plc hc900 honeywell

8/10/2019 PLC HC900 Honeywell

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HC900 Training Part 1 1Version 4.1 11/16//06Honeywell Proprietary

Industrial Measurement and Control

HC900 Hybrid Controller

Training - Part 1Controller, OI & HC Designer


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3 Components Integrated Together

Controller, Operator Interface, Hybrid Control Designer


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Controller


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HC900 Controller

Ethernet Supervisory

Peer-to-peer

1 port on C30 & C50

Remote I/O port

(not on C30)

I/O Modules I/O Status LEDsController

Module

Power

Supply

Termination

Cover &

Label

Field

Wiring

Terminals

Size: Height 5.5

139.7 mm Width10.5

266.7 mm

Depth 5.9

149.9 mm

Serial Ports (RS232/485

Configuration Modbus Master/Slave

. Honeywell OI


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Modular Design

Select appropriate componentsto match application requirements purchase only what is needed

expand any time

replace any component

any I/O module can be located in any I/O slot

any chassis size can be a CPU rack

4 I/O slot rack

8 I/O slot rack

12 I/O slot rack

Can be a Controller or a Remote I/O Scanner Module


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HC900

RemoteI/O Racks

Moxa Hub

10Base-T

CAT5 STP cables

100m each

300 m max.

Rack 2

Remote I/O Racks

Main CPU

Rack 1

Rack 3

Rack 4

Rack 5

Ethernet private (proprietary protocol)

link, 10Base-T, 10MBits/sec.

Fast scan rate reduced 50ms

I/O data synchronized with start of scan

Supports all control Output types

I/O removal / insertion detected

Max. of 4 Expansion I/O Racks

Industrial Hubs can be used to increase

distance to 984ft (300m)

Scanner failure results in use of previous

scan data. Three consecutive scans with

failure and scanner is removed from scan

and CPU posts a diagnostic.


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Family of Processors

C30 C50 C70 C70RFamily of CPUs for desired performance and price points

C30 C50 C70 C70R

Economy Workhorse Performance RedundancyMax I/O 384 1920 1920 1920

Max AI 192 960 960 960

I/O Slots 12 60 60 60

Remote I/O NO YES YES YES

Function Blocks 400 2000 5000 5000

Enet, RS232/485, Peer YES YES YES YES

Redundancy NO No No YES

Min Process scan rate 500ms 500ms 500ms 500ms

Min Logic scan rate 54ms 27ms 27ms 54ms


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HC900 Controller Ports

Modbus Master/Slave

or ConfigurationConf: 9.6 - 57.6KB, private protocol

Modbus RTU: 9.6 57.6KB

Modbus Master/Slave

or 559/1042 OI2-wire RS-485, 3-pin connector

OI: 38.4, 57.6KB, private protocol

Modbus RTU: 9.6- 57.6KB

HC 900 Controller CPU

Host, Peer-to-PeerEthernet, 10Base-T (RJ-45)

(single port on C30 & C50)

Remote I/OEthernet Private, 10Base-T (RJ-45)

(not on C30)

2000 Ft or Modem2000 Ft or Modem


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PC to Controller Connections

Serial Port ConnectionsSerial Port S1 is factory configured

as RS232 with ELN Protocol . Used for HC Designer

Serial Port S2 is factory configuredAs RS484 with ELN Protocol. Used for OI

Ethernet Connections

E1 and E2 always active

Up to 10 Sockets

Auto-detecting Ports

Default IP Addresses

E1 = 192.168.1.254E2 = 192.168.2.254

E1 & E2 Must be on different Sub-nets

10/100BaseT support


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Serial Ports

Serial Port SetupSwitches on the CPU are used to configure serial ports

In a redundant configuration the

lead and Reserve CPU must match

Label provides switch settings

Selections

RS232/RS485 (Default)

RS232/RS232

RS485/RS485*

Protocols supported (selected via HC Designer)

ELN

Modbus RTU Slave (2)

Modbus RTU Master(1)

*Note: Although Honeywell operator interfaces use RS485,

only one OI may be connected to a C70R redundant pair.


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HC900 I/O

I/O Designed for Process Control with FamiliarPackaging Style

Intelligent (CPU per Module) LED pt indicators on Digital I/O cards

Fault Status indicator on all cards

Field Wiring Labels

Remove & Insert Under Controller

Power

Safe handling I/O connector housing

Three (3) Terminal Block DesignsBarrier (lug screw)Euro (compression block)Remote Termination Panels

I/O Modules

Analog In 8 pt

Analog In 16pt

Analog Out 4 pt Contact DI 16 pt

24 vdc DI 16 pt

24 vdc DI 32pt

120/240 vac DI 16 pt

24 vdc DO 16 pt

24 vdc DO 32 pt

120/240 vac DO 8 pt

Relay DO 8 pt

Pulse/Freq In 4 pt


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HC900 Training Part 1 Version 4.1 11/16//06Honeywell Proprietary

Analog Inputs

High Level Analog Input Specifications

Inputs per module 16(isolated)

Input types V, mA

Input Isolation 400 VDC point to point,

Accuracy 0.1 % of range.

A/D Resolution 15 Bits

Update rate 500ms

Calibration Stored in non-volatile memory.

Field Calibration via HC Designer

1

3

5

7

9

11

8

2

18

19

23

25

27

29

31

35

33

4

6

8

10

12

14

16

20

22

24

26

28

30

32

34

36

In 1+

In 2+

In 1-

In 2-

In 3+

In 4+

In 3-

In 4-

In 5+

In 6+

In 5-

In 6-

In 7+

In 8+

In 7-

In 8-

In 9+

In 10+

In 9-

In 10-In 11+

In 12+

In 11-

In 12-

In 13+

In 14+

In 13-

In 14-

In 15+

In 16+

In 15-

In 16-

NC

NC

NC

NC

21

13

15

1

3

5

7

9

11

8

2

18

19

23

25

27

29

31

35

33

4

6

8

10

12

14

16

20

22

24

26

28

30

32

34

36

In 1+

In 2+

In 1-

In 2-

In 3+

In 4+

In 3-

In 4-

In 5+

In 6+

In 5-

In 6-

In 7+

In 8+

In 7-

In 8-

In 9+

In 10+

In 9-

In 10-In 11+

In 12+

In 11-

In 12-

In 13+

In 14+

In 13-

In 14-

In 15+

In 16+

In 15-

In 16-

NC

NC

NC

NC

In 1+

In 2+

In 1-

In 2-

In 3+

In 4+

In 3-

In 4-

In 5+

In 6+

In 5-

In 6-

In 7+

In 8+

In 7-

In 8-

In 9+

In 10+

In 9-

In 10-In 11+

In 12+

In 11-

In 12-

In 13+

In 14+

In 13-

In 14-

In 15+

In 16+

In 15-

In 16-

NC

NC

NC

NC

21

13

15

Analog Input Specifications

Inputs per module 8 (isolated)

Input types mV, V, T/C, RTD, ohms, mA, slidewire assigned to

any channel

Input Isolation 400 VDC point to point

Burnout T/C, mV, V (see manual for exceptions)

configurable to upscale, downscale, defined value,

Stored in non-volatile memory.

Field Calibration via HC Designer

Calibration

Via 2 RTDs at top/bottom of moduleReference Junction

15 BitsA/D Resolution

0.1 % of rangeAccuracy


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Analog Input Wiring

12

34

5 6

78

91 0

1 1

1 21 3

1 4

1 51 6

1 71 8

1 9 2 0

12

34

5 6

78

91 0

1 1

1 21 3

1 4

1 51 6

1 71 8

1 9 2 0

IN 1 +

IN 1 -

IN 1 & 2

I N 2 +

IN 2 -

IN 3 -

I N 3 +m V , V

I n p u t

X m t r

2 4 V dc

2 5 0

O h m s4 2 0 m A

IN 8 +

I N 8

R T D

T h e r m o c o u p le

I N 5 +

I N 6 +

I N 4 +

I N 6 -

I N 3 +

I N 4 -

IN 7 -

I N 5 -


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Analog Outputs

Outputs per

module

4 (isolated)

Current 0 to 21.8 mA, range selectable

Loadresistance

750 ohms max

Isolation 500VDC Channel to Channel

600 VDC Channel to Logic

Accuracy 0.1% full scale

Modulesper rack

10 max

Calibration

Data

Stored in non-volatile memory.

Field Calibration via HC

Designer

D/A

Resolution

12 bits

12

3 4

56

78

910

11

1213

14

1516

1718

1920

Out 1 +

Out 1 -

Out 2 +

Out 2 -

Out 3+

Out 3 -

Out 4+

Out 4 -

12

3 4

56

78

910

11

1213

14

1516

1718

1920

12

3 4

56

78

910

11

1213

14

1516

1718

1920

Out 1 +

Out 1 -

Out 2 +

Out 2 -

Out 3+

Out 3 -

Out 4+

Out 4 -


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Digital Inputs

12

34

56

78

910

1112

1314

1516

1718

1920

In 1+

In 2 +

In 7+

In 8+

In 9+

In 10+

In15+

In 16+

In 3+

In 4+In 5+

In 6+

1-8 COM

1-8 COM

9-16 COM

9-16 COM

In 11+In 12+

In 13+

In 14+

12

34

56

78

910

1112

1314

1516

1718

1920

12

34

56

78

910

1112

1314

1516

1718

1920

In 1+

In 2 +

In 7+

In 8+

In 9+

In 10+

In15+

In 16+

In 3+

In 4+In 5+

In 6+

1-8 COM

1-8 COM

9-16 COM

9-16 COM

In 11+In 12+

In 13+

In 14+

Operating

Voltage

10 to 32 VDC

80 to 264 VAC

No Power for Contact

Inputs perModule

16

Isolation 2 Groups of 8

DC Input Type Sinking

ResponseTime

34 ms (off to on) AC50 ms (on to off) AC

4 ms (off to on) DC

4 ms (on to off) DC

4 ms (off to on) Contact

6 ms (on to off) Contact

12

34

56

78

910

1112

1314

1516

1718

1920

12

34

56

78

910

1112

1314

1516

1718

1920

In 1

In 2

In 7In 8

In 9

In 10

In15

In 16

In 3

In 4In 5

In 6

1-8 COM

1-8 COM

9-16 COM

9-16 COM

In 11In 12

In 13In 14


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Digital Input Wiring


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Digital Outputs

12

34

56

78

910

11

1213

14

1516

1718

1920

Out 1+

Out 2 +

Out 7+

Out 8+

Out 9+

Out 10+

Out15+Out 16+

Out 3+

Out 4+Out 5+

Out 6+

+ V1

1-8 COM

+ V2

9-16 COM

Out 11+Out 12+

Out 13+Out 14+

12

34

56

78

910

11

1213

14

1516

1718

1920

12

34

56

78

910

11

12

1314

1516

1718

1920

Out 1+

Out 2 +

Out 7+

Out 8+

Out 9+

Out 10+

Out15+Out 16+

Out 3+Out 4+Out 5+

Out 6+

+ V1

1-8 COM

+ V2

9-16 COM

Out 11+Out 12+

Out 13+Out 14+

Specifications:

Operating

Voltage

6.5 to 32 VDC

85 to 240 VAC

Form A & C Relays

Qutputs perModule

16 DC Outputs

8 AC Outputs (Triac w/fuse)

8 Relay Outputs

Isolation 2 Groups of 8 DC

Per Output ACMaximum Load

AC

DC

Relay

2A per point, 8A per module

1A per point, 8A per module

4A@240vac/30vdc (resistive)

Response Time 10 ms (off to on) DC

5 ms (on to off) DC

2 ms + cycle AC

12

34

56

78

910

1112

1314

1516

1718

1920

Out 1 H

Out 1NO

Out 3 H

Out 3 NO

Out 6 H

Out 6 NO

Out 8 HOut 8 NO

Out 2 H

Out 2 NO

Out 4 H

Out 4 NO

Out 5 HOut 5 NO

Out 7 HOut 7 NO

12

34

56

78

910

1112

1314

1516

1718

1920

12

34

56

78

910

1112

1314

1516

1718

1920

Out 1 H

Out 1NO

Out 3 H

Out 3 NO

Out 6 H

Out 6 NO

Out 8 HOut 8 NO

Out 2 H

Out 2 NO

Out 4 H

Out 4 NO

Out 5 HOut 5 NO

Out 7 HOut 7 NO

12

34

56

78

910

1112

1314

1516

1718

1920

Out 1 NO

Out 1COM

Out 3 NOOut 3 COM

Out 6 NO

Out 6 COM

Out 8 COM

Out 8 NC

Out 2 COM

Out 2 NC

Out 4 NO

Out 4 COM

Out 5 NOOut 5 COM

Out 7 NOOut 7 COM

Out 1 NC

Out 2 NO

Out 7 NC

Out 8 NO

1

2

3

4

5

6

7

8

9

10

1112

13

14

15

16

17

18

19

20

1

2

3

4

5

6

7

8

9

10

1112

13

14

15

16

17

18

19

20

Out 1 NO

Out 1COM

Out 3 NO

Out 3 COM

Out 6 NO

Out 6 COM

Out 8 COM

Out 8 NC

Out 2 COM

Out 2 NC

Out 4 NO

Out 4 COM

Out 5 NOOut 5 COM

Out 7 NO

Out 7 COM

Out 1 NC

Out 2 NO

Out 7 NC

Out 8 NO


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Digital Output Wiring


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32 Channel DI, 24vdc

1

19

In 1+

2+

3+4+

5+

6+

7+8+

9+10+

11+

12+13+14+15+

16+1-16COM

1-16COM17+

18+

19+

20+

21+

22+23+

24+25+

26+

27+

28+29+

30+

31+

32+17-32COM17-32COM

Input 10 to 32 VDC

Type Sinking


On to off

response time

5ms

Off to On

response time

5ms

Specifications:

Uses 36 point terminal block

Model # 900TCK-0001


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32 Channel DO, 24vdc

Output 10.5 to 32 VDC

Type Sourcing


Maximum Load 0.5A per channel,

12 Amp per card

(resistive load)

On to off

response time

6ms

Off to On

response time

6ms

Fusing Electronic

Limiting

Specifications:1

3

5

7

9

11

13

15

17

2

18

23

25

27

29

31

35

33

4

6

8

10

12

14

16

20

22

24

26

28

30

32

34

36

Out 1+

2+

3+4+

5+

6+

7+8+

9+

10+

11+

12+13+14+15+

16++V1

COM1

Out 17+18+

19+

20+

21+

22+23+

24+25+

26+

27+

28+29+

30+

31+32+

+V2

COM2

21

19


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Pulse/Frequency/Quadrature Module (PFQ)

Multi-function module used with high spped digital pulse generatingdevices such as flow meters, gas meters, proximity switches, speed

sensors, etc. Has 4 user configurable input channels (4 modules per

rack)

Pulse counting counts pulses and provides a rate over a settable time

period. Preset value compared against accumulated count to perform control

action with output on block & module (PREI)

Pulse Frequency measures pulses occurring at a frequency (10hz to

100Khz) scaled to represent a rate. An application example is a flow meter torepresent gallons/hour.

Pulse Output generates a pulse train output. An application example is

conveyor speed control using a variable speed drive. Configurable to

generate a finite # of pulses at a specified rate or a continuous pulse train

Quadrature Input Determines direction, speed and position of moving

devices using 2 digital inputs. Typical input would be from a digital encoder.


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Pulse Input

Specifications:

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

In 1+

In 1 -

In 4+

In 4 -

COM

In 2+

In 2 -

In 3+

In 3 -

INDEX+

INDEX-

OUTPUT1

ENCODE+

SENSE+

OUTPUT2

OUTPUT3

OUTPUT4

ENCODE-

SENSE-

+V

Inputs per module Up to 4

Input 0 to 24Vdc

ON Voltage 4.5V

OFF Voltage 0.5V

Minimum Pulse 3 Microseconds

Counter size 32 bits

Discrete Preset

Output

Pulse ON, or Hold

ON

Output type Open collector(sinking)

Output Rating 5 to 24Vdc, 30mA


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Pulse Output

Outputs permodule

Up to 4

Output Type Open collector, 5 to 30Vdc,

30mA max

Frequency Range 25 Hz to 10KHz

Duty Cycle 50% - fixed

Pulse train

duration

Number of pulses: up to

999999 and continuous

Used to generate a pulse train Each output consumes a module channel

Provides square wave outputs (50% duty cycle)

User specified frequency

Specified quantity of pulses generated

Continuous pulse output is selectable Failsafe Action

Stop (low)

Finish pulse train


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Frequency Input

Inputs per Module Up to 4

Input 0 to 24 VDC

ON Voltage 4.5V Min.

Off Voltage 0.5 V Max.

Frequency 10 to 100KHz

Minimum Pulse

Widths

10-500Hz = 500usec

500-5KHz = 50usec

5K-100KHz = 2.5usec

Module Digital

Output

On if frequency out of range

Fusing Electronic Limiting

Specifications:

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

In 1+

In 1 -

In 4+

In 4 -

COM

In 2+

In 2 -

In 3+

In 3 -

INDEX+

INDEX-

OUTPUT1

ENCODE+

SENSE+

OUTPUT2

OUTPUT3

OUTPUT4

ENCODE-

SENSE-

+V


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Quadrature Input

Quadrature Used to measure position, speed and directionusing pulse count, frequency and phase of two digital inputs.

Inputs per

Module

One (1)

Input Voltage Differential: +/- 6 V (0V&5V=off, 5V&0V=on)

Single Ended 0 to 24V (0V&5V=on, 0V&0V=off)

On Voltage Differential: 0.2V min

Single ended 2V minimum

Off Voltage Differential: +/-2V MaxSingle Ended 1V max.

Module Encoder

Power

5V, 0.5A

Input Frequency 200KHz Max.

Quadrature

Modes

3

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

In 1+

In 1 -

In 4+

In 4 -

COM

In 2+

In 2 -

In 3+

In 3 -

INDEX+

INDEX-

OUTPUT1

ENCODE+

SENSE+

OUTPUT2

OUTPUT3

OUTPUT4

ENCODE-

SENSE-

+V


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Quadrature Wiring

IN1+

IN1-

IN2+

IN2-

IN3+

IN3-

IN4+

IN4-

INDEX+

INDEX-

OUTPUT1

OUTPUT2

OUTPUT3

OUTPUT4ENCODE+

ENCODE-

SENSE+SENSE-

V+COM

A+

-

B+

-

Quadrature Inputs

I+

-Quadrature Input

DC Power to encoder+

-

Isolated 5 VDC 500mA max

Single Ended

Low 0.0 to 1.0 VDC

High 3 to 24 VDC

Differential

Low -200 to -6.0 VDCHigh 200mV to 6.0 VDC

Internal

connection at

encoder

1

2

3

4

5

6

7

8

9

10

1112

13

14

15

16

1718

19

20


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Remote Terminal Panels

3 RTP types and pre-wired cables: (1, 2.5 and 5m)

Reduces Customer Wiring Cost

Provide Field power disconnect for RIUP

Provide 250 ohm shunts for mA inputs

24Vdc power terminals and fuses for transmitters High & low voltage cables to match I/O module type TC inputs not supported

HC900

Rack

RTPs

Field wiring

Cables

with

Connectors


28/179


Redundancy


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Controller Rack


30/179


C70R Redundant Controller Operation

All user and process interaction is with the Lead CPU.All user and process interaction is with the Lead CPU. Either CPU can be the LeadEither CPU can be the Lead

Both CPUs receive InputsBoth CPUs receive Inputs

Both CPUs execute function blocksBoth CPUs execute function blocks

Lead CPU writes outputsLead CPU writes outputs

Lead CPU automatically configuresLead CPU automatically configuresReserveReserve

All Communication isAll Communication iswith Lead CPUwith Lead CPU

Redundant Switch Module (RSM)Redundant Switch Module (RSM)

Visual Indication of the Lead and Reserve CPUsVisual Indication of the Lead and Reserve CPUs

Provides Manual FailProvides Manual Fail--over of the Lead CPU (Key switch)over of the Lead CPU (Key switch) Passive modulePassive module

Function Block execution resumes on start of next scan followinFunction Block execution resumes on start of next scan following a failg a fail--overover

Lead CPU Reserve CPU

Power for

Reserve CPU

Power for

Lead CPU

RSM To I/O

Racks


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Redundant Switch Module

RSM Module

Positioned between CPU A and CPU B

Identifies CPU A and CPU B

Identifies Lead CPU and Reserve CPU

Mode Switch

Changes the mode of both CPUs

Mode change via Key switch

Remove key from RUN & RUN/PGRM Positions

Key cannot be removed while in Program

Fail-over is a momentary position

RIUP

S


32/179


Scanner

One Scanner2 Module per I/O Rack

Two ports one for each C70R CPU

Maintains communications with Leadand Reserve C70R CPUs to facilitatefail-over

Reads inputs from modules & writesoutputs to modules in rack

Status LED Indicator

Connection to C70R-A (I/O A)

Connection to C70R-B (I/O B)

RIUP

R d d t P


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Redundant Power

Provides backup power for Racks with I/O

May be used with Redundant and Non-redundant systems

Supports P01 (60W), P02 (28W) and P03 (24VDC) Power Supplies

Available for 8-Slot and 12-Slot I/O Racks

Power Status Module (PSM) provides status of power supplies

Uses new extended rack to hold a 2nd (Reserve) power supply andPower Status Module.

Maintains power to the rack if the Primary power supply fails

Allows either power supply to be replaced while maintaining power tothe rack.

Available as an optional field installation kit

O t I t f


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Operator Interface

Honeywell Operator Interface ConnectionsOnly Lead CPU Communicates

No Fail-over detection on loss of link

RS 485

ELNProtocol

OI maintains communication to new Lead

following Fail-over

Only one OI per CPU pair

HC Designer Network Settings


35/179


HC Designer Network Settings

New Device Name for controller + IP Address

Two IP addresses must be on different Sub-Net

Redundancy Diagnostic Monitoring


36/179


Redundancy Diagnostic Monitoring

PC with Simplex Network


37/179


PC with Simplex Network

BA

100 base-T

Up to 100m

Ethernet

Switch

RS-485

Twisted Pair

10/100 base-T

Small Redundant System


38/179


Small Redundant System

BA

100 base-T

Up to 100m

10/100 base-T

RS-485

Twisted Pair

Vista R400, Specviewor 3rd Party Software

OPC Server

with Dual

Ethernet support

Controller withRedundant Power,

Redundant CPU,

RSM

Ethernet

Switch

Large Redundant System


39/179


Large Redundant System

BA

100 baseT

10/100 baseT

Peer to Peer

Data Exchange

Ethernet Switch,

Honeywell 8 Port

Switching Hub

Controller

Rack

OPC Server

to PC Software

Ethernet

Switch

I/O

Rack

Redundant HC900 Controller with Five I/O Racks

Expanded Architecture


40/179


Expanded Architecture

Network with Redundant & Non-redundant Controllers

B

A

100 baseT

10 baseT

Peer to Peer

Data Exchange

Redundant HC900, Redundant Network Non-Redundant HC900

I/O Rack

Controller & I/O

Rack

I/O Rack

I/O Rack

Controller

Rack

OPC Server with

Redundant Network Support


41/179


HC Designer

Save Time Using HC900s One-Stop Tool


42/179


g p

Control Strategy configuration Drag and drop and soft-wire function blocks

Multiple worksheets for process segmentation

Operator Interface Configuration

Standard and User defined displays

OI Data Storage Configuration

Configure data groups, storage rates, continuous or batch selection

Create files for data storage setup

Alarms and Events, plus E-mailed Alarm/Event Setup

Select tags for alarms/events, set priorities for e-mail of occurrence Set up alarm groups, remote acknowledge plus common alarm output

Communications Setup Ethernet Host and Peer-to-peer

Serial Modbus Master/Slave

Documentation - Preview, Print Out, and Export Function block configurations, Tag List / Modbus addresses, I/O list, OI Display

setup

Recipes, profiles, schedules, sequences

Significant Features


43/179


g

RUN Mode editing, with limited process disturbanceAdd, delete, modify analog and logic blocks, add tags, change soft-wiring

On-line monitoring for debug and setup

Use watch windows, view multiple function blocks, change internal block values,force block outputs including I/O, view live logic power flow, signal trace back & find

Operate Control Loops, SP programmers, SequencersOn-line operation for testing, or override (includes auto-tune)

Annotate configuration with 4 text sizes

4 colors, plus Bold, Italic attributes

Controller / Network Diagnostics

Check I/O, Controller, Network Host Connections, Peer Controller status

Architecture


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Use Ethernet 10Base-T, RS232 direct, or RS232 modem connectionfor access including monitoring, run-mode configuration edits

Windows NT, 2000 & XP compatible

Access multiple controllers connected via Ethernet or over Internet

Use concurrently with HMI, DAQ software over Ethernet

Ethernet 10Base-T LAN or Internet / Intranet

Direct RS-232, RS-485

9.6 57.6KB

Modem

9.6 - 38.4 KB

Or

Or

Switch

See Quick Start Guide

HC Designer Layout


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File Browser

WorksheetToolbox

Function Block

Worksheets (20) Worksheet Category Tabs

Graphic

Configuration Page

Fast, Normal Scan

& ConfigurationFunction Block Lists

Main Toolbar

Main menu

WorksheetToolbar

Functional Tabs


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Listing of Controller

I/O Used Including Ranges

Operator Interface Display Key AssignmentsFunction Block Diagram Worksheet Pages

Controller Utility Functions

Hybrid Control Designer Organizes Your Configuration and Setup Tasks

with Separate Tools Related to Each Function

Graphic Function Block Configuration


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Simply Drag and Drop Function Blocks and Soft-Wire

Over 100

Function Block Types!

Click on desired item

and drag to diagram

Click on output

pin and connect to input

pin of another block

or to a Signal Tag

Click on block to

view dialog box for

block entries

Analog Input Dialog box - simple address, input type and range assignment backup

HC900 Function Blocks


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What are Function Blocks?

Pre-programmed

functions or

algorithms for user

configuration of

control strategiesthrough soft-wire

connection

Function Block Attributes


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Function Block Number

assigned by the sequence

of programming.

AI = mnemonic

267 = block #267

Block Order number, or sequenceof execution during On-line

operation.

11 = the 11th block to be executed.

The order may be changed from

the Configure menu

Principal Blocks such asPID Blocks and Setpoint

programmer blocks have

tag names.

Outputs

Inputs

Analog Pin

Digital Pin

I/O BlockPhysical address:

010201 = Rack #1,

Module #2, Channel #1

=Transitional

(Rising Edge) Trigger

Function Block Attributes


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Digital

Variable for

disabling

analog input

Softwire connectionsDouble-click on output pin

& single-click on input pin

Analog Input Function Block

Analog Output

Function Block

PID Function

Block

Signal Tags for reference and

use by OI & Host devices

Page Connectorto connect function block pins

on same page, different pages or different

worksheets. Does not use Modbus address

Analog

Variable

for RSP

HC Designer Worksheets


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Segment Your Configuration Logically for Convenient Access

Use Signal Tags and Connectors for reference within / between worksheets orto substitute for soft-wiring

Signal Tag

Connector

HC Designer Tool Bars


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Convenient Tool Bars are Provided for Configuration Selections

Main Tool bar

For Function Block programming:

Add Worksheet Cut, Copy &

Paste

Zoom In, Out

Set up Alarms, Events

Readjust

Block Order Unlock protected

Worksheet

Upload, Download Configuration

For 1042 OI Display configuration

Monitor ModeSignal

Traceback

Show / Hide Tool Box, Browser

Help topics

Controller Operations

Configure e-mail

alarms, eventsSet Controller name

Print I/O list

Configure

DisplaysConfigure

Data Storage

Configure alarms, events

Configure

OI security

Configure

Help Displays

Find GridPropertiesPrint

Worksheet

Unlock Display

Worksheet

File

Names

Startup

Display

Print Report

Re-arrange sheets

Print

Display

List

Unlock Controller

Operations Worksheet

Operator Interface Configuration


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Its Simple - because the database is integrated!

Select OI Display Button (1- 8)Apply Display Format to a Display Position

Select Tags for Display Group,Apply to Display Format

Configuration Editing


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Make Configuration Changes While In the RUN Mode

Add/delete analog and logic blocks (other than I/O blocks), tags, invert logic inputs

Change soft-wiring

Add a worksheet

Change / add profiles, sequences, schedules, recipes

Change / add operator interface displays

Download Complete

Hot Start

The Controller is in RUN Mode

Use the configuration I just downloaded. Do not re-

initialize the controllers memory. Outputs will be held

during restart. Stay in RUN mode.

Cold StartUse the configuration I just downloaded. Re-initialize

the controllers memory. Outputs will be de-energized

during restart. Return to RUN mode.

AbortDo not use the configuration I just downloaded. I want

to continue as if I did not perform this new download.

Stay in RUN mode.

Stay in

PROGRAM

Mode

Not available in this mode.

Save, then download configuration (held in a memory buffer)

The controller validates the change

Using Hot Start selection, outputs are then held, configuration is updated in

minimal time with continuation at the beginning of a scan

Use configuration with changes

Actions for enabling RUN Mode change:

Use configuration with

changes, initialize all values

Keep present configuration now

running in controller

Configuration Editing


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Increase Process Up-timeWith

Expanded Hot-start after download

Provides approximate time

outputs will be held.

Supports I/O changes

and extensive edits

(previous Cold Start only)

Outputs are held during

Hot-start restart.

Users choice to doHot-start or Cold-start.

HCD Monitoring Mode


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Tools For Testing Your Configuration

Watch

Windows Data Categories

- Tags

- Variables- I/O

- Display data

User-defined

data Window

Column Sorting

Write values Force outputs

Select Tag to

go to location

Multiple Block

Monitoring

Block Entries

Force outputs

Operate loops,

programmers,

sequencers

Pin

Monitoring

(live data)

Color-Coded Logic Power Flow

Signal Traceback


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Use Signal traceback to determine source of input for debug

Right click on function block pin to trace back to source, even

through multiple worksheets

Return back by clicking on source tag to Find where used

Click line to

Access

Location

Where does PB1 tagoriginate?

Configuration Security


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Password Protect Your Configuration

From General Read Access (No access without password)

On a Worksheet Basis (allows access to other Worksheets or to other functions only)

Protect Operator Interface Display Changes

Protect Controller Changes for Controller Name, E-Mail Setup

Total Read Access

Password

Entry

Selective

Worksheet

Protection

Utility Functions

C i t A f


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Convenient Access for:

Setup, Test,

Selection of

PC Ports for

Controller

Access

Setup of

Controller

Serial Ports

Setup of

Controller Ethernet

Address, Name.Mail Server address,

Mode, Time

OI Data Storage

SetupCalibration

of Analog I/O

Controller,I/O,

Remote Rack

Diagnostic

Status

Upload/

Download

Configuration Reports


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Make Selection of Desired Report Printout:

Controller I/O

Used List

Function Block Diagram

Worksheets

Operator Interface Display List

Recipe, Profile,

Schedule, Sequence

Printout by name

Alarm Groups,

Events Assigned

Principal block

(PID, SPP, etc.) lists

User-defined Modbus

register map with data types

assignable (for interface to

touch panels and HMI software)

Signal Tags, Variables &

Function Block Parameters

by number with Modbus addresses

Sample Reports


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Function Block Diagram Pages

Sample Reports


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Setpoint Profile Report

Sample Reports


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Select .csv or .txt formats, export

to Excel or Word: I/O list

Tag lists with Modbus addresses

(for 3rd Party HMI Interface)

Recipes

Sample Reports


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I/O Configuration File (.txt format)

Tag Information Report ( CSV File)

Report File Export Signals & Variables


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Viewing tag export forHC900 Signal Tags in Excel

Tag Information Report (.CSV File)

Signals Only, Variables Only or Signals and Variables Lists Modbus addresses in Hex and decimal formats

Used for HMI integration (edit format and import where applicable)

Report File Export PID Loops


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Viewing Modbus function

block registers in Excel

PID Loops .CSV File (lists all PID parameters)

Report File Export Where Used List

Identify data source and


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Identify data source and

all blocks that use the data

Save time troubleshooting.

Document configurations.

Verify function block connections.

Worksheet Page

Alarms - Overview

A li d t Di it l Si l T


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Applied to any Digital Signal Tag

Capacity- 240 Alarm Points

20 Alarm Groups (12 Alarm Points per Group)

Only active when put into an Alarm Group orassigned to an OI Alarm Display

Alarm Detection- Choice of Off-to-On or On-to-Off on a per Alarm Point basis

Alarm Acknowledgement- Choice of Manual or Automatic for each point

Auto will acknowledge the alarm when point returns to non-alarmstate (will not transition into Clearedstate). Does not require useracknowledgement

Alarm Priority for each point Low (2), Medium (3), High (4), Emergency (5)

Alarm Priority is used for Routing alarms to E-mail

Alarm Blocks

HITEMP output is on


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HITEMP output is on

when SIGNAL A isgreater then HIALMSP1

This Alarm block has been configured

to alarm when F2ZONE1PV is greater

them F2ZON2PV by the value ofZONEDVSP. The alarm output

ZONEDEV is configured to latch on

Selections

Alarms Contd

Alarm Group Function Block


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Alarm Group Function Block

ACTIV pin ON if any alarms in the group are active

UNACK pin ON if any alarms in the group have

not been acknowledged

Lo-to-Hi transition on ACK pin acknowledges allalarms in the group

Alarm Details & Storage


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Details -

Number of Alarm Occurrences

Counts number of transitions into alarm state Per Alarm Point

Displayed on OI Alarm Point Detail Screen

Reset on controller cold start

Storage on OI Disk

Alarm File Record Limit

Configurable from 150 to 1500 alarm records

Events


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64 Event Points

Choice of On-to-Off or Off-to-On on a

per Event Point basis Event Priority

Events do not have multiple priorities as

do Alarms Events considered at a priority lower than

alarms

Event processing in the OI


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Filtering Each event point may be configured to go to:

OI Event File on the data archive disk

OI Status Line and Event Summary Screen

E-Mail

Any or all (at least one) of the above

Summary Screen

Last 150 events

Adds tag name and state text to event descriptor for

each record

Storage on OI Disk

Event File Record Limit

Configurable from 150 to 1500 event records

Alarm Setup


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20 Alarm Groups, each with 12 alarms provides a total of 240 alarms

Event Setup


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Provides reportable event 16-character notification on OI banner line,

replaced by next reportable event

Email Notification Setup


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Alarm & Event E-Mail


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Email will contain From: Controller Name

Subject: (Configurable Text)

Body of E-mail: Date & Time

Alarm or Event Tag Name

Alarm State

48 Character alarm or event text

HC Utilities


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Configure recipes, data storage files off-line Save to floppy disk or load to pool in controller directly

Monitor configurations using serial or Ethernet ports Use all HC Designer Monitor tools

Alter values on-line Variables, loop parameters, block values, etc.

No forcing allowed of I/O, block outputs

Save Configurations

No Function Block Configuration Changes Allowed!

HC Utilities

Create and Edit


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Create and Edit

Recipe Files

Save files and download

separately or load via OI disk.

Save to File

Download to pool

Model/Revision Numbers


80/179


HC900 components that may change as the CPU firmware changes.Scanner Modules

Hybrid Control Designer Software

Hybrid Control Utilities Software

1042, 559 Operator Interfaces

User Manuals/CD

HC900 Firmware Revisions


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CPU - use HC Designer, controller diagnostic function in the Monitor mode(also displayed on OI Unit Setup, Controller Status display)


I/O Scanner- use HC Designer, rack diagnostic function in the Monitor


82/179


mode


HC Designer- In HC Designer, under the Help pull-down menu, select About.


83/179




84/179


Operator Interface Appears in lower right corner of Log Off display

UNIT LOGGED OFFAUG09

11:30

HYBRID

CONTROLLER

HC900

WHEN YOU NEED MORE THAN

JUST DISCRETE CONTROL

PRESS ENTER TO LOG ON

51452188 FIRMWARE VERSION 4.000

UNIT LOGGED OFFAUG09

11:30

HYBRID

CONTROLLER

HC900

WHEN YOU NEED MORE THAN

JUST DISCRETE CONTROL

PRESS ENTER TO LOG ON

51452188 FIRMWARE VERSION 4.000


Firmware can be downloaded (no-charge) at:


85/179


http://content.honeywell.com/ipc/faq/



86/179


Downloading CPU firmware upgrade

Use Utilities functional tab

Industrial Measurement and Control

HC900 H b id C t ll


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HC900 Training - Part 2 5/31/06 Honeywell Proprietary 1Version 4.1 11/16//06

HC900 Hybrid ControllerTraining - Part 2

Function Blocks

Process Control (65 Algorithms)

Process Function Blocks (21)

AI, AO, PID, ON/OFF

Math / Calculations (19)

Scale and Bias


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Carbon Potential (CARB)

3 Position Step (TPSC)

Time Proportional Out (TPO)

Position Proportional Out (PPO)

SP Programmer (SPP) SP Scheduler (SPS) / Aux (SPSA)

Loop, Mode, State Switches

Mode, State Flags

Write Tuning Con, Auto Man. Bias

Recipe Selector, Event Decoder

(ADD, SUB, MUL, DIV, ABS

4ADD, 4SUB, 4MUL, SQRT

Relative Humidity, Dew Point

Compare, Deviation Compare,

Negate, Totalizer, Cont. Average Free Form Math

Mass Flow, Max-Min-Avg-Sum

AGA

Auxiliary (16)

Function Generator

Lead Lag, Track and Hold

Alternator, Stage, Ramp

Device Control, Hand-Off-Auto

High-Low Limiter, Velocity Limiter Rate of Change

Read Constant, Write Constant

Digital Encoder/Decoder

Alarm Monitor / Selector (9)

High, Low and System Monitor

Analog Alarm High Selector, Low Selector

Analog Switch, Rotary Switch

Bumpless Transfer

Logic Control (45 Algorithms)

Logic Function Blocks (21) DI, 8DI, DO, 8DO

Communications (6)

Peer Read


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2, 4, 8 AND; 2, 4, 8 OR, XOR, NOT

Digital Switch, Trigger, Latch

Toggle Flip-Flop, Pushbutton

Free-Form Logic

Four Selector Switch

Sequencer

System Monitor

Peer Read Peer Write

Peer Comm

Modbus Slave

Modbus Read

Modbus Write

Modbus TCP Slave

Modbus TCP Read

Modbus TCP Write

Counters/Timers (5) Resetable Timer Periodic Timer

Off Delay Timer, On Delay Timer

Up Down Counter

Real Time Clock Calendar

Control Execution

InputsInputsInputsInputs


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Comm.Comm.

Processing

Fault detectFault detect

Processing

Fast ScanFast Scan

Processing

Normal ScanNormal Scan

Processing Processing ProcessingProcessingProcessing

OutputsOutputsOutputs Outputs

500ms (typical)500ms (typical) 27 to 107ms27 to 107ms

Inputs measured, outputs set each scan

No over-sampling

400 fast logic blocks at 27msec (50msec. with remote I/O) Cycle time will adjust to level the processor load

Normal Scan cycle time not linked to number of AI modules

HC900 Capacity

5100 total function block capacity


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5100 - total function block capacity 5000 user blocks

100 reserved (system) blocks

Execute regardless of configuration system monitor (fast and slow)

rack monitor (5)

alarm group (30)

port blocks

variables

constants

User defined blocks start at 101

Database Expansion Some Examples

V2.4 V4.0


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HC900 Training - Part 2 5/31/06 Honeywell Proprietary6

Version 4.1 11/16//06

Item

Type

C30 C50 C70 C70R C30 C50 C70 C70R

User FB 400 2000 5000 5000 400 2000 5000 5000

PID 8 32 32 32 400 2000 2568 856

SPP 8 8 8 8 400 1325 1325 441

SEQ 4 4 4 4 400 >1100 >1100 >360

Device 16 16 16 16 400 2000 5000 5000

Alternator 6 6 6 6 400 1820 1820 606

Variables 600 600 600 600 2048 2048 2048 2048Alarms 240 240 240 240 360 360 360 360

Signals 2000 2000 2000 2000 Available

Memory

Available

Memory

Available

Memory

Available

Memory

Modbus

Slave

16 16 16 16 32 32 32 32

Slave

values

384 384 384 384 1024 1024 1024 1024

Database Expansion contd

HCD displays memory utilization and normal

& fast cycle times


93/179


Version 4.1 11/16//06

& fast cycle times

HC900 Database size vs Performance

No preset limits on individual function block type quantity Limited only by available memory and required scan rate

User can allocate memory for function blocks recipes etc to


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Version 4.1 11/16//06

User can allocate memory for function blocks, recipes, etc. to

maximize the power of HC900

C 70 CPU Performance examples

Total

Function

Blocks

PID

Blocks

Fast

Scan

Blocks

Recipes

&

Profiles

Config

Memory

Usage

Normal

(Process)

Scan Time

Fast

(Logic)

Scan

Time

230 40 50 99 7.37% 507 ms 27 ms

630 75 225 99 9.64% 533 ms 53 ms

1015 100 375 99 12.12% 800 ms 53 ms1975 125 750 99 17.45% 1067 ms 107 ms

1975 125 750 1000 70.93% 1067 ms 107 ms

AI Block


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Version 4.1 11/16//06

Burnout check - T/Cs Bad Channel Detection Un-

checking eliminates diagnostic failureindication in controllerDisable Channel -

Output value when

channel is disabled.Range: For Linear Inputs Only

Actuation Input = 4-20mA

Process variable = Flow

Range of Flow = 0 to 250 gal/minHigh Range Display Value = 250

Low range Display Value = 0

Filter Time - Digital filter

smooths the input.Configurable the first order

lag time constant from 1 to

120 seconds. Noisy Sensor

Bias To compensate

input for drift of an input

value due to deterioration

of a sensor, or some

other cause. Calibration

Failsafe - Value output will go to protect

against the effects of failure of the

equipment, such as, fuel shut-off if there is

loss of flame in a furnace, or a sensor

break.

AI with Remote CJ


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Version 4.1 11/16//06

Process

Remote

Junction

Panel

Compensated

Leadwire

Copperwire

Compensated

Leadwire

Process

Remote

Junction

Panel

Compensated

Leadwire

Copperwire

Compensated

Leadwire

AI with Remote CJ

In the I/O folder


97/179


Version 4.1 11/16//06

In the I/O folder Use when TC Cold Junction is NOT

at the AI Module terminals

Thermocouples only

Use dedicated AI channel to measureRemote Junction Temp:Connect Output to all associated RCJ Input(s).Connect Fail Pin to all associated RSTAT Input(s)

Copper Wire connection from RemoteTerminals to AI Module

Rcj Input in C only

Rcj Temp Range: -30 to 90 CWarn or Fail if outside limits (user configurable)

AI with Remote CJ Sample Configuration

RCJ i t i D C


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Version 4.1 11/16//06

RCJ input in Deg C

AO Block

Slew Rate is the

maximum rate of

change required todri e the o tp t from


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HC900 Training - Part 2 5/31/06 Honeywell Proprietary

13

Version 4.1 11/16//06

drive the output from

full OFF (0% - typically

4 mA) to full ON (100%

- typically 20mA).

Convert this to a

maximum change of themilliamp output per

execution cycle of the

block. 0.0 to 99

Failure output on module error

Output Pin (mA)

Failsafe - CPU Comm failure ormodule not available

Use Value - sets the output to the

programmed value when failure is

detected. 0 to 21 mA Default = 0

High - sets the output of the blockto the High Output Range Value

when failure is detected

Low - sets the output of the block

to the Low Output Range Value

when failure is detected

Hold - maintains the last value of

the block just prior to the failure

being detected

See Note Page

DI Block

Digital Inputs

Configurable Inversion


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14

Version 4.1 11/16//06

g FAIL output pin

TRUE when input card fails

Configurable failsafe (per

channel on 8 Input block) Fail OFF, Fail ON, Fail HOLD

8 Input Block

All inputs on the same module

(channels 1-8 or 9-16)


101/179

Pulse Input Block

Reads input pulses (3 usec) and measures rate (pulses/time in EU).

Sends the preset values, reset, preset action, and hold flags to the module

Module returns pulse count, preset indicator (PREI), overflow (OVFL), and FAIL. Preset value in EU (triggers block and module output)


102/179


16

Version 4.1 11/16//06

Preset value in EU (triggers block and module output)

Preset action checked = Pulse output for 1 second when Count = Preset

Preset Action unchecked = output ON and count stopped until Reset

Inputs

HOLD = ON holds count (OUT) at current value.RPRES = Remote preset value.

^RST = Resets pulse counter & OUT to zero.

OutputsFAIL = ON when module reports a failure. Cleared by the ^RST input.

PREI = ON when the count (OUT) reaches the local or remote preset value.OVFL = Overflow flag turns ON when the counter on module is full.

RATE = Rate in pulses in EU/Time (hour,min,sec)

Out = Accumulated EU count

Pulse Ouput Block

Generates a pulse train following a start instruction

Pulse frequency is selectable. Output controls an output transistor on the module.


103/179


17

Version 4.1 11/16//06

p p

Pulses remaining (following start) present on OUT

InputsENABL = ON enables the block

^START #PLS = ON transition starts the pulse train#PULSES = Number of pulses in the pulse train

START CONT. = Start Continuous Pulse Train.

Superceedes ^START #PLS.OutputFAIL = On when module reports a failure.

OUT = Pulses remaining when START CONT. is off.Zero if START CONT. is ON

Frequency Input Block

Measures speed and rate.

The signal is scaled from the selected frequency span tothe selected output range


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18

Version 4.1 11/16//06

p g

Provides an output value in engineering units.

Signal is rejected if it is not within selected pulse width range.

Rejection causes output to go to failsafe and a

failure-to-convert error occurs.

InputsENABL = Enables block. Ignored if not connected and default

state is enabled. If block is disabled the output goes to zero.

Outputs

FAIL = ON when module reports a failure.OUT = The frequency input value scaled to engineering units

(after filters, ranges, bias, or failsafe conditions have been

applied).

Frequency Span

50-400HzPulse Width (Range)10-500Hz

Quadrature Block

Measures/controls movement of an actuated device.

Digital encoder produces two square wave channels.

There are 4 logic states between these two waves.

Counting the passing rising edges of the square waves the block measures:

1) Di t h t EU b i t ll d b th d i


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19Version 4.1 11/16//06

1) Distance or whatever EU are being controlled by the device.

2) Distance from zero marker (position)

3) Sequence between channels; A leads B or B leads A (direction).

InputsBIAS = Value added to the output in EU.

ENBIAS = The bias is added to the output.

ICLR = Index - resets the output to zero (plus bias).

^RST = Resets the output to zero (plus bias).

^CLFG = Clears error flags to zero.

OutputsINC = Count is incrementing

DEC = Count is decrementing

INDEX = Index pulse is detected and ICLR are asserted.

CNTERR = Count overflow or underflow (32 bit counter)

RNGERR = Count exceeds range limits.CDIS = Module detects a cable disconnect.

FAIL = Module failed. (INC and DEC both ON).

OUT = Count in EUs.

Quadrature

LRL URL

15 i h

Uses two pulse inputs, A & B

1st input detected indicates


106/179


20Version 4.1 11/16//06

-15 inches0 pulses

15 inches15,000 pulses

0 inches7,500 pulses

position

-9.8 inches2,600 pulses

p

direction

Index input on Module resets

counter to zero

Sense input on the moduleconfirms Encoder connection

Modes

X1- rising edge of A are countedX2- rising/falling edge of A are counted

X4- rising/falling edged of A & B arecounted

Process Control PID Loops

PID Block 2 Setpoints (1 local and 1 remote or 2 local)

32 Loops-C50/C70,C70R, 8 Loops -C30


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21Version 4.1 11/16//06

p ( )

2 Sets of PID constants (bumpless transfer selection)

2 Alarms (2 levels each)

PID-A or PID-B (only integral response to SP change)

Feedforward Input Output Tracking of external input

Logic interface for control of mode (A/M, R/L)

Logic interface for tuning constant selection, auto-tuning

Soft-start (output limiting on startup)

Control Types Duplex - Heat/Cool (Dual Output)

Internal Cascade

Ratio (with bias)

Position Proportioning (3-position step)

Position Proportioning with slidewire feedback for actuators)

AI Block

PID Block

Output Block

(4-20mA)

PID Block


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HC900 Training - Part 2 5/31/06Honeywell Proprietary

22Version 4.1 11/16//06

INPUT - PV

OTHER INPUTS

Working Set Point in EU

Alarm 1 Digital Signal

Alarm 2 Digital Signal

Autotune Indicator (ON = Autotune in progress)

A/M Output & Setpoint Mode indication (to MDFL block)

Back Calculation Output (for Cascade control)

OTHER OUTPUTS

Remote Set Point Signal (Eng. unit or %)

Feed Forward value in %

Output Track value in %

Output Track Command (ON/OFF) or Soft Start

Remote Bias Value for Ratio PID

Switch Inputs (from SWO on LPSW function block)

External Mode request (from MDSW block)

Back Calculation Input (for Cascade control)

Direct or Reverse Output Status

(see note page)

CONTROL OUTPUT

PID Block - General Tab

PID A, a step change in setpoint will result in a

step change in output. The output can be

adjusted between 100 % and 0 %. It applies allthree control actions


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HC900 Training - Part 2 5/31/06Honeywell Proprietary

23Version 4.1 11/16//06

PID B - Controller gives only an integral

response to a setpoint change, with no effect

on the output due to the Gain or Rate

DUPA - like PID A but provides an automatic

method to switch tuning constant sets forHeat/Cool applications.

DUPB - like PID B but provides an automatic

method to switch tuning constant sets for

Heat/Cool applications

Direct - causes output to increase as processvariable increases.

Reverse - causes output to decrease as

process variable increases

Track PV - When control mode is "manual", local setpoint tracks process variable.

Track RSP - When setpoint is "remote setpoint", local setpoint tracks remote setpoint. Used when

switching from remote to local setpoint.

PID Block - Start/Restart Tab

Output at Power up

Failsafe - Failsafe output value


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Version 4.1 11/16//06

p

Last Out - Same as at power down value

Initial Setpoint Value - Use initial LSP

Click on radio button to select. Enter InitialLocal Setpoint Value

High Output Overide Limit

Delay Time - time in minutes to use TRV

as the output high limit.

Ramp Rate - for High Limit Output (%

per minute to ramp the default output high

limit after delay time elapses

Initial Mode - Cold start or from program

mode.

Control Loops

PID Soft-Start Alternate selection for TRC and TRV inputs


111/179


Version 4.1 11/16//06

Provides dynamic output limiting

TRV input sets the initial high limit for the PIDoutput when the TRC input is ON.

User entries: Limit time - Sets the amount of time the output

will be limited.

Rate of increase- Sets the rate at which theoutput limit will increase until the normal PIDlimit is reached.

Soft-start cancelled if TRC turns OFF

Soft-Start is Reset when TRC Off, then ON.

Zero time - TRV sets the PID output when

TRC in ON ( no time or ramp rate)

Control Loops

Soft Start (Continued)


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Setup Dialog

Normal PID Limit

Output %Output %

00

100100

PID Output Limit with SoftPID Output Limit with Soft--startstart

Ramp Rate

Time

Time Delay

PID Block - RSP Tab

Use RSP Input (EU) - Use Remote Setpointin Engineering Units

Use RSP Inp t (%) U R mot S tpoi t


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Use RSP Input (%) - Use Remote Setpoint

in Percent. When used in a secondary loop

of a cascade configuration.

Use LSP2 (EU) - Use Local Setpoint #2 in

Engineering Units

No Ratio or Bias - No ratio and bias

applied to the RSP

Use Local Bias - Use Bias value selectedon Tab. Enter value at "Local Bias Value"

on tab.

Use Bias Input - Use Bias value attached

to an input to the block

Local Bias Value (EU) - Enter local biasvalue in engineering units.

Ratio - Gain value for Ratio PID 20 to

+20

PID Block - Range/Limit Tab

Ranging

PV High Range - PV High Range Value

PV Low Range - PV Low Range Value


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Limiting

SP High Limit - prevents the local & remote

setpoints from going above this value.

SP Low Limit - prevents the local & remote

setpoints from going below this value

Out High Limit - highest automatic output

value (5 % - 105 %)

Out Low Limit - lowest automatic output

value (5 % - 105 %)

SP Rate Down - rate at which setpoint will

change from original down to the new one. 0

(off) to 99999 (eu/min)

SP Rate Up - rate at which setpoint will

change from original setpoint up to the newone. 0 (off) to 99999 (eu/min)

Display

Decimal Places - Digits to display after

decimal point (0 to 5)

Units - Text to display for EU (4

characters)

PID Block - Tuning Tab

Tuning Constants

Proportional Band (PB) - % of the range ofthe measured variable for which a proportional

controller will produce a 100 % change in its


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controller will produce a 100 % change in its

output. (0.1 to 1000%)

Gain - ratio of output change (%) over the

measured variable change (%) that caused

it.where PB is the proportional Band (0.1 % to1000 %)

Reset - Integral Time - adjusts the controller

output according to both the size of the

deviation (SP-PV) and the time it lasts. (0.02

to 50)

Rate - affects the controllers output whenever

the deviation is changing; and affects it more

when the deviation is changing faster. (0 or 0.1

to 10.00 minutes)

Manual Reset - Allows correction of output toaccount for load changes to bring the PV up to

setpoint. Not applicable with Reset (integral time).

100 to 100 (in % of Output)

Feedforward Gain - Feedforward Input is

multiplied by this value. (0.0 to 10.0)

PID Block - Accutune III Tab


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Accutune III

Cycle Tuning

- Normal (conservative) and Fast (aggressive) response selections- Cycles the output between the output limit values to create two process oscillation

cycles about SP. The PV does not have to be stable as with Setpoint tuning. Rate time isusually the Reset time

- Simplex or duplex output support (calculates one or two tuning sets)


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- Simplex or duplex output support (calculates one or two tuning sets)

Duplex, three action selections:

Auto calculate both heating and cooling tuning

Manual manually tune each side

Disable use only one set of tuning parameters

Setpoint Tuning-Tunes (on demand) based on the process response to step change in the SP (normal &

fast response selections) with the objective of reducing process overshoot

-Introduces a temporary change in the SP by % of FS in the direction selected and holds

the output at a calculated value until the process response is identified and tuning

parameters are recalculated. Then normal automatic control is resumed using the

original SP value. The identification determines tuning parameters values based on one

or two lag process models with consideration to dead time. If single lag there is no rate

component.

- Requires a STABLE PV that is at or nearthe SP before starting.

-Additional selections: SP Change amount and Change direction.

- PV Adaptive Tuning

- Monitors the PV and adjusts tuning constants to eliminate process oscillations over time. -

If the PV does not oscillate then there are NO tuning parameter changes.

PID Block - Alarms Tab


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Alarm Setpoints

99999 to 99999 in Engineering

Units

Within the PV range when alarm type

is PV or SP

Within PV span when alarm type is

DEV

5 % to 105 % when alarm type is

output.

Alarm Hysteresis - 0 % to 5 %

PID Associated Blocks

Activate auto-tune

Change control action Force Bumpless Transfer

Select tuning constants


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Change Auto/Man

& Rem/Loc SP

Select tuning constants

Write tuning

constants

based onENable ON

Mode Status

PID Block #accepting writes

See note page for LO & IMAN

Position Proportional Output

Up to 64 Blocks per configuration

Motor travel time from 12 to 300 Sec. Direct Slidewire Measurements

F ll A i F db k C lib i


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Motor position feedback in %Failed or stalled motor

Failed slidewire (Defaults to TPSC)

Slidewire Feedback

100 1000 ohms

0 to 5V, 0 to 1V

0 to 20mA, 4 to 20mA

Forward & Reverse

Digital Outputs

Fully Automatic Feedback Calibration

SP Programmer

Library of 99 Profiles in controller

Up to 50 segments each

1 Profile ASetpoint Programmer Load Profile by # or Name


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Setpoint Programmer

Function Block

Running Profile

(On-line edits)

Load Profile by # or Name2 Profile B

3 Profile C

4 Profile D

99 Profile ZZ

Reload on Reset

Edit & Save Profile by #

Using HC Designer: At OI

Copy/Paste/Delete a Profile/Recipe

Save to a file

Upload from a file and add to Profile/Recipe poolPrint a Profile/Recipe

Download selected Profile/Recipe

Edit Profile Segments

Save to pool or file

Load from file

SP Programmer - Inputs

ENABL, Disabled if no connection, ON state = Block Enabled

PV1 PV2 PV3AUX PV

Used for Soak

Guarantee

Aux

Output


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NPGM , New Program Number (1 to 99)

NSEG, New segment number (1 to 50)

SET, a pulse input used to load the profile on NPGM

Jog, a pulse input to Jog to a predefined segment

RESTRT, Pulse input for restart action after a powerinterruption

GHOLD, Input ON holds program, input OFF restartsprogram (level)

RESET, Pulse input to reset the program

HOLD, Pulse input to hold the program, RUNneeded to restart

RUN, Pulse input to start the program

ADV, Pulse input to advance the program

SP Programmer Block Outputs

Outputs


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Setpoint Out Value

Auxiliary Analog Output Value

Time Remaining in Current Segment

Segment Elapsed Time

Elapsed Program Time

Program in Guarantee Soak Hold

Program in Reset StateProgram in Hold State

Program in Run State

Program at End

Segment #Program State Program #

Status

0 = Until block is first

run after power up

1 = Reset2 = Hold

3 = Run

4 = Ghold

5 = Stopped

Event Decoder Block

SP Programmer Setup


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Setpoint Profile Set Up

Rack Monitor Block

Monitor the status of a Rack


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Part of the reserved block

space (blocks 96-100)

Always in the configuration

Sized to 16 modules to allowfor possible future products

System Monitor Block

CYCTIME - Control Block Cycle Time in seconds

CYCMINS - Control Block Cycle Time in minutesNEWSTART - On for one control block cycle, following a New start (prog run)

RESTART - On for one control block cycle, following power up. [Warm Start}


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y , g p p [ }

ALM ACTIV - On if any operator panel alarm is ON.

ALMUNACK - On if any operator panels alarm is unacknowledged.

HWOK - On if no faults. Off when a Rack Monitor Block,s RACK OK pin is off.

LOWBTRY - On if the battery is low, Off when battery is good.

HI TEMP - On if the CJ temperature is >70 Deg C on any rack. (see notes)

MSTR FAIL - On when Modbus master diagnostic is not good

BAD BLOCK - On when block(s) are not operating properly (see notes).

LOCKED - Controller locked in current mode by switch position.

TIME OFF - Number of seconds power was turned off. Valid for one cycle of

control blocks execution following power up. Then it is cleared to zero.

DS LIMIT - On when the configured storage warning limit is exceeded. OFF when

the storage capacity falls below the warning limit.

RSV_AVAIL Reserve CPU available (appears only in C70R configuration)

Restart Logic for SP Programmer

The restart feature provides a controlled ramp back to set point after a power loss to prevent shock to

the process work (such as in a kiln). The System Monitor block output pin (Restart) is

on for the first scan cycle after power loss plus the TIME_OFF output indicates the time the power has

been off. A Compare block can be used to evaluate the time off (the SET-TOFF Variable sets the

compare time in secs) which will cause an output to initiate the restart through the AND logic block if this

time is exceeded.


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Power loss

SP=PV onpower restore

*Restore RAMP rate

Program continues

* mustbe entered under SP Profile properties

One scan cycle

IfRESTART is On,

the block will use

PV1 as a starting

value and ramp at

Restart Rate backto the last SP

value, then

complete the

remaining portion of

the segment.

Restart Rate is aproperty of the

profile (program)

Recipes

Load setpoints, select setpoint programs, activate

valves, set alarm limits and enter other values with a

single selection


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Unlimited Recipes

Up to 50 Variables/Recipe-Analog Values

Setpoints

Timer presets

Compare values

- Digital On/Off states

- Setpoint Profile/Sequence numbers

Select recipe at OI or via a Recipe blockRUN

Pushbutton Display Configuration

PUSH-BUTTON GROUP

PMP1-LSON PUMP1-MASTER ActionF1

F2

Confirmation


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F4

F3

Toggle

Flip/Flop

Digital

output

ConfirmationDigital Input

(Optional)

American Gas Association (AGA) Blocks

AGA8GS Compressibility (Gross)

AGA8DL Compressibility (Detail)

AGA3OM Orifice Meter

AGA7TM Turbine Meter


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AGA9UM Ultrasonic Meter

All are in the Calculations folder

AGA8 Compressibility (Gross)

The Gross method approximates natural gas compressibilityand density. It works over a limited range of conditions butrequires less instrumentation to implement.

There are two methods: Method 1 calculates from knowledge of the relative

density, heating value, carbon dioxide, hydrogen andcarbon monoxide components.M th d 2 l l t f k l d f th l ti


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Method 2 calculates from knowledge of the relativedensity, Nitrogen, carbon dioxide, hydrogen and carbonmonoxide components.

HW is differential pressure. Only used with AGA3 meter block Gas components are local or remote Bottom pin is connected to an AGA meter block. It allows data

to be passed to the meter block for its calculation. Calculated output pins are supplied for reference only.

Typically, they are not connected to other blocks. ERR indicates the calculated outputs are set to 0 due to an error

WARN indicates the calculated outputs are compromised

STATUS is a number used in a lookup table to determine the nature of the

error or warning

Local gas composition can be changed in run-mode by HCD or Modbus

Block has tagname for Modbus access

AGA8 Gross with Turbine Meter


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AGA8 Compressibility (Detail)

The Detail method uses the gas analysis of up

to 21 components to calculate the super-compressibility factor, gas density at flowing

and standard conditions, and gas relative


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density at standard conditions.

Used when accurate gas analysis is availableeither via an on-line gas analyzer or from

laboratory measurements.

If this information is available, the Detail

method is preferable, as accurate results areobtainable over a wider range of conditions

than the Gross method.

ACCESS HCD Calcs.

AGA8 Detail with Orifice Meter


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AGA3 Orifice Meter

Calculation is based on AGA Report 3

Supports both flange and pipe-tap orifice meters

Top pin must be connected to an AGA8 output pin to inherit


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AGA8 configuration and calculation results.

QV, QB, QM, QH outputs are rates of flow which are typicallyconnected to totalizers.

Rate outputs are individually configurable to be per day or per

hour, and each have a scale multiplier.

ERR indicates the calculated outputs are set to 0 due to an

error. WARN indicates the calculated outputs are compromised due

to marginal input values used in the calculation.

STATUS is a number used in a lookup table to determine the

nature of the error or warning.

Disable pin forces all calculated outputs to 0, ERR/WARN to

OFF, and STATUS to 99.

AGA7 Turbine Meter

Calculations for gas measurement by TurbineMeters

QR is the raw flow in ft3/hr or m3/hr


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plc hc900 honeywell

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