Honeywell ControlEdge 900 platform Technical manual

ControlEdge 900 Platform
Hardware Planning and Installation
Guide
HWDOC-X430-en-J
November 2018
ControlEdge PLC
ControlEdge UOC

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 2018 - Honeywell International Sàrl
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CONTENTS
Contents 3
Chapter 1 - About this guide 7
Chapter 2 - Overview 13
Chapter 3 - ControlEdge PLC 15
PLC I/O Network Topology 15
Hardware Configuration of CPM 22
Hardware Configuration of EPM 27
Hardware Configuration of IO 27
Device Replacement 27
Chapter 4 - ControlEdge UOC 33
UOC I/O Expansion Network Topology 34
HSR Ring to 900 I/O 34
Non-Redundant or Redundant Star to 900 I/O 36
DLR Direct Connection to 900 I/O and EIP devices 38
DLR ETAP Connection to 900 I/O and EIP Devices 39
Non-Redundant Star to 900 I/O and EIP Devices 41
Hardware configuration of UOC-CPM 43
Hardware Configuration of UOC EPM 46
Hardware configuration of I/O 46
Device Replacement 47
Chapter 5 - ControlEdge 900 Common Reference Information 53
Installation 53
Rack options 53
Rack Types 55
Rack installation 64
Power Supply 77
Environmental considerations 81
Power Status Module 82
Contents

Expansion Processor Module 82
Serial Communication Module 84
ControlEdge 900 I/O 87
Terminal block styles 100
Terminal Block-to-Field (Signal) Wiring 106
Chapter 6 - Wiring and cabling planning 149
Electrical considerations 149
Wiring and cabling distance guidelines 153
Chapter 7 - Maintenance 155
Safety considerations - PLAN AHEAD! 155
Periodic checks 157
Removal and Insertion Under Power (RIUP) 157
Replacing the power supply 158
Replacing an EPM 160
Replacing an I/O module 161
Spare parts and model numbers 164
Chapter 8 - Diagnostics and Troubleshooting 169
EPM Indicators 169
Serial Communication Module Indicators 171
I/O Indicators 172
UIO Indicators 176
Chapter 9 - Special Condition of Use and Approved Standards 179
Approval Rating 179
Special Condition of Use for Division 2/Zone 2 Hazardous Location
Installation 179
For the United States 179
For Canada 180
For ATEX 180
Approved Standards for Division 2/Zone 2 Hazardous Location 181
US Approval Standards 181
Canadian Standards 181
European Standards (Zone 2) 182
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Contents

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CE LVD and EMC Compliance Standards 182
UL Compliance Standards 184
Appendix A - Installing RTP 185
Overview of RTPs 186
RTP Dimension 187
Using the RTP to field wire the IOMs 188
Using an RTP to field wire the UIO 189
Using an RTP to field wiring the UAI 191
Using Dual RTPs to field wiring the 16 Point AI 196
Using an RTP to field wiring the 16 Point AC DI 199
Using an RTP to field wiring the 16 Point DC DI 202
Using Dual RTPs to field wiring the 32 Point DC DI 204
Using an RTP to field wiring the 8 Point AC DO 207
Using Dual RTPs to field wiring the 32 Point DC DO 210
Using an RTP to field wiring 4 Channel Analog Output 212
Using an RTP to field wiring the 8 Channel Analog Output 214
Using an RTP to field wiring Relay Output 217
RTP Cable wire positions, colors, and internal schematic 219
Securing the RTP to the DIN rail 228
Contents

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Contents

CHAPTER
1ABOUT THIS GUIDE
Scope
This guide describes how to set up the ControlEdge 900 platform and
install UOC or PLC.
Revision history
Revision Date Description
A September
2016
Initial release of document
B November
2016
Update for PLC R130.2 Release including:
lDelete the Self-powered 3–wire transmitter for UIO AI,
and updated Self-powered 4-wire transmitter for UIO AI.
lAdd 900RTP-H1xx RTP Cable
lAdd MOXA Unmanaged Ethernet Switch EDS-308 and
EDS-316-MM-SC.
C April 2017 Update for the PLC R140 Release including:
lFive new I/O modules
lAdd new RTP and RTP Cables
lNew Terminal Blocks
lNew accessory parts
D June 2017 Update for PLC. Adding the following items:
lAdd UIO wiring limitation and hardware version
comparison
lAdd RTP dimension for installing
E September
2017
Added UOC information (for Experion R505 release)
F November Update for UOC network topologies
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Revision Date Description
2017
G December
2017
Update for ControlEdge PLC R150 Release including:
lFive new I/O modules
lAdd new relay RTP
I July 2018 Update DLR topologies for UOC
J November
2018
Update for UOCOne Slot Rack added
Update for ControlEdge PLC R151 Release including:
l8 channel Analog Output
l16 Channel DC/AC Digital Input
lQuadrature Input and Pulse Output
lSerial Communication Module
lEtherNet/IP
Intended audience
This guide is primarily intended for Honeywell field personnel who do
hardware planning, installation, operation, and maintenance for the
Honeywell ControlEdge™ 900 Controller.
Related documents
The following list identifies publications that may contain information
relevant to the information in this document.
PLC Specific
Doc Name PLC document
Set
ControlEdge Builder Software Installation User’s Guide RTDOC-X285
ControlEdge Builder Software Change Notice RTDOC-X166
ControlEdge PLC and ControlEdge RTU Getting started RTDOC-X287
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Chapter 1 - About this guide

9
Doc Name PLC document
Set
ControlEdge Builder User’s Guide RTDOC-X283
ControlEdge Builder Function and Function Block Configuration
Reference Guide
RTDOC-X286
ControlEdge Builder Protocol Configuration Reference Guide RTDOC-X288
ControlEdge PLC and ControlEdge RTU Network and Security
Planning Guide
RTDOC-XX75
ControlEdge EtherNet/IP User's Guide RTDOC-X548
UOC Specific
Doc Name Experion document set for deployments of
UOC
Control Building User's Guide EPDOC-XX19
Firmware Manager User's Guide EPDOC-X404
ControlEdge UOC Software Change
Notice
EPDOC-X166
Control Builder Parameter References
Guides
EPDOC-XX18
UOC User's Guide EPDOC-X512
Control Builder Components Theory EPDOC-XX16
Introduction to ControlEdge Technology
Item Description
ControlEdge
PLC
ControlEdge 900 controllers running the eCLR (IEC 61131-3)
execution environment with PLC software options configured with
ControlEdge Builder.
ControlEdge
RTU
ControlEdge 2020 controllers running the eCLR (IEC 61131-3)
execution environment with RTU software options configured with
ControlEdge Builder.
Chapter 1 - About this guide

Item Description
ControlEdge
UOC
ControlEdge 900 controllers running the Honeywell control execution
environment (CEE) configured with Experion Control Builder.
Special Terms
The following table describes the commonly used industry-wide and
Honeywell-specific terminology:
Terminology Description
AI Analog Input
AO Analog Output
CEE Control Execution Environment (Experion)
ControlEdge
900
A family of controller and I/O hardware which can be assembled to
create PLC or UOC systems.
ControlEdge
Builder
Software configuration tool for PLC.
Control
Builder
Experion Control Builder, configuration tool for UOC.
COTS Commercial Off the Shelf
CPM Control Processor Module (commonlyreferred to as the controller).
The ControlEdge 900 CPM, can be loaded with PLC firmware to
become the PLC or with UOC-CPM firmware to become the UOC-
CPM.
DCS Distributed Control System
DI Digital Input
DLR Device Level Ring
DO Digital Output
EPM Expansion Processor Module (used to connect multiple I/O racks to
the Control Processor Module)
Expansion
I/O rack
I/O rack with EPM installed
Ethernet/IP EtherNet/IP™ is a trademark protocol owned by ODVA.
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Chapter 1 - About this guide

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Terminology Description
HMI Human Machine Interface
HSR High Availability Seamless Redundancy
I/O Rack ControlEdge 900 form factor rack with 4, 8, or, 12 I/O slots and one
slot for non-redundant CPM or EPM.
PLC Programmable Logic Controller
PSM Power Status Module
PSU Power Supply Unit
PWA Printed Wiring Assembly
Redundant
Controller
Rack
ControlEdge 900 rack capable of hosting a redundant pair of CPMs.
RM Redundancy Module
RTP Remote Termination Panel
RIUP Removal and Insertion Under Power
SCADA Supervisory Control and Data Acquisition
UIO/UIOM Universal Input/ Output (Module)
UOC Unit Operations Controller (Experion). This is a term used to refer to
the CPM when used as a controller in the Experion PKS Distributed
Control System.
Chapter 1 - About this guide

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Chapter 1 - About this guide

CHAPTER
2OVERVIEW
Make sure all the hardware modules used in the system are installed
with the right firmware version and the engineering station has the
latest ControlEdge Builder. You can find the firmware and software
updates on http://www.honeywellprocess.com with valid credentials.
If the equipment is not used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
ControlEdge 900 hardware components can be deployed in two
distinct types of control systems.
nThe ControlEdge Programmable Logic Controller (PLC)
nThe ControlEdge Unit Operations Controller (UOC)
For Control Processor Module (CPM), both the UOC and PLC use it
but with different firmware loaded.
ControlEdge PLC can be deployed standalone or with a SCADA
system including Experion PKS. Within Experion, ControlEdge PLC
can also communicate in a peer relationship to the DCS controllers
such as C300 and ContorlEdge UOC.
ControlEdge UOC is a DCS controller always deployed within
Experion PKS.
This document has been divided into three major sections.
nControlEdge PLC - contains details specific to PLC.
nControlEdge UOC - contains details specific to UOC.
nControlEdge 900 common reference information and other
chapters- contains details applicable to ControlEdge platform,
both PLC and UOC.
How to Use this Guide
The following table outlines the tasks involved in planning and
installing a Honeywell ControlEdge 900 Controller. The links provided
will navigate the user through those tasks.
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Revision PLC Specific UOC Specific
Check the model number of
the hardware components
See the section Spare parts and model numbers
Plan the architecture of the
system
See the section System
architectures planning
See the section System
architectures
Understand and plan the
hardware components of the
system
See the section Hardware components
Plan the wiring of the system See the section Wiring and cabling planning
Install the racks to house the
system
See the section Rack installation
Install and wire the I/O
modules
See the section I/O Module installation and wiring
Troubleshoot the system See the section Diagnostics and Troubleshooting
Remove or replace system
components
See the section Maintenance
Software configuration See ControlEdge Builder
User’s Guide for PLC
systems.
See Control Building
User’s Guide for UOC
systems.
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Chapter 2 - Overview

CHAPTER
3CONTROLEDGE PLC
Honeywell ControlEdge 900 family comprises a set of hardware and
software enabling users and OEMs to assemble a system that fits a
broad range of requirements. Any configuration can be readily
modified or expanded as requirements dictate.
This section provides the following information:
nPLC Expansion Network Topology
nHardware Configuration of PLC-CPM
nHardware configuration of EPM
nHardware configuration of I/O module type
nDevice Replacement
PLC I/O Network Topology
The ControlEdge PLC is configured with a non-redundant Control
Processor Module (CPM) or a redundant CPM. This section provides
details of each configuration.
ControlEdge PLC includes provisions for communication via Ethernet
with host systems such as the Honeywell Experion Human Machine
Interface (HMI) and other HMI software that support Modbus/TCP or
OPC UA protocols. The communication structure of the ControlEdge
PLC enables remote placement of input/output components, allowing
economies in cabling and wiring.
The Ethernet ports provide a layer of protection against cyber-attacks.
Multiple layers of protection are always considered good cyber-
security practice so using a firewall device configured to prevent
uncontrolled messages into the CPM is advised. The figures in this
manual assume the firewall is installed properly above the CPM's
Ethernet port(s) ETH1 and ETH2.
While the CPM has an embedded firewall, it is still recommended to
apply network firewall(s) to the control system as the application
requires.
Close all Ethernet ports into PLC-CPM except:
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nModbus TCP Slave
nOPC UA Server
nHART IP
nControlEdge Builder Controller Configuration protocol
nPrivacy protocol
nSNTP (if NTP server is enabled)
nDestination DHCP for uplink
nModbus Master and OPC UA Client that configured in the relative
function blocks
nCDA Responder
The port number can be configured in ControlEdge Builder, and see
the following table for the default port numbers.
Table 3-1: Default port numbers
Port number Port number type Description
41103 Fixed destination port Builder protocol
24558 Fixed destination port Discovery protocol
9050 Fixed source port Discovery protocol
123 Fixed source port SNTP protocol
123 Fixed destination port SNTP protocol
68 Fixed destination port DHCP Client for uplink
500 Fixed destination/source port IPSec for uplink (IKE ports)
4500 Fixed source port IPSec for uplink(IKE ports)
55601 Fixed destination port IPSec for uplink(CertMngr cleartext)
55602 Fixed destination port IPSec for uplink(CertMngr encryption)
80 Fixed source port IPSec for uplink (SCEP)
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I/O Network
In the I/O network used to connect the PLC-CPM to expansion I/O
racks via the EPM, two network topologies are supported in the
network: Ring and Star.
nUp to 144 I/O modules can be configured. Rationale: 12 racks x
12 modules per rack.
nUp to 4608, channels can be configured. Rationale: 12 racks x 12
modules per rack x 32 channels per module (applicable for certain
I/O module types only)
Figure 3-1: System architecture with non redundant PLC-CPM

Figure 3-2: System architecture with redundant PLC-CPM
Physical cabling/connection of the nodes forming the ring, applicable
to the purple HSR/Ring topology on the right side of the above
illustration, must be connected as follows:
nCPM port 3 (ETH3) must be connected to CPM port 4 (ETH4) or
EPM port 2 (ETH2).
nCPM port 4 (ETH4) must be connected to CPM port 3 (ETH3) or
EPM port 1 (ETH1).
nEPM port 1 (ETH1) must be connected to EPM port 2 (ETH2) or
CPM port 4 (EHT4).
nEPM port 2 (ETH2) must be connected to EPM port 1 (ETH1) or
CPM port 3 (EHT3).
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Table 3-2: System component list for ControlEdge 900 PLC Hardware
Item Component
Name Description Source
1 I/O Rack System may consist of 5 different types of
I/O racks:
l4-slot w/1 power supply
l8-slot w/1 power supply
l12-slot w/1 power supply
l8-slot w/redundant power supplies
l12-slot w/ redundant power upplies
Local I/O Rack l1 I/O Rack
l1 CPM (for controller racks) or 1 EPM
(for I/O racks)
lUp to 4, 8 or 12 I/O modules
l1 or 2 Power Supplies
Optional second Power Supply and
Power Status Module (PSM) on 8-
and 12-slot I/O rack.
A Power Status Module (PSM) is
required with redundant power
supplies.
2 Redundant CPM
Rack l1 Redundant Controller Rack
l2 Power Supplies
l2 CPMs: Redundancy is provided by
two CPMs operating in a Redundant
Controller Rack; this rack has no I/O
modules.
l1 Filler block cover
Honeywell
3 Expansion I/O
Rack (Optional)
Includes:
l1 rack
l1 Power Supply
lOptional second Power Supply and
Honeywell

Item Component
Name Description Source
Power Status Module (PSM) on 8-
and 12- slot I/O rack.
l1 Expansion Processor Module
(EPM)
lUp to 4, 8 or 12 I/O modules
lA Power Status Module (PSM) is
required with redundant power
supplies.
System may consist of 5 different types of
I/O rack:
l4-slot w/1 power supply
l8-slot w/1 power supply
l12-slot w/1 power supply
l8-slot w/redundant power supplies
l12-slot w/ redundant power upplies
4 Human-Machine
Interface (HMI)
(Optional)
PC links to Ethernet network, which
includes other HMIs, other ControlEdge
900 Controllers, and other networks
(including Internet). Typically includes HMI
operating software which includes
configuration tool from Honeywell.
HMI software
is available
from
Honeywell or
from third-
party
supplier.
5 Configuration
Station
Connects from ETH1/ETH2 of the certain
CPM or network switch linking CPMs.
Configuration
software is
from
Honeywell.
6 Un-managed
Ethernet
100Base-T
Switch
(Only for Star topology) Enables
connection of the private Ethernet
100Base-T port on a CPM to the EPMs on
Expansion I/O rack. (The switch is not
required if there is no expansion I/O or
only one expansion I/O rack in the system.)
Third-party
suppliers or
Qualified
third party
devices
available
from
Honeywell
7 Ethernet
100Base-T
Enables inter-connection of several Third-party
suppliers.
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