cables
1. After installing your tap, locate the drop-cable identifying labels in your tap kit.
2. Apply labels as follows:
lApply one red A label at the Supervisory ControlNet (A) drop cable connector.
lApply one yellow B label at the Supervisory ControlNet (B) drop cable connector.
lApply two red A labels at the I/O ControlNet (A) drop cable connector.
lApply two yellow B labels at the I/O ControlNet (B) drop cable connector.
3. If desired, you may use this marking code system for module connections, taps, and trunk cables.
4. Save any unused labels for future use.
4.3 Installing Repeaters
The following general rules must be applied when mounting either the model 9904-RPT or the model
9904-RPTD:
lAir flow, in/out of the air holes on the top and bottom of the repeater, for proper ventilation, must not
be impeded. Make sure there is a minimum of 5.1 cm (2 in) from surrounding equipment.
lFor proper ventilation, air flow through holes on the top and bottom of the repeater must not be
blocked. Make sure NEMA enclosures must be employed in environments where protection from
dust, moisture or corrosive atmospheres is required.
lMount to a grounded metal plate if possible.
For more details on selecting where to use repeaters, refer to the Control Hardware Planning Guide,
Connecting your Links and Segments .
lMounting dimensions for repeaters
lMounting your repeater
lGrounding your repeater
lConnecting ControlNet cables to your repeater
lConnecting power and relay circuitry
4.3.1 Mounting dimensions for repeaters
Figure 4.1 Repeater mounting dimensions
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