Honeywell HC900 Operating manual

HC900 Process & Safety Controller
User and Installation Manual
Doc. No.: 51-52-25-154
Revision: 6
Date: 21 April 2017

ii HC900 Process & Safety Controller User and Installation Manual Revision 6
21 April 2017
Notices and Trademarks
Copyright 2017 by Honeywell
Revision 6, 21 April 2017
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
Honeywell is a U.S. registered trademark of Honeywell
Other brand or product names are trademarks of their respective owners.

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About This Document
Abstract
This document provides descriptions and procedures for the installation, operation and maintenance of the HC900
Process Controller hardware.
References
The following list identifies all documents that may be sources of reference for material discussed in this
publication.
Document Title
ID #
HC900 Process Controller Technical Overview Specification
51-52-03-31
HC900 Module Specification
51-52-03-41
HC900 Controlware Specification
51-52-03-42
Designer Software Specification
51-52-03-43
Legacy HC900 Process Controller Installation and User Guide
51-52-25-107
HC900 Process Controller Operator Interface User Guide
51-52-25-108
HC900 Designer Software User Guide
51-52-25-110
HC900 Process Control Utilities User Guide
51-52-25-126
HC900 Process Controller Function Block Reference Guide
51-52-25-109
HC900 Process Controller Communications User Guide
51-52-25-111
HC900 Controller Redundancy Overview & System Operation
51-52-25-133
900 Control Station For use with HC900 Process Controller
51-52-25-148
Station Designer Software manual
51-52-25-149
HC900 Process & Safety Controller Safety Manual
51-52-25-153

iv HC900 Process & Safety Controller User and Installation Manual Revision 6
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Revision Information
Document Name
51-52-25-154 HC900 Process & Safety Controller User &
Installation Manual
Revision Number
Publication Date
First release
2.1
January 2014
Redundancy updates
2.2
June 2014
Cyber Security updates
3.0
July 2014
SafetyWrite updates
4.0
June 2015
Speed Improvement, 12 racks and Safety Peer
communication support updates
5.0
Mar 2017
Updated with fiber optic specification
6
21 Apr 2017
Support and 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
www.honeywellprocess.com
HPS Technical tips
https://www.honeywellprocess.com/en-
US/explore/products/control-monitoring-and-safety-
systems/scalable-control-solutions/hc900-control-
system/Pages/hc900-controller.aspx
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]

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Symbol Definitions
The following table lists those symbols that may be used in this document and on the product 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
CAUTION, HOT SURFACE: This symbol warns the user of potential hot surfaces
which should be handled with appropriate caution.
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 and 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.

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Contents
Introduction .....................................................................................................................1
Purpose....................................................................................................................................................1
Model Selection Guide.............................................................................................................................2
Functional Description .............................................................................................................................9
Feature Summary ..................................................................................................................................13
Components and Architecture.......................................................................................17
Overview ................................................................................................................................................17
Components...........................................................................................................................................17
Redundant components.........................................................................................................................20
Hardware Components..........................................................................................................................23
I/O Network ............................................................................................................................................33
I/O implementation requirements include: .............................................................................................35
Ethernet Open Connectivity Network.....................................................................................................35
Serial Ports.............................................................................................................................................42
Network and Security Planning.....................................................................................44
Overview ................................................................................................................................................44
Pre-Installation Planning ...............................................................................................45
Overview ................................................................................................................................................45
AC Power Supply Selection for racks with I/O.......................................................................................46
DC Power Supply...................................................................................................................................48
Rack Orientation and Mounting .............................................................................................................48
Remote Termination Panels ..................................................................................................................51
Environment...........................................................................................................................................51
Heat Rise De-rating................................................................................................................................52
Cable/Wiring Distance Planning ............................................................................................................54
Electrical Considerations .......................................................................................................................56
Hardware and wiring requirements for safety configuration ..................................................................62
System Monitor Function Blocks............................................................................................................64
Rack Installation............................................................................................................65
Overview ................................................................................................................................................65
Mount Racks ..........................................................................................................................................68
Assemble Controller Rack .....................................................................................................................70

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Assemble I/O Expansion Racks.............................................................................................................74
I/O Module Installation and Wiring ................................................................................78
Overview ................................................................................................................................................78
Module Placement in Racks ..................................................................................................................78
Remote Termination Panel (RTP)..........................................................................................................80
Terminal Block-to-Field (Signal) Wiring .................................................................................................80
Removal and Insertion Under Power (RIUP).........................................................................................83
I/O Module Installation Procedures........................................................................................................84
I/O Terminal Block Wiring Diagrams......................................................................................................91
Communications Installation .......................................................................................127
Overview ..............................................................................................................................................127
Wiring and cabling................................................................................................................................127
Connecting the Operator Interface to the Controller............................................................................131
Connecting the HC900 Controller to a PC with the Designer Software...............................................132
Connecting the HC900 Controller to Modbus device(s) ......................................................................152
Operating Characteristics............................................................................................155
Introduction ..........................................................................................................................................155
Overview ..............................................................................................................................................155
Power Down / Power Up......................................................................................................................155
Controller Modes..................................................................................................................................158
File Download/Upload Functions .........................................................................................................163
Redundant Operating Characteristics .........................................................................165
Overview ..............................................................................................................................................165
Start-Up................................................................................................................................................165
Modes of operation (Figure 87)............................................................................................................165
Steady State Operations......................................................................................................................166
Failover ................................................................................................................................................169
File Download/Upload Functions .........................................................................................................170
Diagnostics and Troubleshooting................................................................................173
Overview ..............................................................................................................................................173
External Indications of Diagnostic Information.....................................................................................173
Controller CPU indicators ....................................................................................................................174
Scanner indicators ...............................................................................................................................182
I/O Module Indicators...........................................................................................................................187
Overview ..............................................................................................................................................192
Removal and Replacement Procedures......................................................................196