Honeywell Experion PKS Instruction manual

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Experion PKS®
CEE-based Controller
Specifications and Technical Data
EP03-300-200
Release 200
Revision Date: December 2003
Version 1.0

Experion PKS CEE-based Controller Specifications and Models
ii
Experion PKS

CEE-based Controller
Specifications and Technical Data
Table of Contents Page
Introduction.............................................................................................................................................1
Experion PKS CEE-based Controller Overview ..................................................................................3
Communication Infrastructure..............................................................................................................5
Fault Tolerant Ethernet Overview.........................................................................................................................5
ControlNet Overview ............................................................................................................................................5
Ethernet Overview................................................................................................................................................5
Functional Description...........................................................................................................................6
Control Execution Environment............................................................................................................................6
Control Strategy Building......................................................................................................................................7
Control Functions.................................................................................................................................................9
Control Libraries.................................................................................................................................................11
21 CFR Part 11 ..................................................................................................................................................12
Experion PKS Process Simulation .....................................................................................................................13
On-Process Migration.........................................................................................................................................13
Specifications and Sizing ....................................................................................................................15
Controller Environmental and Compliance Certifications...................................................................................15
Control Processor Module Hardware Specifications..........................................................................................16
ControlNet Specifications...................................................................................................................................17
Control Net Cable...............................................................................................................................................18
Function Block Types.........................................................................................................................................20
Control Builder Specifications ............................................................................................................................21
Network Specifications.......................................................................................................................................22
Control Execution Environment Specifications...................................................................................................24
Controller Communications Performance ..........................................................................................................24
Controller Redundancy Specifications ...............................................................................................................26
I/O Module and Fieldbus Capacity.....................................................................................................................27
C200 Control Processor Processing and Memory Resources...........................................................................29
C200 Simulation Environment Specifications.....................................................................................................32
Models Numbers...................................................................................................................................33
Models-at-a-Glance Examples...........................................................................................................................33
Controllers, Racks, Power Supplies & Communications Modules.....................................................................38
Miscellaneous Hardware....................................................................................................................................38
Cables and Connectors......................................................................................................................................39
Controller Software.............................................................................................................................................40
Application Controller Environment (ACE) Software..........................................................................................42
Simulation System Software ..............................................................................................................................43

Experion PKS CEE-based Controller Specifications and Models
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Revision Status
Revision Date Description
Ver 0.1 October 2003 Preliminary Release for R200
Ver 0.2 November 2003 Updated On-Process Migration section
Ver 1.0 December 2003 Updated for final version
Revision Description
Section Change Description
Throughout M Minor edits
ACE Node A Information on AFDSIO
Legend for Change column:
A -- Added
D -- Deleted
M -- Modified

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Introduction Experion PKS®embeds three decades of Honeywell process control, asset
management, and domain expertise, combined with Six Sigma methodologies,
into a unified Process Knowledge System architecture. Experion PKS optimizes
work processes, improves routine maintenance efficiencies, and releases
personnel from manual processes. Capturing and managing untapped process
knowledge in a single Process Knowledge Solution™, Experion PKS delivers
process and control data using innovative technologies that are only offered by
Honeywell. These technologies fully integrate with existing Honeywell systems,
including TPS, TDC2000®, TDC3000®, TotalPlant®Alcont, FSC, and the PlantScape®system.
Process Knowledge – Beyond Distributed Control
Experion PKS Process Knowledge capabilities expand the role of distributed control, addressing all of
manufacturing’s critical business objectives to facilitate knowledge sharing and workflow management.
The result is improved operating profit, capital cost and cash flow. Delivering a robust, scalable, plant-
wide system, Experion PKS connects your operations staff with the latest automation technology as
well as with each other. Built on a rock-solid foundation of process control and safety system know-
how, this next-generation system provides
unprecedented connectivity through all levels of process
and business operations. This is a truly collaborative
production and safety management solution.
In addition to embedding Distributed Control System
(DCS) technologies, Experion PKS integrates powerful
knowledge-driven decision support and diagnostic tools,
providing information where and when it is needed. This
revolutionary system approach unifies business,
process, safety, and asset management to:
• Facilitate knowledge capture
• Promote knowledge sharing
• Optimize work processes
• Accelerate improvement and innovation
Unified, Collaborative Architecture
Experion PKS is a unified, collaborative architecture with state-of-the-art DCS capabilities that
encompass Abnormal Situation Management®(ASM®), Safety Management, and Information
Management technologies. Experion PKS interfaces with FOUNDATION* Fieldbus, Profibus,
DeviceNet, LON, ControlNet and Interbus. Robustness, security, compliance, control, safety, and
reliability are plant-wide, penetrating all layers of the architecture to provide the only available high-
performance, plant-wide infrastructure. Experion PKS’ distributed control features include a complete
continuous, logic, sequential, and drive object-oriented control environment hosted on fully redundant
controllers.
By unifying the plant-wide architecture, Experion PKS allows you to make the right product at the right
time, optimize and automate, increase workforce effectiveness, and increase availability of resources
while reducing incidents. Rather than taking the narrow instrument-centric approach that informs you
only when there is a need to replace a valve or perform maintenance, Experion PKS establishes a
broad, process-centric view of your plant operations by focusing on the impact to operational
objectives, not only the replacement of devices. This is the key to optimizing performance. Combining
DCS functionality and a plant-wide infrastructure, the Experion PKS unified architecture provides
collaborative production management solutions for Knowledge Management, Asset and Abnormal
Situation Management, Business Process Integration, and Optimization and Automation.
Experion PKS
The Next
Generation
Process
Knowledge
System

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Architecture Overview
Experion PKS comprises many different integrated hardware and software solutions depending upon
the needs of the installation. Figure 1 is a representation of many of the possible nodes that can be
utilized in an Experion PKS architecture. The Experion PKS architecture is highly scalable and not all
nodes are necessary or required.
This document contains specifications and model numbers for the Experion PKS Controller. For
more information about Experion PKS, please refer to:
EP03-100-200 Experion PKS Process System Overview
EP03-200-200 Experion PKS Server Specification and Technical Data
EP03-210-200 Experion PKS Station Specification and Technical Data
EP03-400-200 Experion PKS Chassis I/O Modules - Series A Specification and Technical Data
EP03-410-200 Experion PKS Rail I/O Modules - Series A Specification and Technical Data
EP03-420-200 Experion PKS Galvanically Isolated/Intrinsically Safe Rail I/O Modules - Series H
Specification and Technical Data
EP03-430-200 Experion PKS PM I/O Specifications and Technical Data
EP03-440-200 Experion PKS DeviceNet Specification and Technical Data
EP03-450-200 Experion PKS PROFIBUS DP Specification and Technical Data
TPS, TDC2000, TDC3000
www
eServer
Casual Users
Fault Tolerant Ethernet
Wireless
Devices
(Operations and Maintenance)
Allen-Bradley
ControlLogix
PLC
C200
Digital Video Manager
Redundant
Servers
FSC
SCADA Devices
(OPC, Modbus,
DH+, and many
more!)
PM I/O
Ethernet
Experion
Stations
Application
Control
Environment
Remote
Engineering
Tools
Investment
Protection –
Complete
Integration
Unlimited Secure Access
Video as a Process In
p
ut
!
Comprehensive
Support for
Smart Field
Devices
State-of-the-Art Operation and Engineering Tools
Advanced Applications and Integration
GEFanuc
Versamax
MTL8000
Frequency
Converter
PMD
TPS, TDC2000, TDC3000
www
eServer
Casual Users
Fault Tolerant Ethernet
Wireless
Devices
(Operations and Maintenance)
Allen-Bradley
ControlLogix
PLC
C200
Digital Video Manager
Redundant
Servers
FSC
SCADA Devices
(OPC, Modbus,
DH+, and many
more!)
PM I/O
Ethernet
Experion
Stations
Application
Control
Environment
Remote
Engineering
Tools
Investment
Protection –
Complete
Integration
Unlimited Secure Access
Video as a Process In
p
ut
!
Comprehensive
Support for
Smart Field
Devices
State-of-the-Art Operation and Engineering Tools
Advanced Applications and Integration
GEFanuc
Versamax
MTL8000
Frequency
Converter
PMD

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Experion PKS CEE-based Controller Overview
The Experion PKS CEE-based Controller comprises 30 years of controller development and
technology. The solution combines robustness, flexibility and uniformity in a Control Execution
Environment (CEE) that is hosted on different platforms. Its open architecture allows integration with
existing Honeywell controllers, third party control systems and devices. This document describes in
detail the configuration, design and architecture of the different controllers.
The CEE is the foundation of the controller and provides a configured control execution environment.
It makes this control application execution deterministic, consistent and reliable. A single builder tool,
Control Builder, allows integrated application configuration. The Control Execution Environment
offers dedicated function blocks to cover all control requirements for continuous processes, batch
processes, discrete operations, and machine control applications. Experion PKS currently features two
CEE-based controllers, the C200 Process Controller and the Application Control Environment
(ACE). The system also supports a simulation environment, the C200 Simulation Environment (SIM-
C200), which provides complete system simulation on PCs without requiring dedicated controller
hardware or process connections.
The C200 Controller consists of a
chassis, ControlNet communication
module or the new FTE Bridge module,
the Control Processor module (CPM)
and, optionally, the Redundancy
Module. The ACE node is hosted on a
server-grade PC platform. The C200
controller is a compact and cost-
effective solution located close to the
process with direct IO connections. It
is ideal for integrated regulatory, fast
logic, sequential, and batch control
applications. The ACE node is ideally
suited for supervisory control solutions
and integration with third party control
systems.
With Experion PKS, the user configures the system instead of building it from the ground up. Most
industrial process control applications require a number of common elements, such as
communications protocols and control algorithms. Experion PKS includes such elements in its
standard operating framework, allowing the user to concentrate on the application, not the system.
Control functions are provided through a library of block types called Function Blocks (FBs).
Strategies are easily built and configured using a single state-of-the-art graphical engineering tool
called Control Builder. Once built, control strategies can be loaded and monitored using Control
Builder.
The wide range of Experion PKS controller features include:
• Process Controller for integrated process and discrete control
• Powerful Control Processor Module
• Redundant or Non-redundant configuration options
• 50 msec or 5 msec base Control Execution Environments
• Flexible, compact chassis-based I/O family with optional Remote Termination Panels
• Honeywell Process ManagerTM I/O Integration
• Galvanically Isolated/Intrinsically Safe I/O family for hazardous area requirements
• Cost-effective rail-based I/O family
• Allen-Bradley PLC5 and Logix 5550 Programmable Logic Controller Integration
• FOUNDATION Fieldbus, HART and Profibus device integration
An Experion PKS C200 Process Controller

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• PC based Supervisory Control
• Powerful Windows 2000 Server- based Application Control Environment (ACE)
• 500 msec base Control Execution Environment
• Uses the same Function Block libraries as the Process Controller
• Integrates OPC data access directly into the control environment
• Process Simulation System
• Full simulation of the Experion PKS System
• PC based C200 Simulation Environment (SIM-C200) with no controller hardware required
• Support for advanced Honeywell ShadowPlant features
• Experion PKS Software
• Supervisory software with features such as dynamic data caching, alarm/event management,
reporting, and much more!
• Control Builder with Comprehensive Control Libraries for process point building
• HMIWeb Builder for powerful html-based operator graphic creation
• Knowledge Builder On-Line HTML-Based Documentation
• System Configuration and Diagnostic Utilities
• Process Control Networks
• FTE – supporting the Fault Tolerant Ethernet network for the highest level of availability
• ControlNet -- supporting redundant media for high system robustness
• Ethernet – (single ethernet) for flexibility based on open technology (only for existing
ethernet customers)
The Experion PKS supervisory system is highly integrated with the CEE-based controller architecture.
These integrated features include:
• Integrated Database -- Control Builder configuration includes information for both the Control environments
and Experion PKS Server. Information is entered once, not repeated in several databases.
• Integrated Alarms and Events – Alarms are configured by Control Builder, generated by the Controller,
recorded into the event system, and acknowledged by operators on the Experion PKS Operator Station
alarm summary display. Users do not have to separately configure process alarms in both the controller and
the supervisory system.

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Communication Infrastructure
Experion PKS supports three different communication networks to connect the system’s supervisory
layer (or human-machine-interface layer) with the control layer, to meet the customer’s specifications.
The network types are:
• Fault Tolerant Ethernet (FTE),
• ControlNet, and
• Single Ethernet.
The system only supports one type of Supervisory Control Network per Experion PKS Server.
Fault Tolerant Ethernet Overview
Fault Tolerant Ethernet: High Availability Ethernet for Industrial Applications
The evolution of open Ethernet technology has introduced high-performance, low-cost networking to
industrial plants. Until now, providing the robustness of industrial control networks with commercial-off-
the-shelf (COTS) Ethernet equipment remained a major hurdle. Honeywell unites the benefits of
Ethernet technology with their expertise in designing robust networks to deliver the patented Fault
Tolerant Ethernet (FTE) solution. For more detailed information see the Fault Tolerant Ethernet (FTE)
Specification and Technical Data, EP03-500-200.
The controller or Fieldbus-only chassis is connected with the FTE network through a newly designed
FTE Bridge module that is placed in the controller/FIM chassis. The FTE Bridge module supports
redundancy so can be used in a redundant Controller and Fieldbus chassis as well. See the Models-at-
a-Glance Examples sections for a topology and more detailed information.
As stated above, the Experion PKS server only supports one Supervisory Control Network type.
However, the Experion PKS server does support the ControlNet interface card in conjunction with the
FTE Supervisory Control Network for SCADA connections to ControlNet resident Allen-Bradley
devices. This also requires RSLinx software installation on the server. A SCADA solution is also
supported through a single Ethernet connection. Allen-Bradley devices can be connected via single
Ethernet with an FTE switch. With a separate Ethernet module, a remote or non-redundant controller
chassis can be connected with the same FTE switch as an Allen Bradley PLC.
FTE is the only network that supports the new Experion Station - Console.
ControlNet Overview
ControlNet: Based on the ControlNet International Standard
ControlNet is an open network specification specifically designed for industrial control applications. It
can be deployed in a single or redundant fashion to provide higher availability of the network.
ControlNet can be deployed as Supervisory Control Network to connect the control layer with the
supervisory layer of the system. It is also the only supported network to connect additional IO chassis
to a controller.
The controller or Fieldbus-only chassis is connected with the ControlNet network through a ControlNet
Interface Module (CNI) with single or redundant media connections. The CNI module supports
redundancy so can be used in a redundant Controller and Fieldbus chassis as well. See the Models-at-
a-Glance Examples sections for a topology and more detailed information.
Ethernet Overview
Ethernet: Open Network Technology
Ethernet is an open network technology that is used to communicate the Ethernet/IP protocol through
the single media Ethernet module. It can only be deployed in a single fashion; therefore it has the
lowest availability of the three supported network types. Ethernet can be deployed as Supervisory
Control Network to connect the control layer with the supervisory layer of the system

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The controller chassis is connected with the Ethernet network through an Ethernet Module with a
single media connection. The Ethernet module does not support controller redundancy or the Fieldbus
Interface Module. Refer to the Models-at-a-Glance Example section for more detailed topology
information.
The Ethernet module is supported for existing Ethernet users only, new installations should make use
of the FTE solution listed above.
Functional Description
Control Execution Environment
The Control Execution Environment (CEE) is the common core software used in the various controllers
supported by Experion PKS. This includes the C200 controller, the Application Control Environment
(ACE) and the C200 Simulation Environment (SIM-C200). The CEE provides an execution and
scheduling environment in which the user-configured Control Modules and Sequential Control Modules
execute. It also provides for a peer-to-peer communication layer used to seamlessly communicate
between controllers. Implementation is transparent so that peer-to-peer connections are configured in
the same way as intra-controller connections.
The CEE is specialized for each platform to provide optimal execution on that specific hardware and
operating system. Specific functions are also added specifically for that platform. The platform specific
versions include: the Control Solver for the C200, the ACE base software for the ACE node, and the
SIM-C200 base software for the SIM-C200 node.
The CEE supports a large number of Function Blocks, which are detailed in table 11. Since the CEE is
common to all platforms, applications using these Function Blocks can be moved easily between the
different platforms. This allows the user the make optimal use of control resources without the need for
re-implementation.
The Control Solver is the specialized control execution environment for the C200 Control Processor
module. It is available in two base execution rates, 50 msec (normal) and 5 msec (fast). It features:
• Individual per-module selectable execution rates of 50, 100, 200, 500, 1000 and 2000 msec for the 50
msec CEE and 5, 10, 20, 50, 100 and 200 ms for the 5 msec CEE. All Control Modules and Sequential
Control Modules, regardless of Function Block content, can, in each case, execute at any of these 6 rates.
All Function Blocks within a CM or SCM execute at the same rate.
• Configurable phase assignment of any module executing slower than the base rate. This provides the
flexibility to “load balance” a Controller.

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Control Strategy Building
Experion PKS control strategies are built using Control Builder, a graphical, object-oriented tool that
supports the Control Execution Environments of the Experion PKS Control Processor, Application
Control Environment and Simulation Control Environment. It allows system design, documentation, and
monitoring. It provides comprehensive handling of various I/O points, including Fieldbus, Profibus,
and DeviceNet. In addition, it covers continuous, logic, motor, sequential, batch and advanced control
functions through a library of Function Blocks (FBs). Function Blocks are basic block types provided
by Honeywell to perform different control functions. Each block supports parameters that provide an
external view of what the block is doing. FBs easily interconnect via “soft wires” to construct control
applications or strategies.
Function Blocks are grouped together and contained in Control Modules (CMs) and, in the case of
sequential FBs, Sequential Control Modules (SCMs). SCMs greatly simplify batch logic
implementation by sequencing a group of process equipment through a series of distinct steps to
accomplish one or more process tasks. CMs and SCMs act as “containers” for Function Blocks.
This is a very powerful tool for creating, organizing, and checking out control strategies. Figure 3
illustrates a simple Control Module -- in this case a PID loop -- consisting of basic FBs. In this
example, several FBs are “contained” within the CM named FIC101, and the AI and AO FBs are
executing in FOUNDATION Fieldbus devices. Each Control Module may be scheduled at its own
execution rate from 5 msec to 20 sec (depending on the controller), and the user can schedule
Function Blocks and Control Modules to execute in any desired order.
Figure 2. Control Builder Supports a Powerful Set of Algorithm
Libraries for Implementing Process Control Strategies

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Control Builder uses icons to represent control blocks, which can be “wired” together using simple point
and click techniques. Control drawings can be used on-line to monitor control execution and make
changes to control parameters, thereby significantly simplifying control strategy checkout. Control
drawings are also accessible to the operator via detail displays.
Control Builder also supports Hierarchical Building that enables nesting of Control Modules
regardless of their controller assignment and the creation of projected parameters. These are FB
parameters, which are now promoted to the boundary of the control module with a user-defined name.
These parameters are used to make wired connections between Control Modules and/or FBs. It also
provides the configuration engineer with the ability to organize the control configuration in a more
process-oriented way. For example, a user may create one Control Module named “Reactor” and
embed the individual temperature, pressure and agitator Control Modules and the fill sequence. Any
interconnection can be “soft- wired”
between user-defined parameters.
The user can switch the Control
Builder view between the traditional
assignment view (controller oriented
view) and the new containment
view.
Projected parameters can be
defined without immediately
resolving the source parameter.
This supports a “top-down”
implementation. In a top down
design, the overall control strategy
is defined on a high level with minor
detail. Once the overall strategy is
defined, more detail is added to the
underlying Control Modules.
The Control Builder enables the
creation of reusable control strategies, which can be duplicated, with minimal effort through a simple
copy and paste action. To further increase the engineering productivity of Control Builder, it optionally
supports User Templates. With this licensed option, the user can create block templates and/or
Control Module templates. These templates appear under the user library on the library tab. These
user templates can be instantiated and loaded to a control environment. Whenever a change is made
in the template, it will automatically propagate the change through all instances. Propagation of
template defining parameters is unconditional. Non-template defining parameter propagation is
conditional, where the change is propagated if the value of the parameter in the instance is equal to the
old template parameter value.
Control Builder also supports a multi-user control strategy development and debugging environment.
The function provides remote access to engineering databases across any media capable of TCP/IP
and UDP/IP communication. For maximum security, access is password protected. Several users
can create, configure and load control strategies at the same time from different workstations. Multiple
users can have the same chart open, with full write access to the first user who opens a chart.
When multiple users open a chart for monitoring, all users can change controller values based on their
security level.
The Fieldbus Configuration Tools integrates the Controller with Fieldbus devices. Key features
include:
• Communication through the ControlNet path from the Experion PKS Server
• Block and Device tag and address setting
• An easy-to-use graphical environment for creating linkages, loops and a schedule based upon Fieldbus
concepts.
• Configuration of hardware information, ControlNet network addressing, Linking Device paths, Device
descriptions, and the base directory to store Device Description information.
Figure 3. Simple Control Module Example

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Control Functions
Control functions currently supported in the Experion PKS Control Builder libraries are listed in the
Specifications section. Standard available function blocks include Process Variable, Regulatory
Control, Fieldbus (Device and Control blocks), Motor Control, Discrete Logic and Sequential Control,
as well as general-purpose blocks like Flags, Numerics, Timers and Arrays.
Regulatory Control
The regulatory control library includes many standard function blocks, such as PID, PID Feed Forward,
Ratio/Bias, etc. Experion PKS R200 introduces the Profit Loop PKS™ block (PID-PL). Profit Loop
PKS utilizes a Honeywell patented algorithm that represents a single input/single output (SISO) model
predictive controller specifically designed with the operating simplicity and computational efficiency of a
standard PID controller. This allows it to be executed in either the C200 controller or ACE node. Profit
Loop PKS also provides an integrated set of tools (Profit Loop Assistant and Control Builder
Enhancements) that allow easy configuration and model identification.
The Profit Loop function block (PID-PL) is a hybrid of a PID and model based controller; it contains
both PID and Profit Loop capabilities to enable the easy replacement and on-line conversion from an
existing PID to a PID-PL block. Users can take a well-tuned PID controller and directly translate it into
a Profit Loop controller and immediately benefit from improved control delivered by Profit Loop
technology. The PID-PL function block uses a simple process model to predict the effect of past,
present, and future control moves on the process variable. It can be used in place of PID, Smith
Predictors, gap controllers, and optimizers since Profit Loop can anticipate future process behavior.
This allows the controller to know exactly how much to move the process to meet the desired control
objectives. The Profit Loop solution can be used to control temperatures, pressures, flows, discrete
analyzers, tank levels, and it is ideal for control processes with process delay, inverse response, non-
linear effects, and noisy process signals.
The level of effort to configure a PID-PL block is similar to that of the PID, but due to its model-based
formulation, this algorithm outperforms PID while being easier to tune and maintain than conventional
controllers. After its initial model is implemented, Profit Loop controllers are easily adjusted using a
single tuning parameter to obtain the desired control performance. The Profit Loop Assistant and
Control Builder enhancements deliver a variety of tools that greatly simplify the initial determination of
the process model and assist in diagnosing control loop problems:
• Direct conversion of existing PID tuning to a Profit Loop model
• Profit Stepper - an automated on-line identification tool that steps the process and calculates
the process model for the user.
• Basic Model creation based on Loop Type
• Valve Doctor - diagnoses valve hardware problems prior to controller implementation.
In addition to standard control features, Profit Loop also offers a wide range of expanded capabilities
that extend beyond existing regulatory control algorithms:
• Anti-windup handling (including handling windup on secondary loops)
• Range control
• Target optimization
• Predictive alarming on controller predictions
• Asynchronous inputs for direct analyzer control
Profit Loop model implementation results in significantly reduced valve travel that directly translates
into decreased valve maintenance and extended valve life.

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Sequential Control
Due to its rich set of standard features, SCMs greatly simplify batch logic implementation. The SCM
implementation follows the S88.01 standard. Standard features include abnormal handling, providing
an alternative sequence execution for user specified abnormal conditions. Abnormal handlers support
restart capabilities, re-starting the sequence from the position it was left or any other Step the process
requires to continue. Standard Abnormal handlers include: Checking, Interrupt, Restart, Hold, Stop
and Abort. Each sequence supports up to 50 recipe parameters. These include a range, material
code and scale option. In addition, it has 50 history parameters for reporting the amount of actual
dosed material and/or reached process conditions. The mode track option allows for different
operating philosophies. Devices, such as motors, pumps, and controllers, will follow SCM mode
changes allowing either operator or sequence device control. The devices can also be pre-configured
with the action required after an SCM start, abnormal situation or restart. This reduces the SCM step
configuration.
One feature of particular importance is the Common SCM function. A Common SCM is one that can
control several equipment units, one at a time, depending upon the unit selected. It saves
implementation, test and maintenance time required to support the application. The selected unit may
be determined at configuration time or changed dynamically during run time. An example application
might be header dosing in a batch plant. SCMs, including this Common SCM function, are fully
integrated into Honeywell’s TotalPlant Batch package for flexible batch operation.

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Control Libraries
In addition to the standard Control Builder libraries, Experion PKS also supports special function block
libraries that are licensed separately, such as the Profibus, Fieldbus, American Gas Association (AGA)
Flow Rate Calculation, and Allen Bradley Drive Interface Libraries.
Libraries are licensed per control system. All function block libraries appear in the library tab of the
Control Builder. This enables the user to see, use and learn all available function blocks on the project
side of the Configurator. Only the standard and licensed function blocks can be loaded to a controller.
The AGA Flow Rate Calculation Library provides the ability to normalize gas flow based on ambient
temperature, pressure and composition of a gas. Calculations are based upon reference C code
(Version 1.3, July 1997) provided by AGA (copyright © 1992-1995 Starling Associates, Inc.):
S AGA3OM_92: AGA Report 3 – 1992 (part III and IV) Orifice Metering of Natural Gas
S AGA7TM_96: AGA Report 7 – 1996 Measurement of Gas by Turbine Meters
S AGA8DL_94 and AGA8GS_94: AGA Report 8 – 1994 Compressibility Factors of Natural Gas and Other
Related Hydrocarbon Gases
S AGA9UM_96: AGA Report 9 – 1998 Measurement of Gas by Multi-path Ultrasonic Meters
S AGA3OM_98, AGA7TM_96 and AGA9UM_98 also include AGA Report 5 – 1996 Fuel Gas Energy
Metering calculations
Once the library license is enabled on the system, the meter run can be configured and loaded using
these special function blocks. Advantages of running the AGA flow rate calculations in the controller
include:
S Native support of controller redundancy
S All parameters are available at the controller level,
allowing, for example, on-line analyzers to provide
gas composition data directly to the algorithm.
Gas composition information can be entered directly into
the algorithms when an off-line analyses is used. Data is
protected from changes by the normal access control
features of Experion PKS. All information can be
historized and used in trends for analysis or reporting
purposes.
The operator has easy access to all information related
to the calculations. Orifice and gas composition information is presented through an extensive set of
detail displays provided with this option. Detailed information related to AGA calculation error
conditions is presented in the detail displays. The error is also written to the system event log.
Allen-Bradley Drive Interface Library provides the ability to interface directly with Allen-Bradley
variable speed drives making a PLC as an intermediate device unnecessary.
Two specific drives are supported – the 1305 AC Drive and the 1336 Plus II drive. The drives are
connected to a special Allen-Bradley ControlNet communication module (1203-CN1) to communicate
with the drive interface library. A generic interface function block is provided for other drives that can
connect to the scan port module 1203-CN1. The I/O data transfer of the generic drive has to be similar
to the 1305 and 1336-PLUS-II drive.
The function blocks provide access to all drive status and command information without the need for
additional configuration. The information is available for the operator through a detail display and as
parameters in the controller for control purposes. In addition to the standard status and command data,
additional drive parameters can be accessed through four Datalinks, which have to be configured on
the drive and in the function blocks.
Standard initialization processing is supported on the frequency output to the drive, making bumpless
transition possible on communication recovery.

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21 CFR Part 11
The Experion PKS system provides enhanced capabilities to support the regulated industry and their
unique requirements related to FDA regulations, particularly compliance with 21 CFR Part 11. The
Control Builder related features are discussed in this section. The Server-related features are
described in EP03-200-200, Experion PKS Server Specifications and Technical Data. For more detail
on validating an Experion PKS System, consult ‘System validation with Experion PKS’ White Paper.
The Control Builder supports three levels of version control:
- Manual Version Control,
- Basic Version Control, and
- Qualification and Version Control System (QVCS).
These three options are discussed below. The last option, QVCS, specifically supports the regulated
industries and makes system validation easy and efficient.
Manual Version Control is the system default. It allows a user to enter version specific information in
a version parameter available on each configurable Control Builder object. The user is responsible for
updating and controlling the version information. Four additional parameters are maintained by the
system: date created, created by, date modified and modified by.
Basic Version Control is standard available and is enabled through the system preferences menu. It
differs from the functionality mentioned above by automatically assigning a version number and
incrementing it on-change. The version number increment is based on a minor or major change. The
system defines a major change as the addition of a FB or the creation of a parameter connection. A
minor change is, for example, a parameter change or a graphical change. In addition, the version
number is shown on the Control Builder tree view and in the chart title.
Qualification and Version Control System (QVCS) is a licensable option. QVCS is more than a
version control system because it simplifies system qualification by defining and enforcing a user
defined development lifecycle. The user also defines, as part of the lifecycle, what configuration may
be loaded to a controller. The enforced lifecycle guarantees an implementation procedure and reduces
the number of Standard Operating Procedures while eliminating manual signatures and paper trails.
QVCS provides the user with the
ability to define the development
lifecycle and the electronic
signatures required to qualify a
configuration object. The system is
flexible and allows for single or
multiple electronic signatures.
Objects can only be modified once
they are checked out of the QVCS
system. Only the user who checked
the object out can modify the
object. The full user name is stored
in the QVCS log for each user
interaction with the system.
For each configuration object, the system maintains an individual audit trail and stores each individual
version in a version repository. The user is able to retrieve specific versions into the project side of the
Control Builder. The QVCS also allows a specific version of an object to be compared with the checked
out version, the version currently on the monitoring side of Control Builder, the previous version or a
specific version selected in the QVCS. The difference report will indicate in detail, which changes,
additions and deletions have occurred between the two versions.

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To make configuration management easier, the user can apply revert labels to specific versions of one
or more objects. The user can now easily retrieve them by using the revert label. Revert labels can be
assigned in bulk or individually.
The QVCS does not interfere directly with the configuration currently loaded in the controller. The user
performs a separate action to load a new version to a controller.
Experion PKS Process Simulation
Experion PKS supports two levels of simulation:
• Strategy check-out (on an Experion PKS server R200 and above), and
• High fidelity simulation (on a dedicated Experion PKS Simulation system).
An Experion PKS server (R200 and above) can be expanded with one or more C200 simulation
environments (SIM-C200), formerly known as the Simulation Control Environment, for a quick and
simple strategy checkout. The SIM-C200 environment counts as a controller in the maximum number
of controllers per server sizing rule.
The SIM-C200 supports restricted peer-to-peer communication with other controller environments such
as C200 and ACE nodes. This prevents upsets in a process due to simulation activities. The SIM-C200
reads from on-process environments, but is safely restricted from writing back to those environments.
In the case of a store command, the SIM-C200 will indicate a successful store although the value
never reaches the on-process environment. Similarly, the on-process environment is not allowed to
read from the SIM-C200 but they can store values. The SIM-C200 supports full peer-to-peer with other
SIM-C200 environments. The SIM-C200 supports high fidelity features when deployed with a
Honeywell ShadowPlant license.
For operator training and high fidelity process simulation, a very attractive Experion PKS Process
Simulation system offering is available. This offering includes a full server license and a number of
simulation environments for a fraction of the cost. It allows full Experion PKS system simulation without
the need for dedicated controller hardware. The simulation license is used in combination with the
Honeywell ShadowPlant process simulation system (see dedicated ShadowPlant product information).
The simulation system includes a system license that enables many standard server options and the
new C200 Simulation Environment (SIM-C200). A simulation system consists of an Experion PKS
Server, one or more operator stations, one or more SIM-C200 environments and a ShadowPlant
server (requires separate hardware and software purchase). The SIM-C200 supports advanced
simulation features such as control freeze, unfreeze, store current dynamic state of the process, and
initialize controllers to a particular process state, and others in combination with the ShadowPlant
simulation server.
On-Process Migration
Experion PKS supports on-process migration. The server-related functionality is described in the
Server Specifications and Technical Data EP03-200-200 document. This document specifically
describes the controller-related functionality. Server migration is performed before controller migration.
Controller on-process migration is supported on all redundant components, redundant controllers with
or without FIM modules, and IO Link modules. The FTE Bridge and ControlNet Interface (with single or
redundant media) communication modules are both supported. In addition, the redundant FIM-only
chassis is supported.

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An on-process migration is performed through a migration wizard, which will perform the following high-
level actions:
1. The migration wizard first focuses on the secondary chassis.
2. The secondary chassis is interrogated to determine the module types and versions. All
modules that require firmware updates will be updated automatically during the migration
process.
3. The static database is loaded after the new controller firmware is loaded.
4. Next, the dynamic information is synchronized between the primary (executing the old
software) and the secondary (executing the new software). During this limited period, the
control is frozen (several seconds). When the transfer of all dynamic data is complete, a
failover occurs (identical to a normal failover between redundant controllers) and the
secondary chassis using the new software will assume the role of primary controller.
5. Finally, the ‘old’ primary chassis is migrated and will then synchronize with the primary
controller after which a normal redundant controller pair exists.
In addition, the Experion PKS system supports release interoperability, which provides the flexibility to
leave controllers on an older release while they remain interoperable with the new server and
controllers in the system. Each Software Change Notice describes in detail which releases are
interoperable.

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Specifications and Sizing
Controller Environmental and Compliance Certifications
The Experion PKS C200 Controller and I/O Modules meet the following certifications:
Table 1. C200 Controller & I/O General Environmental and Agency Certifications
Parameter Specification
Environmental Conditions
Operating Temperature
Storage Temperature
Relative Humidity2
Temp. Rate of Change
0 to 60 °C (32 to 140°F)
-40 to 85°C (-40 to 185°F)
5 to 95% non-condensing
≤1°C/min. (≤5°C/min. storage)
Uncoated Models (TC-xxxxxx)
Coated Models (TK-xxxxxx)3Mild (G1) Moderate (G2) or Harsh (G3)
Operative and Storage Limits Transportation Band
Vibration (3 axes)
Frequency
Acceleration
Displacement
10 to 60 Hz
0.5 g max.
0.1 inches
10 to 60 Hz
1 g max.
0.1 inches
Mechanical Shock
Acceleration
Duration
5 g max.
30 ms max.
20 g max.
30 ms max.
Barometric Pressure
Altitude
-300 to +3000 m Any
UL 508 Industrial Control Equipment
Class I, Div 2, Groups A, B, C & D
Hazardous and Ordinary locations
(Maintenance may require a hot work
permit)
89/336/EEC, EMC Directive
EN 50081-2, Emissions, Industrial
EN 50082-2, Immunity, Industrial
Agency Certification
(when product is marked)
(C-Tick) Meets requirements of the Australian
Radiocommunications Act of 1992,
Section 182, relating to electromagnetic
compatibility.
Removal/Insertion Under Power
(RIUP) PERMITTED when equipment is installed in ordinary, non-
hazardous, locations (I/O modules reload automatically).
Not permitted when equipment is installed in a Class I, Division 2,
Hazardous (Classified) Location.
1The above environmental and agency specifications apply to all Experion PKS Chassis Series A models,
including Controllers, Power Supplies and I/O, except where noted.
2The maximum relative humidity specification applies up to 40
° C. Above 40 ° C the RH specification is de-
rated to 55% to maintain constant moisture content.
3With an enclosure.

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Compliance to European Union Directives. This product has the CE mark and is approved for
installation within the European Union and EEA regions. It has been designed and tested to meet the
following directives:
• EMC Directive. This apparatus is tested to meet Council Directive 89/ 336/ EEC Electromagnetic
Compatibility (EMC) using a technical construction file and the following standards, in whole or in
part:
• EN 50081- 2 EMC – Generic Emission Standard, Part 2 – Industrial Environment
• EN 50082- 2 EMC – Generic Immunity Standard, Part 2 – Industrial Environment
The product described in this document is intended for use in an industrial environment.
• Low Voltage Directive. This product is also designed 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.
Table 2. Agency Standards Compliance
Agency Standard Description
CE Mark Standard Compliance Electrical Emissions and Susceptibility
CSA C22.2 No. 142-M1983 Process Control Equipment
C22.2 No. 0-M1982 General Requirements Canadian Electrical Code, Part II
C22.2 No. 4-M1982 Bonding and Grounding of Electrical Equipment
FM ISA S12.12 Non-incendive Electrical Equipment for Use in Class I & II, Div.
2 and Class III, Div 1 & 2 Hazardous (Classified) Locations
UL 508 Industrial Control Equipment
C-Tick Australian
Radiocommunications
Act of 1992
Electromagnetic Compatibility
Control Processor Module Hardware Specifications
The Experion PKS C200 Control processor module meets the following specifications:
Table 3. TC-PRS021, TK-PRS021 Specifications
Parameter Operative and Storage Limits Transportation Band
Module Power Requirements +5 VDC +/- 5% @ 1.5 A
+3.3 VDC +/- 5% @ 1.0 A
Module Battery Backup Time1
Lithium Battery (standard, built in)
Battery Extension Module (BEM)
144 hours (non-rechargeable,
replaceable) - 6 days
120 hours (rechargeable) - 5 days
Lithium battery is
disconnected during
shipment.2
1CPM backup is provided via the Lithium Battery or the Battery Extension Module (BEM), but not by both. The Lithium
battery must be removed from the Control Processor if a BEM is used in the rack. A label inside the CP front door
provides that warning.
2The 1/2AA Lithium Battery has a non-restricted classification due to its size. It can be shipped without any special
documentation or note on the shipping list. The battery is specified for operation from -55 °C to +85 °C.
See Table 1 (previous page) for all general environmental specifications and agency certifications.

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ControlNet Specifications
Table 4. 9904-KTCX15, TC-PCIC01, TC-CCN013, TC-CCR013, TK-CCR013
Parameter Specification
Data rate 5 Mbit/sec
Redundancy Single cable or redundant operation supported
ControlNet Components End devices (workstations and controllers), taps, trunk cable, cable
connectors, terminators, segments, repeaters, and bridges.
Cable Type and Topology RG-6 Quad Shield cable, BNC connectors, trunk & drop, bus
topology. See next page for recommended cable types.
Cable Type by Application
• Light industrial applications
• Heavy industrial applications
• High and low temperature applications,
as well as corrosive (harsh) areas
• Moisture Resistant (direct burial,
flooding, etc.)
• Standard PVC CM-CL2
• Lay-on Armored and Interlocking Armor
• Plenum FEP CMP-CL2P
• Flood burial
Maximum Distance and Total
number of Repeaters Between any
two (2) Nodes
• Maximum Coax plus Fiber length of 10 km
• Maximum of 5 Repeaters (6 Segments)
• Maximum Coax Segment Length
• Maximum Fiber Segment Length • 1000 m (3280 ft.) - 16.3 m (53.4 ft.) x [number of Taps - 2]
• See Repeater Specifications below
Maximum Total Length Differential
Between A and B Trunk • 800 m (2624 ft.) (total link)
Fiber Optic Repeater Specifications – TC-RPA002, TC-RPRS01, TC-RPFM01
Mounting DIN rail mountable (35 mm wide rail)
Maximum number of Fiber Modules per
TC-RPA002 ControlNet Module Adapter Four (2 ports/module)
Power Requirements (TC-RPA002) 24 VDC, 700 mA maximum
Fiber Optic Repeater Model TC-RPFS01 (300 M) TC-RPFM01 (3000 M)
Optical power budget 4.2 dB 9.3 dB
Cable wavelength specification 650 ηm (red) 1300 ηm
Fiber Type 200 µm glass (HCM) 62.5 µm
Fiber Termination Type Versalink ST Termination
Maximum fiber optic segment distance is dependentupon the quality of the fiber, number of splices, and connectors. For more
ControlNet topology information, refer to the Planning Guide in Knowledge Builder or to EP-DCXX21.
Local ControlNet Trunk
R1 T1 R2 T2
TC-RPA001 TC-RPFM01
R1 T1 R2 T2
Remote ControlNet Trunk
Tap
Fiber Segments -- 3 Km max each
24Vdc
TC-RPA001
R1 T1 R2 T2
TC-RPFM01
R1 T1 R2 T2
24Vdc
Tap
R1 T1 R2 T2
TC-RPA001 TC-RPFM01
R1 T1 R2 T2
24Vdc
R1 T1 R2 T2
TC-RPFM01
R1 T1 R2 T2
Figure 3. ControlNet Fiber Optic Example -- Use of 2 Fiber Segments to
Interconnect 2 Non-Redundant-Media ControlNet Trunk Segments