Honeywell ControlEdge 900 platform User manual

Honeywell Process Solutions
900 Control Station
For use with HC900 Controller
User Guide
Doc. No.: 51-52-25-148
Revision: 9
Date: May 2014

ii 900 Control Station User Guide Revision 9
May 2014
Notices and Trademarks
Copyright 2014 by Honeywell
Revision 9, May 2014
Warranty/Remedy
Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact
your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of
coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole
remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is believed to be accurate
and reliable as of this printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the
customer to determine the suitability of the product in the application.
Honeywell Process Solutions
1250 W Sam Houston Pkwy S
Houston, TX 77042
HC900 is a U.S. registered trademarks of Honeywell
Other brand or product names are trademarks of their respective owners.

About This Document
Abstract
Revision 9 900 Control Station User Guide iii
May 2014
About This Document
Abstract
This manual describes the installation and operation of the 900 Control Station Operator Interface.
References
The following list identifies all documents that may be sources of reference for material discussed in this
publication.
Document Title Doc ID
HC900 Control Station Installation 51-52-33-147
900 Control Station Specification 51-52-03-46
Legacy HC900 Controller Installation and User Guide 51-52-25-107
Station Designer User Guide 51-52-25-149
HC900 Designer User Guide 51-52-25-110
Control Designer Function Block Reference Guide 51-52-25-109
HC900 Controller Communications User Guide 51-52-25-111
HC900 Controller Redundancy Overview & System Operation 51-52-25-133
Revision Information
Document Name
This manual … 51-52-25-148 900 Control Station
Revision Number Publication Date
New
Error! Unknown
document property
name.
April 2009
Languages added, IP address setup, model specific
notes Revision 2 October 2009
Summary Displays added, Alarms & Events added,
batch Logging and Download and upload
configurations + others
Revision 3 March 2010
Variable Recipes added, Alarm & Events section
updated, Compact Flash Min/Max added Revision 4, 5 October 2010
CS 15” USB conflict note added Revision 6 September 2011
“USB 3.0 support is only available for 900CS10”
note added Revision 7 March 2013
Information on I/O Safety Function block added Revision 8 September 2013
CE conformity updates Revision 9 May 2014

iv 900 Control Station User Guide Revision 9
May 2014
Support & Contact Information
For Europe, Asia Pacific, North and South America contact details, refer to the back page of this manual
or the appropriate Honeywell Solution Support web site:
Honeywell Organization WWW Address (URL)
Corporate
http://www.honeywell.com
Honeywell Process Solutions
http://www.hpsweb.honewell.com/ps
HPS Technical tips
http://hpsweb.honeywell.com/Cultures/en
-
US/Products/Instrumentation/hybrid/hc900/TechnicalTips
/documents.htm
Telephone and Email Contacts
Area Organization Phone Number
United States and
Canada Honeywell Inc.
1-800-343-0228 Customer Service
1-800-423-9883 Global Technical Support
Global Email Support Honeywell Process Solutions
Email: (Sales)
[e-mail]
or (TAC)
[e-mail]

Contents
Revision 9 900 Control Station User Guide v
May 2014
Symbol Definitions
The following table lists those symbols that may be used in this document to denote certain conditions.
Symbol Definition
This DANGER symbol indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
This WARNING symbol indicates a potentially hazardous situation, which, if
not avoided, could result in death or serious injury.
This CAUTION symbol may be present on Control Product instrumentation
and literature. If present on a product, the user must consult the
appropriate part of the accompanying product literature for more
information.
This CAUTION symbol indicates a potentially hazardous situation, which, if
not avoided, may result in property damage.
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,
42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these
instructions could result in death or serious injury.
ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices
Protective Earth (PE) terminal. Provided for connection of the protective earth
(green or green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.
Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requirements.

Contents
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Contents
Symbol Definitions ............................................................................................................................... v
Introduction ..................................................................................................................... 1
Overview.............................................................................................................................................. 1
What’s in this guide ......................................................................................................................................... 1
Typical readers of this guide ............................................................................................................................ 2
What you can do with the Control Station......................................................................................................... 2
Specifications....................................................................................................................................... 2
CE Conformity (Europe)....................................................................................................................... 2
Components ........................................................................................................................................ 3
Preparation and startup................................................................................................... 4
Site Preparation ................................................................................................................................... 4
Control Station Mounting...................................................................................................................... 4
Noise Protection................................................................................................................................... 4
How to configure your Control Station .................................................................................................. 4
Startup................................................................................................................................................. 5
Features.......................................................................................................................... 7
Overview.............................................................................................................................................. 7
Touch screen ....................................................................................................................................... 8
Navigation and data entry................................................................................................................................ 9
Status bar ..................................................................................................................................................... 10
Keys .................................................................................................................................................. 11
CompactFlash.................................................................................................................................... 11
Status LEDs....................................................................................................................................... 12
Ports.................................................................................................................................................. 13
900 Control Station 10 inch model ................................................................................................................. 13
900 Control Station 15 inch model ................................................................................................................. 13
USB Device .................................................................................................................................................. 14
USB Host...................................................................................................................................................... 14
Ethernet........................................................................................................................................................ 14
RS485 .......................................................................................................................................................... 14
RS232 .......................................................................................................................................................... 14

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Main Menu .................................................................................................................... 15
Overview............................................................................................................................................ 15
Access.......................................................................................................................................................... 15
Functions...................................................................................................................................................... 15
Main menu tree ............................................................................................................................................. 16
Controller........................................................................................................................................... 17
Controller Status ........................................................................................................................................... 17
Controller Setup............................................................................................................................................ 19
Summary Displays ............................................................................................................................. 20
About Summary Displays .............................................................................................................................. 20
Communications ................................................................................................................................ 22
Menu Overview............................................................................................................................................. 22
Serial Port S1/S2........................................................................................................................................... 22
Ethernet Port E1/E2 Status............................................................................................................................ 27
Expansion Rack Communications.................................................................................................................. 29
Modbus Slave Devices .................................................................................................................................. 31
Host Connections.......................................................................................................................................... 32
Peer Connections.......................................................................................................................................... 33
Troubleshooting a Comm Quality problem...................................................................................................... 35
Troubleshooting Data Link Errors................................................................................................................... 35
Diagnostics ........................................................................................................................................ 36
Menu Overview............................................................................................................................................. 36
Controller Diagnostics ................................................................................................................................... 37
I/O Module Diagnostics and I/O Calibration.................................................................................................... 42
Communication Diagnostics .......................................................................................................................... 48
Redundant Overview..................................................................................................................................... 48
Lead/Reserve CPU Diagnostics..................................................................................................................... 56
Station Settings.................................................................................................................................. 61
View Data ..................................................................................................................................................... 61
Delete Data................................................................................................................................................... 61
Export Data to USB....................................................................................................................................... 61
Format Memory Device ................................................................................................................................. 62
Station Setup ................................................................................................................................................ 62
Station Status................................................................................................................................................ 62
Station Comm Ports ...................................................................................................................................... 62
Change Passwords ....................................................................................................................................... 62
Language Menu Selection............................................................................................................................. 62
Log On............................................................................................................................................... 63
Alarms and Events............................................................................................................................. 64
Alarm Access................................................................................................................................................ 64
Alarm Definition............................................................................................................................................. 64
Alarm Indicator.............................................................................................................................................. 64
Display Details .............................................................................................................................................. 64
Alarm Groups................................................................................................................................................ 65
Alarm Group Indication.................................................................................................................................. 66
Alarm Group Overview .................................................................................................................................. 66
Alarm Point Indication.................................................................................................................................... 67
Alarm Point Detail ......................................................................................................................................... 67
Alarm Acknowledgement............................................................................................................................... 67
Event Access ................................................................................................................................................ 68
Event Definition............................................................................................................................................. 68
Event Indication ............................................................................................................................................ 68
Display Details .............................................................................................................................................. 68

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Data Logging ..................................................................................................................................... 69
View Alarm & Event Logs .............................................................................................................................. 69
View Data Logs............................................................................................................................................. 70
View Audit Logs ............................................................................................................................................ 70
Export Data Logs to USB............................................................................................................................... 71
View Batch Groups & View Batch Status........................................................................................................ 71
Delete Data Logs .......................................................................................................................................... 74
Downloading and Uploading Controller Configuration......................................................................... 75
Download Configuration Files ........................................................................................................................ 75
Upload Controller Configuration..................................................................................................................... 77
Uploading Database Image................................................................................................................ 79
Uploading and Downloading Recipe Files........................................................................................... 80
Download Recipe Files.................................................................................................................................. 80
Upload Recipe Files ...................................................................................................................................... 82
Uploading and Downloading Security Settings.................................................................................... 84
Upload Security Displays and Functionality.................................................................................................... 84
Download Security Displays and Functionality................................................................................................ 86
Using Barcode Reader....................................................................................................................... 86
Process Displays........................................................................................................... 87
Overview............................................................................................................................................ 87
Access.......................................................................................................................................................... 87
Widget displays............................................................................................................................................. 87
How to edit a parameter ................................................................................................................................ 89
Pushbuttons, signals and variables .................................................................................................... 90
AGA8DL & AGA8GS.......................................................................................................................... 91
AGA Detail Gas Components ........................................................................................................................ 95
AGA8 Gross Setup........................................................................................................................................ 96
4-Selector Switch............................................................................................................................... 97
Device Control ................................................................................................................................... 98
Device Control Setup..................................................................................................................................... 99
Hand/Off/Auto Switch....................................................................................................................... 100
Stage ............................................................................................................................................... 101
Stage setup display..................................................................................................................................... 102
Ramp............................................................................................................................................... 103
Ramp setup display..................................................................................................................................... 104
Alternator......................................................................................................................................... 105
Alternator Setup display............................................................................................................................... 106
Alternator Edit Setup display........................................................................................................................ 106
Calendar Event ................................................................................................................................ 109
Calendar Event Block Menu ........................................................................................................................ 110
Edit Event Setpoints.................................................................................................................................... 111
Set Active Setpoint Group............................................................................................................................ 111
Edit Special Days........................................................................................................................................ 111
View Special Days Event Setup................................................................................................................... 112
Wireless transmitters........................................................................................................................ 113
XYR5000 Base Radio.................................................................................................................................. 113
XYR5000 Transmitter.................................................................................................................................. 114
XYR6000 Transmitter.................................................................................................................................. 115

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VARIABLE RECIPES .................................................................................................. 117
Overview.......................................................................................................................................... 117
Description.................................................................................................................................................. 117
Variable Recipe Load vs. Variable Recipe Upload/Download........................................................................ 117
Setpoint Programmers ................................................................................................ 119
Overview.......................................................................................................................................... 119
Description.................................................................................................................................................. 119
Setpoint Programmer Overview widgets....................................................................................................... 120
Setpoint programmer – Pre Plot Display........................................................................................... 122
General Description..................................................................................................................................... 122
Setpoint Programmer Pre-Plot Graph attributes............................................................................................ 123
Process Variable Trend Plot attributes ......................................................................................................... 124
Special cases and actions ........................................................................................................................... 124
Auxiliary SP and PV Pre-plot ....................................................................................................................... 125
Setpoint programmer Operate.......................................................................................................... 125
View/Edit profile ............................................................................................................................... 129
View/Edit Profile Segments .............................................................................................................. 131
Edit Type and Value.................................................................................................................................... 131
Edit Events ................................................................................................................................................. 132
Setpoint Scheduler...................................................................................................... 133
Overview.......................................................................................................................................... 133
Setpoint Scheduler Operate ............................................................................................................. 134
View/Edit schedule........................................................................................................................... 137
View/Edit Schedule Segments.......................................................................................................... 138
Edit Setpoints.............................................................................................................................................. 138
Edit Auxiliary Setpoints................................................................................................................................ 138
Edit Time & Recycles .................................................................................................................................. 139
Edit guarantee hold ..................................................................................................................................... 139
Edit segment events.................................................................................................................................... 139
Sequencers ................................................................................................................. 141
Overview.......................................................................................................................................... 141
Sequencer Operate.......................................................................................................................... 142
View/Edit Sequence......................................................................................................................... 144
View/Edit Sequence Steps ............................................................................................................... 145
Edit Time/Events......................................................................................................................................... 145
Edit Auxiliary............................................................................................................................................... 146
View Outputs 1-8/9-16................................................................................................................................. 146
Loops .......................................................................................................................... 147
Overview.......................................................................................................................................... 147
Loop widgets............................................................................................................................................... 147

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Loop Setup ...................................................................................................................................... 148
Overview..................................................................................................................................................... 148
Loop modes................................................................................................................................................ 149
Loop control setup....................................................................................................................................... 150
Loop Tuning................................................................................................................................................ 151
Tuning constants......................................................................................................................................... 155
Alarm setpoints ........................................................................................................................................... 156
High Output Limiting.................................................................................................................................... 157
I/O Calibration ............................................................................................................. 159
Menu Overview................................................................................................................................ 159
Overview.......................................................................................................................................... 160
AI Calibration ................................................................................................................................... 161
Overview..................................................................................................................................................... 161
Calibration equipment.................................................................................................................................. 161
Calibrate AI channel .................................................................................................................................... 162
Cancel Calibration....................................................................................................................................... 162
Restore AI factory calibration....................................................................................................................... 162
CJ Calibration .................................................................................................................................. 163
Cancel Calibration....................................................................................................................................... 163
Restore CJ factory calibration...................................................................................................................... 163
AO Calibration ................................................................................................................................. 164
Cancel Calibration....................................................................................................................................... 165
Restore AO factory calibration ..................................................................................................................... 165
PPO Motor Calibration ..................................................................................................................... 166
Overview..................................................................................................................................................... 166
Calibration Status Information...................................................................................................................... 166
Cancel Calibration....................................................................................................................................... 167
Calibration Errors ........................................................................................................................................ 167
Auto Calibration Procedure.......................................................................................................................... 168
Semi-Auto Calibration Procedure................................................................................................................. 169
Hand Calibration Procedure......................................................................................................................... 170
Motor Setup ..................................................................................................................................... 172
Maintenance................................................................................................................ 173
Troubleshooting ............................................................................................................................... 173
What to do if the Control Station has difficulty starting up.............................................................................. 173
Performing a cold start ................................................................................................................................ 173
What to do if you want to change the IP Address at the Control Station......................................................... 174
Changing or entering IP Address ................................................................................................................. 174
How to remove the rear cover and change the battery of the operator interface? ........................................... 175
Changing the battery of Control Station unit ................................................................................................. 175
Parts................................................................................................................................................ 176
Index ........................................................................................................................... 177
Sales and Service ....................................................................................................... 180

Contents
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Tables
Table 1 Main menu functions............................................................................................................................... 15
Table 2 Main menu tree....................................................................................................................................... 16
Table 3 Controller status details........................................................................................................................... 17
Table 4 Controller Setup details........................................................................................................................... 19
Table 5 Controller modes defined ......................................................................................................................... 19
Table 6 Serial Port S1/S2 Statistics (left side of display)........................................................................................ 23
Table 7 Serial Port S1/S2: Port Diagnostic status.................................................................................................. 24
Table 8 Serial Port S1/S2 Settings (right side of display)....................................................................................... 25
Table 9 Protocol selection versus setup parameters for the Serial Port S1/S2.......................................................... 26
Table 10 Ethernet Port E1/E2 details.................................................................................................................... 27
Table 11 Ethernet Port E1/E2: Port Diagnostic status ........................................................................................... 28
Table 12 Expansion Rack Communication details................................................................................................. 29
Table 13 Expansion Rack Communication Status................................................................................................. 30
Table 14 Modbus Slave Status.............................................................................................................................. 31
Table 15 Host Connections................................................................................................................................... 32
Table 16 Host Connection Status Indicators .......................................................................................................... 32
Table 17 Peer Connections ................................................................................................................................... 33
Table 18 Peer Connection Status........................................................................................................................... 34
Table 19 Rack n diagnostics ................................................................................................................................ 37
Table 20 I/O module diagnostics.......................................................................................................................... 42
Table 21 I/O module Details................................................................................................................................ 43
Table 22 I/O Module Error Status........................................................................................................................ 44
Table 23 Bad module details................................................................................................................................. 46
Table 24 Bad Channel details ............................................................................................................................... 47
Table 25 Redundant Overview............................................................................................................................. 48
Table 26 Details of Rack diagnostics error status messages .................................................................................. 51
Table 27 Details of Lead or Reserve CPU diagnostics error status messages......................................................... 57
Table 28 AGA Parameters.................................................................................................................................... 92
Table 29 AGA Error Codes ................................................................................................................................. 92
Table 30 Device control display details................................................................................................................ 98
Table 31 Device states.......................................................................................................................................... 99
Table 32 Stage setup details............................................................................................................................... 102
Table 33 Ramp operator display details.............................................................................................................. 103
Table 34 Edit ramp display details ..................................................................................................................... 104
Table 35 SPP inputs and current state................................................................................................................. 119
Table 36 Setpoint Progammer Overview widget features..................................................................................... 120
Table 37 SPS inputs and current state................................................................................................................. 133
Table 38 Loop modes ........................................................................................................................................ 149
Table 39 Calibration Errors................................................................................................................................. 167
Table 40 Auto Calibration Procedure ................................................................................................................ 168
Table 41 Semi-Auto Calibration Procedure ......................................................................................................... 169
Table 42 Hand Calibration Procedure................................................................................................................. 170
Table 43 Parts ................................................................................................................................................... 176

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Figures
Figure 1 900 Control Station menu ........................................................................................................................ 1
Figure 2 Home display........................................................................................................................................... 5
Figure 3 Features.................................................................................................................................................... 7
Figure 4 Examples of buttons and data entry fields.................................................................................................. 9
Figure 5 Status bar................................................................................................................................................ 10
Figure 6 Status LEDs............................................................................................................................................ 12
Figure 7 Main Menu............................................................................................................................................ 15
Figure 8 Variable Recipe Selection Display ....................................................................................................... 118
Figure 9 Recipe Load ......................................................................................................................................... 128
Figure 10 Recipe Save........................................................................................................................................ 128
Figure 11 IMAN loop mode............................................................................................................................... 149

Revision 9 900 Control Station User Guide 1
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Introduction
Overview
What’s in this guide
This guide contains instructions on assembly, installation, wiring, and operation of the 900 Control Station,
shown in Figure 1.
Figure 1 900 Control Station menu

Introduction
Specifications
2 900 Control Station User Guide Revision 9
May 2014
Typical readers of this guide
The typical users of this guide are:
•the technician who installs the Control Station,
•the engineer who configures the Control Station,
•the operator who views/controls/monitors the process.
What you can do with the Control Station
The Control Station lets you perform these tasks:
•Monitor and control a process.
•Load/Store/Run Recipes, Profiles, Schedules, Sequences.
•Display various process data such as trends, alarms, diagnostics, setpoint profiles, and control loops.
•Store process data to disk.
Specifications
Refer to 900 Control Station Specifications document #51-52-03-46.
CE Conformity (Europe)
This product is in conformity with the protection requirements of the following European Council
Directives: 2006/95/EC , the Low Voltage Directive, and 2004/108/EC , the EMC Directive. Conformity of
this product with any other “CE Mark” Directive(s) shall not be assumed.
ATTENTION
The emission limits of EN 50081-2 are designed to provide reasonable protection against
harmful interference when this equipment is operated in an industrial environment. Operation
of this equipment in a residential area may cause harmful interference. This equipment
generates, uses, and can radiate radio frequency energy and may cause interference to radio
and television reception when the equipment is used closer than 30 meters to the antenna(e).
In special cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the electromagnetic
emissions of this equipment.

Components
Revision 9 900 Control Station User Guide 3
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Components
PC 900 Control Station HC900 Controller
• Honeywell’s HC Designer
application configures your
HC900 Controller’s process
• Honeywell’s Station Designer
application configures how your
Control Station interfaces with
the HC900 Controller. Build
custom displays using pre-
configured objects (called
“widgets”) for interfacing with
principal function blocks such as
loops and SPPs. Configure data
logs for storage and trend
viewing.
• Lets you monitor and adjust the
HC900’s process through
custom-built displays and pre-
configured “widgets”
• Load/store/run recipes, profiles,
data logs
• Monitor alarms, diagnostics,
events
• Store data logs
• Integrate loops of control with
digital I/O
• Setpoint programming
• Setpoint scheduling
• Sequencing
• Recipe management
• Alarm processing
• PID control, Advanced control,
autotuning, fuzzy logic

Preparation and startup
Site Preparation
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Preparation and startup
Site Preparation
The cable that connects the Control Station to the controller module contains low voltages. Keep the cable
away from high voltage wires that can cause interference.
Control Station Mounting
See HC900 Control Station Installation document #51-52-33-157.
Noise Protection
See document 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise
Environments.
How to configure your Control Station
The Control Station is shipped from the factory unconfigured. Use Honeywell’s Station Designer
application to configure your Control Station.
The overall steps for configuration are as follows.
Step Action
1 Using Station Designer application, open .sds file, add device, update IP address and create
data tags from your HC900’s .cde configuration file.
2 In Station Designer, build custom displays to be used by Control Station for viewing and
interacting with your HC900 Controller process.
3 In Station Designer, assign data tags to the custom displays.
4 Save the Station Designer configuration as an .sds file.
5 Download the .sds file via USB or Ethernet to the Control Station.
6 Your Control Station is now configured and ready to use.

Preparation and startup
Startup
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Startup
After connecting the Controller and Control Station and downloading your .sds file to the Control Station,
the Home display appears with 16 buttons. (Actual button text may vary.)
Figure 2 Home display

Preparation and startup
Startup
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Features
Overview
1
2
4
3
5
Figure 3 Features
Item Feature Description Details
1 Touch screen Interactive touch screen shows menus and displays.
(Optional protective film available.)
See page 8
2 Keys Key functions are more generic than button functions. See page 11
3 CompactFlash For data storage and booting up from an image file. See page 11
4 Status LEDs Status of power, CompactFlash and alarms. See page 12
5 Ports Connections for data storage and communications. See page 13

Features
Touch screen
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Touch screen
Item Feature Description Details
1 Navigation and
data entry
A button is an onscreen object that when touched
causes an action. Shown here are the buttons on the
Main Menu. Buttons come in various shapes, sizes
and colors but a graduated blue background is the
most common.
See page 9.
2 Status bar Always visible. Shows status of:
• Logs
• Diagnostics
• Alarms
• Events
• Controller
• Language
See page 10.
1
2