Honeywell HC900 User manual

Honeywell Process Solutions
HC900 Process Controller
Installation and User Guide
Doc. No.: 51-52-25-107
Revision: 19
Date: June 2014

ii HC900 Process Controller Installation and User Guide Revision 19
06/14

About This Document
Warranty/Remedy
Revision 19 HC900 Process Controller Installation and User Guide iii
06/14
Notices and Trademarks
Copyright 2014 by Honeywell
Revision 18, June 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
Honeywell is a U.S. registered trademark of Honeywell
Other brand or product names are trademarks of their respective owners.

iv HC900 Process Controller Installation and User Guide Revision 19
06/14
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
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
Revision Information
Document Name
This manual … 51-52-25-107 HC900 Controller
Installation and User Manual
Revision Number Publication Date
SIL updates/Shielded cable added/CE and ATEX updates Rev.19 June 2014

About This Document
Revision 19 HC900 Process Controller Installation and User Guide v
06/14
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]

vi HC900 Process Controller Installation and User Guide Revision 19
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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.

Introduction - Purpose
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Contents
Introduction .....................................................................................................................1
Purpose..............................................................................................................................................1
Model Selection Guide........................................................................................................................2
Functional Description ........................................................................................................................7
Feature Summary.............................................................................................................................10
Components and Architecture.......................................................................................13
Overview..........................................................................................................................................13
Components.....................................................................................................................................13
Redundant components....................................................................................................................16
Hardware Components.....................................................................................................................18
Ethernet Devices/Considerations......................................................................................................27
I/O Network ......................................................................................................................................28
Ethernet Open Connectivity Network.................................................................................................29
Serial Ports (RS-232 and RS-485 for legacy systems and two RS-485 ports for new systems)..........35
Pre-Installation Planning ...............................................................................................37
Overview..........................................................................................................................................37
AC Power Supply Selection for racks with I/O...................................................................................38
DC Power Supply .............................................................................................................................39
Rack Orientation and Mounting.........................................................................................................39
Remote Termination Panels..............................................................................................................41
Environment.....................................................................................................................................42
Heat Rise De-rating..........................................................................................................................43
Cable/Wiring Distance Planning........................................................................................................45
Electrical Considerations...................................................................................................................47
System Monitor Function Blocks.......................................................................................................54
Rack Installation............................................................................................................55
Overview..........................................................................................................................................55
Mount Racks ....................................................................................................................................58
Assemble Controller Rack.................................................................................................................60
Assemble I/O Expansion Racks........................................................................................................64

Introduction - Purpose
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I/O Module Installation and Wiring.................................................................................67
Overview..........................................................................................................................................67
Module Placement in Racks..............................................................................................................67
Remote Termination Panel (RTP).....................................................................................................69
Terminal Block-to-Field (Signal) Wiring.............................................................................................69
Removal and Insertion Under Power (RIUP).....................................................................................73
I/O Module Installation Procedures ...................................................................................................74
I/O Terminal Block Wiring Diagrams..................................................................................................82
Communications Installation .......................................................................................117
Overview........................................................................................................................................117
Wiring and cabling..........................................................................................................................117
Connecting the Operator Interface to the Controller.........................................................................121
Connecting the HC900 Controller to a PC with the Designer Software.............................................122
Connecting the HC900 Controller to Modbus device(s)...................................................................142
Operating Characteristics............................................................................................145
Introduction.....................................................................................................................................145
Overview........................................................................................................................................145
Power Down / Power Up.................................................................................................................145
Controller Modes............................................................................................................................148
File Download/Upload Functions.....................................................................................................153
Redundant Operating Characteristics.........................................................................155
Overview........................................................................................................................................155
Start-Up..........................................................................................................................................155
Modes of operation (Figure 83).......................................................................................................155
Steady State Operations.................................................................................................................156
Failover ..........................................................................................................................................158
File Download/Upload Functions.....................................................................................................159
Diagnostics and Troubleshooting................................................................................161
Overview........................................................................................................................................161
External Indications of Diagnostic Information.................................................................................161
Controller CPU indicators................................................................................................................161
Scanner indicators..........................................................................................................................171
I/O Module Indicators......................................................................................................................175
Analog Calibration....................................................................................................... 180
Overview........................................................................................................................................180

Introduction - Purpose
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Removal and Replacement Procedures...................................................................... 184
Overview........................................................................................................................................184
Safety Considerations - PLAN AHEAD!...........................................................................................184
Specifications..............................................................................................................194
General Specifications....................................................................................................................194
HC900 Analog Input Ranges vs. UMC800 Analog Input ranges ......................................................200
System Sizing and Availability Summary.........................................................................................203
Fiber Optics Recommendations......................................................................................................204
Appendix - Installation of Remote Termination Panels (RTPs)...........................................207
Overview........................................................................................................................................207
Analog Input...................................................................................................................................208
Relay Output ..................................................................................................................................215
Analog Input/Digital Input/Digital Output/Analog Output...................................................................219
Declaration of Conformity............................................................................................246
ATEX Certification.......................................................................................................247
INDEX......................................................................................................................... 249

Introduction - Purpose
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Tables
Table 1 – Descriptions of Major Components (Figure 4) ....................................................................................15
Table 2 – Descriptions of Major Redundancy Components.................................................................................17
Table 3 – Serial port DIP switch settings............................................................................................................36
Table 4 – Power Applied, by Module Type........................................................................................................43
Table 5 – Guidelines for Grouping Wires...........................................................................................................51
Table 6 – Installation Tools ...............................................................................................................................55
Table 7 – Site and Equipment Preparation..........................................................................................................56
Table 8 – Mount Racks......................................................................................................................................58
Table 9 – Assemble C30/C50/C70 Controller Rack............................................................................................60
Table 10 – Assemble C75 Controller Rack.........................................................................................................63
Table 11 – Assemble I/O Expansion Racks........................................................................................................64
Table 12 – Minimum Recommended Wire Sizes................................................................................................69
Table 13 – RIUP: Potential Hazards and Recommended Actions........................................................................73
Table 14 – Connect Input/Output Wiring ...........................................................................................................74
Table 15 – Typical Thermocouple resistance in Ohms per Double Foot @ 68 degrees F .....................................82
Table 16 – Connect Communications Wiring and Cabling................................................................................117
Table 17 – Links to Controller Communication Ports.......................................................................................118
Table 18 – Parts needed to make RS-485 Cable................................................................................................121
Table 19 – Null Modem Cable Connections.....................................................................................................124
Table 20 – Redundant Network connections in Figure 74.................................................................................136
Table 21 – Redundant network connections .....................................................................................................137
Table 22 – Controller Operating Modes ...........................................................................................................150
Table 23 – Mode Switch Functions..................................................................................................................151
Table 24 – Controller Behavior in Mode Transition..........................................................................................152
Table 25 – Configuration file downloading......................................................................................................154
Table 26 – LED Indications on Controller CPUs..............................................................................................163
Table 27 – Controller Status LED Diagnostics .................................................................................................164
Table 28 – LED Indications on Scanner Module ..............................................................................................171
Table 29 – Scanner LED Diagnostics...............................................................................................................172
Table 30 – LED Indications on I/O Module......................................................................................................175
Table 31 – I/O Module LED Diagnostics.........................................................................................................176
Table 32 – Bad I/O Channel Diagnostics..........................................................................................................177
Table 33 – LED Indications on Ethernet Switch...............................................................................................178
Table 34 – Power Supply Replacement (all except C75)...................................................................................185
Table 35 – Controller Module Replacement.....................................................................................................187
Table 36 – Scanner Module Replacement ........................................................................................................188
Table 37 – RIUP: Potential Hazards and Recommended Actions......................................................................189
Table 38 – I/O Module Replacement................................................................................................................190
Table 39 – Installing Backup Battery (CPU not initialized)...............................................................................192
Table 40 – Replacing a Backup Battery (CPU Powered)) .................................................................................193
Table 41 - HC900 PV Input Types and Ranges ................................................................................................200
Table 42 – System Size and Availability Summary..........................................................................................203
Table 43 – Fiber Optics Equipment Recommendations.....................................................................................204

Introduction - Purpose
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Figures
Figure 1 – Small HC900 Controller Configuration ...............................................................................................7
Figure 2 – Expanded HC900 Controller Configuration (C50/C70 CPU only)........................................................8
Figure 3 – Single process with redundancies........................................................................................................9
Figure 4 – Configuration with Multiple Controllers............................................................................................14
Figure 5 – Redundant Configuration with multiple I/O racks..............................................................................16
Figure 6 – Controller Rack Components ............................................................................................................18
Figure 7 – Redundant Controller Rack Components...........................................................................................18
Figure 8 – I/O Expansion Rack Components......................................................................................................19
Figure 9 – Rack Options....................................................................................................................................20
Figure 10 – Power Supply..................................................................................................................................21
Figure 11 – Power Status Module (PSM)...........................................................................................................22
Figure 12 – Controller Module...........................................................................................................................23
Figure 13 – Redundancy Switch Module............................................................................................................24
Figure 14 – Scanner 1 Module...........................................................................................................................24
Figure 15 – Scanner 2 Module...........................................................................................................................25
Figure 16 – I/O Module Terminal Blocks...........................................................................................................25
Figure 17 – RS-232 Modem Devices .................................................................................................................27
Figure 18 – HC900 Controller Configurations....................................................................................................28
Figure 19 – Modular Network Structure.............................................................................................................30
Figure 20 – Modbus/TCP Framing.....................................................................................................................31
Figure 21 – Typical installation using a Cable Modem.......................................................................................34
Figure 22 – Controller Serial Ports.....................................................................................................................35
Figure 23 – Serial Ports DIP Switch default settings...........................................................................................36
Figure 24 – Rack Dimensions (C30 and C50).....................................................................................................39
Figure 25 – Rack Dimensions with reserve power supply...................................................................................40
Figure 26 – Vertical Spacing of Racks (all models)............................................................................................41
Figure 27 – AC Input Module de-Rating ............................................................................................................44
Figure 28 – Power Supply de-Rating..................................................................................................................44
Figure 29 – Cabinet Wiring, Single Chassis .......................................................................................................48
Figure 30 – Cabinet Wiring, Multiple Chassis....................................................................................................49
Figure 31 – Redundant power supplies each with external fuse and switch .........................................................50
Figure 32 – Master Control Relay Wiring Example............................................................................................53
Figure 33 – I/O Module Installation...................................................................................................................67
Figure 34 – Terminal Block Styles.....................................................................................................................68
Figure 35 – Signal-Wire Grounding...................................................................................................................70
Figure 36 – Wire-Shield Grounding...................................................................................................................71
Figure 37 – Terminal Block Jumper Installation.................................................................................................72
Figure 38 – RTD Inputs.....................................................................................................................................82
Figure 39 – Universal Analog Input Wiring Diagram.........................................................................................83
Figure 40 – Examples of RTD Input Wiring.......................................................................................................84
Figure 41 – Analog Input Wiring - Eight TCs ....................................................................................................85
Figure 42 – Analog Input Wiring - Eight Resistance Inputs................................................................................86
Figure 43 – Analog Input Wiring - Eight RTDs..................................................................................................87
Figure 44 – Analog Input Wiring – Slidewire (Position Proportion Block)..........................................................88
Figure 45 – 16 point High Level Analog Input Wiring........................................................................................89
Figure 46 – 4 channel Analog Output Wiring Diagram.......................................................................................90
Figure 47 – 8 channel Analog Output Wiring Diagram.......................................................................................91
Figure 48 – 16 channel Analog Output Wiring Diagram.....................................................................................91
Figure 49 – DC Input Module Wiring Diagram..................................................................................................93
Figure 50 – DC Input Module Jumper................................................................................................................94
Figure 51 – 32 point DC Input Module Wiring...................................................................................................95
Figure 52 – AC Input Module Wiring Diagram..................................................................................................96
Figure 53 – AC Input Module Jumper................................................................................................................97

Introduction - Purpose
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Figure 54 – AC/DC Isolated Input Module Wiring.............................................................................................99
Figure 55 – Contact Input Wiring Diagram ......................................................................................................101
Figure 56 – DC Output Module Wiring Diagram..............................................................................................103
Figure 57 – DC Output Jumpers.......................................................................................................................104
Figure 58 – 32 point DC Output Module Wiring ..............................................................................................105
Figure 59 – AC Output Module Wiring Diagram..............................................................................................107
Figure 60 – AC Output Module Jumper ...........................................................................................................108
Figure 61 – Schematic Example: Relay Output and External Wiring.................................................................109
Figure 62 – Relay Output Module Wiring Diagram..........................................................................................110
Figure 63 – Relay Output Module Jumpers......................................................................................................111
Figure 64 – Pulse Counting Wiring..................................................................................................................112
Figure 65 – Pulse Output Wiring......................................................................................................................112
Figure 66 – Frequency Wiring.........................................................................................................................113
Figure 67 – Quadrature, Differential, External Power Wiring...........................................................................113
Figure 68 – Quadrature, Single Ended, External Power Wiring.........................................................................114
Figure 69 – Quadrature, Differential, HC900 Power Wiring.............................................................................114
Figure 70 – Quadrature, Single Ended, HC900 Power Wiring...........................................................................115
Figure 71 – A Direct Serial RS-232 Connection...............................................................................................123
Figure 72 – RS-232 Remote Access via Modems .............................................................................................125
Figure 73 Modem Connection..........................................................................................................................126
Figure 74 – Redundant Networks (see Table 20)..............................................................................................135
Figure 75 – Two redundant systems with PC supervision .................................................................................138
Figure 76 - RS-485 Modbus slave wiring.........................................................................................................142
Figure 77 - RS-485 Modbus slave wiring with isolation ...................................................................................143
Figure 78 - XYR 5000 RS-485 Modbus connections with isolator....................................................................144
Figure 79 – Warm Start Operation ...................................................................................................................146
Figure 80 – Cold Start Operation .....................................................................................................................147
Figure 81 – Mode Switches: Controller (left), RSM (right)...............................................................................151
Figure 82 – Pathways for Upload/Download Transactions................................................................................153
Figure 83 – Modes of operation on RSM..........................................................................................................156
Figure 84 – Lead/Controller synchronization....................................................................................................158
Figure 85 – LED Indicators on Controller CPUs (See Table 26).......................................................................162
Figure 86 – LED Indicators on Scanners—1 port (left), 2 port (right) (See Table 28)........................................171
Figure 87 – I/O Module LED indicators...........................................................................................................175
Figure 88 – Terminal Board Connections for AI Calibration.............................................................................182
Figure 89 – Terminal board Connections for AO Calibration............................................................................183
Figure 90 – Extended Distance Example #1.....................................................................................................204
Figure 91 – Extended Distance Example #2 .....................................................................................................205
Figure 92 – Example installation (not shown: 2nd RTP & cable for high capacity AI/DI/DO) ............................207
Figure 93 – Analog input terminals..................................................................................................................210
Figure 94 – Two–wire transmitter connections with common 24 VDC supply..................................................210
Figure 95 – Milliamp input connections with 250 ohm shunt resistance............................................................211
Figure 96 – Volt, millivolt input connections ...................................................................................................211
Figure 97 – Three-wire RTD input connections................................................................................................212
Figure 98 – Two-wire RTD or ohm input connections......................................................................................212
Figure 99 – Slidewire feedback connections for actuators.................................................................................213
Figure 100 Voltage input connections............................................................................................................237
Figure 101 Current connections with 2-wire transmitter ...................................................................................237

Revision 19 HC900 Process Controller Installation and User Guide 1
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Introduction
Purpose
This publication describes the installation, operation, and maintenance of the Honeywell HC900 Process
Controller. This publication includes the following sections.
Chapter Title Page Content
Introduction 1 Model numbers, how to verify component compatibility, function description of
components, feature summary.
Components and
Architecture 13 Functional features and physical characteristics of the system and of each major
component of the HC900 Process Controller. Networking components and
methods of interconnection.
Pre-Installation
Planning 37 Pre-planning considerations and procedural guidelines for planning an installation.
Rack Installation 55 Procedures for installing the major components of the system: controller rack, I/O
expansion racks, and communication interconnections.
I/O Module
Installation and
Wiring
66 Procedures for installing I/O modules in the controller rack and I/O expansion
racks, and for wiring field devices to the terminal block associated with each
I/O module.
Communications
Installation 117 Guidelines for installing RS-232, RS-485 TO USB CABLE, RS-485,and Ethernet cabling and associated components.
Operating
Characteristics 145 Characteristics of the HC900 Process Controller as they relate to configuration of a control strategy, and to operation of an installed and running system.
Redundant
Operating
Characteristics
155 Characteristics of redundant operation.
Diagnostics and
Troubleshooting 161 Mechanisms that detect and react to faults in the operation of HC900 Process Controller hardware and/or software components.
Analog Calibration 180 Hardware configuration required for calibrating AI and AO modules from the
configuration software.
Removal and
Replacement
Procedures
184 Guidelines for replacing system components; includes Cautions andWarnings as
applicable.
Specifications 194 Details of HC900 Process Controller design and functioning.
Appendix -
Installation of
Remote
Termination Panels
(RTPs)
207 The Remote Termination Panel (RTP) provides an easy way to connect the
HC900 controller to the field wiring. The RTP integrates some of the typical
externally connected components, reducing wiring and setup time. It also
minimizes the need for multiple wires under a single screw connection by
expanding the connectivity of the shared terminals of the I/O modules.

Introduction - Model Selection Guide
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Model Selection Guide
Legacy System
Description Model number
Racks
4 I/O Slot Rack 900R04 – 0001
8 I/O Slot Rack 900R08 – 0101
12 I/O Slot Rack 900R12 - 0101
8 Slot Rack -Red. Power 900R08R - 0101
12 Slot Rack - Red. Power 900R12R - 0101
Redundant CPU Rack 900RR0 - 0001
Controllers
Controller C50 CPU Config.SW & Docs 900C51 – 00XX-00
Controller C50 CPU 900C52 – 00XX-00
Controller C30 CPU Config. SW & Docs 900C31 – 00XX-00
Controller C30 CPU 900C32 – 00XX-00
Controller C70 CPU Config.SW & Docs 900C71-00XX-00
Controller C70 CPU 900C72-00XX-00
Controller C70R CPU Config.SW & Docs 900C71R-0000-XX
Controller C70R CPU 900C72R-0000-XX
Redundancy switch module 900RSM - 0001
I/O Scanner - 2 Port (1 per I/O rack) 900C73R-0000-XX
I/O Scanner (for remote rack) 900C53 – 00XX-00
Redundant Power Status Module 900PSM - 0001
Power Supplies
120/240VAC, 60W 900P01 -0001
120/240VAC, 28W 900P02 -0001
+24VDC 900P24-0001
I/O Modules
Analog Input (8 channel) 900A01 - 0102
High Level Analog Input (16 channel) 900A16 - 0001
Analog Output, 0 to 20mA, (4 channel) 900B01 -0101
Analog Output, 0 to 20mA, (8 channel) 900B08 – 0001
Analog Output, 0 to 20mA, (16 channel) 900B16 - 0001
Digital Input, Contact type, (16 channel) 900G01 - 0102
Digital Input, 24VDC (16 channel) 900G02 - 0102
Digital Input, 24VDC (32 channel) 900G32 - 0001
Digital Input, 120/240 VAC, (16 channel) 900G03 - 0102
Digital Input, 120/240VAC, 125VDC (16ch-Iso) 900G04 - 0001
Digital Output, Relays ( 8 channel) 900H01 - 0102
Digital Output, 24VDC (16 channel) 900H02 - 0102
Digital Output, 24VDC (32 channel) 900H32 - 0001
Digital Output, 120/240 VAC (8 channel) 900H03 - 0102
Pulse/Frequency/Quadrature 900K01 - 0001

Introduction - Model Selection Guide
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Description Model number
I/O Components
Low VoltageTerminal Block (Euro style) 900TEK - 0001
Low VoltageTerminal Block (Barrier Style) 900TBK -0001
High VoltageTerminal Block (Euro style) 900TER - 0001
High Voltage Terminal Block (Barrier Style) 900TBR - 0001
High Density Terminal Block 900TCK - 0001
Analog Input Remote Terminal Panel (RTP) 900RTA - L001
I/O Components
Relay Output Remote Terminal Panel (RTP) 900RTR - H001
DI, DO, AO Remote Terminal Panel (RTP) 900RTS - 0001
Low Voltage RTP Cable (1.0M, 3.28ft.) 900RTC - L010
Low Voltage RTP Cable (2.5M, 8.2ft.) 900RTC - L025
Low Voltage RTP Cable (5.0M, 16.4ft.) 900RTC - L050
High Voltage RTP Cable (1.0M, 3.28ft.) 900RTC - H010
High Voltage RTP Cable (2.5M, 8.2ft.) 900RTC - H025
High Voltage RTP Cable (5.0M, 16.4ft.) 900RTC - H050
High Density RTP Cable (1.0M, 3.28ft.) 900RTC - 3210
High Density RTP Cable (2.5M, 8.2ft.) 900RTC - 3225
Filler Block Terminal Cover 900TNF - 0001
Shield Terminal Strip (package of 2) 900TSS - 0001
Terminal board jumpers (10, two pos jumpers) 900J02 - 0001
Terminal board jumpers (10, ten pos.jumpers) 900J10 - 0001
Manuals
Full Document set on CD 900ME1-00XX-XX
Full document set, hard copy - English 900ME2-00XX-XX
Software
HC Designer Config. Software CD 900W01-00XX-XX
HC Utilities Software/Documentation CD 900W02-00XX-XX
Kits & Accessories
Redundant Power, Rack Extension Kit 900RPE-0001
Spare I/O Label Kit 51452262-501
Replacement Battery Kit 51500638-501
Ethernet Cable (10 feet) 51451432-010
Ethernet Cable (20 feet) 51451432-020
Ethernet Cross-over Cable (20 feet) 51451996-020
Null Modem Cable 51404755-501
Null Modem Cable used with 900C70R 50004820-501
250 ohm Shunt Resistor Kit ( (8/pkg.) 51205995-501
Ethernet Switching Hub (8 Ports) 50008930-001
24 VDC Power Supply 51452041-501

Introduction - Model Selection Guide
4 HC900 Process Controller Installation and User Guide Revision 19
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Operator Interface
Description Model number
900 Control Station 10” Screen 900CS10- xx
900 Control Station 15” screen 900CS15-xx
OI Accessories & Kits
CompactFlash Memory Module 50040636-002
USB Programming Cable 50038817-001
10” Screen Protective Films (10) 50038816-501
10” Replacement Backlight 50038818-501
10” Replacement Touch Screen Assy 50038820-501
10” Mounting plate adapter for 1042
replacement 50039118-501
24 VDC Power Supply for 10” 51452041-501
900 Control Station User Manual (paper) 51-52-25-148
15” Screen Protective Films (10) 50038816-502
24VDC Power Supply for 15” 50047098-001
GSM/GPRS Cellular Modem Kit 50047099-501
New Non-SIL System
Description Model number
Racks
4 I/O Slot Rack 900R04 - 0200
8 I/O Slot Rack 900R08 - 0200
12 I/O Slot Rack 900R12 - 0200
8 Slot Rack -Red. Power 900R08R - 0200
12 Slot Rack - Red. Power 900R12R - 0200
Redundant CPU Rack 900RR0 - 0001
Controllers
Controller C30 CPU 900C30-0360-00
Controller C50 CPU 900C50-0360-00
Controller C70 CPU 900C70-0360-00
Controller C70R CPU 900C75-0360-00
I/O Scanner - 2 Port (1 per I/O rack) 900S75-0360-00
I/O Scanner - 1 Port (1 per I/O rack) 900S50-0360-00

Introduction - Model Selection Guide
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SIL System Description Model Number
Controllers
Controller C30 CPU - SIL 900C30S - 0360-00
Controller C50 CPU - SIL 900C50S - 0360-00
Controller C70 CPU - SIL 900C70S - 0360-00
Controller C70R CPU - SIL 900C75S-0360-00
I/O Scanner - 1 Port (1 per I/O rack) - SIL 900S50S - 0360-00
I/O Scanner - 2 Port (1 per I/O rack) - SIL 900S75S-0360-00
Documentation
Full Document set on CD - SIL 900ME1S-0060-00
Full document set, SIL hard copy - English 900ME2S-0060-00
Conventions
Throughout this guide, where the text “Legacy systems” is used, the following model numbers are
applicable.
•Legacy systems Model Numbers
−900C51 – 00XX-00
−900C52 – 00XX-00
−900C31 – 00XX-00
−900C32 – 00XX-00
−900C71-00XX-00
−900C72-00XX-00
−900C71R-0000-XX
−900C72R-0000-XX
−900RSM - 0001
−900C73R-0000-XX
−900C53 – 00XX-00
Throughout this guide, where the text “New systems” is used, the following model numbers are applicable.
•New System (SIL and Non SIL Model Numbers)
−900C30-0360-00
−900C50-0360-00
−900C70-0360-00
−900C75-0360-00
−900S75-0360-00
−900S50-0360-00

Introduction - Model Selection Guide
6 HC900 Process Controller Installation and User Guide Revision 19
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−900C30S - 0360-00
−900C50S - 0360-00
−900C70S - 0360-00
−900C75S-0360-00
−900S50S - 0360-00
−900S75S-0360-00
ATTENTION
For the Legacy systems, it is specifically mentioned in the guide wherever applicable.
The other text is applicable to the new HC900 system. Modems are not qualified with the
new HC900 system.
Checking HC900 Model Numbers for Compatibility
ATTENTION
Be sure to check your model numbers for compatibility before installation. For a HC900
system to be fully compatible, all components must have matching model numbers.
Each component’s model number format is XXXXXXX–XXYY-ZZ. For example, HC900 CPU is
900C71R-0000-40. For redundant CPU systems, component model numbers ZZ numbers must match. For
non-redundant CPU systems, component model numbers YY numbers must match. See examples below.
Example of a compatible redundant system
Component Model Number XXXXXXX-XXYY-ZZ
HC900 CPU 900C71R-0000-40
Scanner 2 900C73R-0000-40
HC Designer Software 900W01-0040-40
Manuals CD 900ME1-0040-40
Example of a compatible non-redundant system
Component Model Number XXXXXXX-XXYY-ZZ
HC900 CPU 900C51R-0040-00
Scanner 1 900C53R-0040-00
HC Designer Software 900W01-0040-40
Manuals CD 900ME1-0040-40

Introduction - Functional Description
Revision 19 HC900 Process Controller Installation and User Guide 7
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Functional Description
All Controllers
The Honeywell HC900 Process Controller is an integrated loop and logic controller that is designed
specifically for small-and medium-scale unit operations
It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range
of process control applications. The HC900 Process Controller can consist of a single rack, as indicated in
Figure 1, or can be can be networked with other controllers via Ethernet linksto expand the dimensions of
control over a wider range of unit processes, as indicated in Figure 2.
Figure 1 – Small HC900 Controller Configuration

Introduction - Functional Description
8 HC900 Process Controller Installation and User Guide Revision 19
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Figure 2 – Expanded HC900 Controller Configuration (C50/C70 CPU only)
The HC900 Controller design enables users and OEMs who are adept in system integration to assemble a
system that fits a broad range of requirements. Any configuration can be readily modified or expanded as
requirements dictate. In initial configuration and in subsequent modifications, the HC900 Controller
affords an optimum balance of performance and economy.
Configurations such as those shown in Figure 1 and in Figure 2, as well as many variations, can be
assembled from modular components. Many of the components are available from Honeywell, and some
are available from third-party suppliers. These modular components are available in any quantity and mix
that make the most sense for a given application.
As indicated in Figure 3, the HC900 Controller includes provisions for communication via Ethernet with
host systems such as the Honeywell Experion HMI and other HMI software that supports Ethernet
Modbus/TCP protocol. Also, the communication structure of the HC900 Controller enables remote
placement of input/output components, allowing significant economies in cabling and wiring.