series c io user's guide

Honeywell Process Solutions

Experion

Series C I/O User's Guide

EP-DCX475 R311.2

May 2009

Release 311.2 Honeywell

ii Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Notices and Trademarks

Copyright 2009 by Honeywell International Inc. Release 311.2 May 21, 2009

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.

Honeywell, PlantScape, Experion PKS, and TotalPlant are registered trademarks of Honeywell International Inc.

Other brand or product names are trademarks of their respective owners.

Honeywell International

Process Solutions

2500 West Union Hills

Phoenix, AZ 85027

1-800 343-0228

R311.2 Experion Series C I/O User's Guide iii May 2009 Honeywell

About This Document The procedures in this guide are intended to give you the ability to perform basic tasks with the Series C I/O such as configuring hardware devices, continuous control strategies. Respective forms are shown to illustrate a procedure/concept only.

Release Information-

Document Name Document ID Release Number

Publication Date

Series C I/O User's Guide - cio_g

EP-DCX475 311.2 May 2009

Support and Other Contacts

iv Experion Series C I/O User's Guide R311.2 Honeywell May 2009


United States and Canada Contact:

Phone: Fascimile: Mail:

Honeywell Solution Support Center 1-800-822-7673 (outside Arizona) 602-313-5558 (in Arizona) Calls are answered by dispatcher between 6:00 am and 4:00 pm Mountain Standard Time. Emergency calls outside normal working hours are received by an answering service and returned within one hour. 602-313-3293 Honeywell TAC, MS P13 2500 West Union Hills Drive Phoenix, AZ, 85027

Europe Contact:

Phone: Fascimile: Mail:

Honeywell TAC-EMEA +32-2-728-2732 +32-2-728-2696 TAC-BE02 Hermes Plaza Hermeslaan, 1H B-1831 Diegem, Belgium

Pacific Contact:

Phone: Fascimile: Mail: Email:

Honeywell Global TAC Pacific 1300-300-4822 (toll free within Australia) +61-8-9362-9559 (outside Australia) +61-8-9362-9564 Honeywell Limited Australia 5 Kitchener Way Burswood 6100, Western Australia [email protected]

India Contact:


Honeywell Global TAC India +91-20- 6603-9400 +91-20- 6603-9800 Honeywell Automation India Ltd 56 and 57, Hadapsar Industrial Estate Hadapsar, Pune 411 013, India [email protected]


R311.2 Experion Series C I/O User's Guide v May 2009 Honeywell

Korea Contact:


Honeywell Global TAC Korea +82-2-799-6317 +82-11-9227-6324 +82-2-792-9015 Honeywell Co., Ltd 17F, Kikje Center B/D, 191, Hangangro-2Ga Yongsan-gu, Seoul, 140-702, Korea [email protected]

Peoples Republic of China Contact:

Phone: Mail: Email:

Honeywell Global TAC China +86- 21-5257-4568 Honeywell (China) Co., Ltd 33/F, Tower A, City Center, 100 Zunyi Rd. Shanghai 200051, Peoples Republic of China [email protected]

Singapore Contact:


Honeywell Global TAC South East Asia +65-6580-3500 +65-6580-3501 +65-6445-3033 Honeywell Private Limited Honeywell Building 17, Changi Business Park Central 1 Singapore 486073 [email protected]

Taiwan Contact:


Honeywell Global TAC Taiwan +886-7-536-2567 +886-7-536-2039 Honeywell Taiwan Ltd. 17F-1, No. 260, Jhongshan 2nd Road. Cianjhen District Kaohsiung, Taiwan, ROC [email protected]


vi Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Japan Contact:


Honeywell Global TAC Japan +81-3-6730-7160 +81-3-6730-7228 Honeywell Japan Inc. New Pier Takeshiba, South Tower Building, 20th Floor, 1-16-1 Kaigan, Minato-ku, Tokyo 105-0022, Japan [email protected]

Elsewhere Call your nearest Honeywell office.

World Wide Web Honeywell Solution Support Online:

http://www.honeywell.com/ps

Training Classes Honeywell Automation College:

http://www.automationcollege.com

Symbol Definitions

R311.2 Experion Series C I/O User's Guide vii May 2009 Honeywell

Symbol Definitions The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

ATTENTION: Identifies information that requires special consideration.

TIP: Identifies advice or hints for the user, often in terms of performing a task.

REFERENCE -EXTERNAL: Identifies an additional source of information outside of the bookset.

REFERENCE - INTERNAL: Identifies an additional source of information within the bookset.

CAUTION

Indicates a situation which, if not avoided, may result in equipment or work (data) on the system being damaged or lost, or may result in the inability to properly operate the process.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in serious injury or death.

WARNING symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

Symbol Definitions

viii Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Symbol Definition

WARNING, Risk of electrical shock: Potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60 VDC may be accessible.

ESD HAZARD: Danger of an electro-static discharge to which equipment may be sensitive. Observe precautions for handling electrostatic sensitive devices.

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 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.

R311.2 Experion Series C I/O User's Guide ix May 2009 Honeywell

Contents

1. INTRODUCTION ............................................................................3 1.1 About this guide.............................................................................................. 3

Intended audience..................................................................................................................3 Prerequisite Skills...................................................................................................................3 Online documentation reference ............................................................................................3 Locating related documentation .............................................................................................3 Terms and acronyms .............................................................................................................3

2. SERIES C I/O PURPOSE...............................................................3 2.1 Overview .......................................................................................................... 3 2.2 Comparing Process Manager I/O and Series C I/O...................................... 3 2.3 What is I/O?...................................................................................................... 3

Series C and I/O.....................................................................................................................3

3. SERIES C I/O PLANNING AND DESIGN ......................................3 3.1 Overview .......................................................................................................... 3 3.2 General Planning References ........................................................................ 3 3.3 Series C I/O appearance and features .......................................................... 3

New look and feel...................................................................................................................3 3.4 Series C I/O and C300 topology..................................................................... 3

Examining the topology rules .................................................................................................3 3.5 Supported Series C I/O modules ................................................................... 3

Available Series C I/O modules..............................................................................................3 Identifying supported Series C I/O modules ...........................................................................3

3.6 Supported Series C I/O options..................................................................... 3 Available Series C I/O options................................................................................................3 Inspecting the Series C I/O library..........................................................................................3 Inspecting IOM function blocks ..............................................................................................3 Inspecting channel function blocks.........................................................................................3 Defining module containment.................................................................................................3

3.7 I/O Link performance specifications ............................................................. 3 Reviewing Link Unit utilization................................................................................................3

Contents

x Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Reducing I/O Link traffic ........................................................................................................ 3 Event collection ..................................................................................................................... 3 PV and Back calculation scanning ........................................................................................ 3

4. SERIES C I/O INSTALLATION AND UPGRADES ....................... 3 4.1 Overview...........................................................................................................3 4.2 Installation Declarations .................................................................................3

Introduction ........................................................................................................................... 3 I/O Link Address Jumpers ..................................................................................................... 3 Cabling .................................................................................................................................. 3

4.3 Installing the Series C IOTA on the carrier ...................................................3 Prerequisites ......................................................................................................................... 3 Considerations ...................................................................................................................... 3 Mounting the IOTA ................................................................................................................ 3

4.4 Mounting the I/O module on the IOTA...........................................................3 Prerequisites ......................................................................................................................... 3 Mounting the module............................................................................................................. 3

4.5 Grounding and power considerations - IOTA boards..................................3 Attaching the IOTA board...................................................................................................... 3 Testing for power................................................................................................................... 3 IOTAs wiring diagrams .......................................................................................................... 3

4.6 Powering the Series C system .......................................................................3 Supplying power to I/O modules............................................................................................ 3

4.7 Fusing - Series C IOTA boards.......................................................................3 Protecting the Series C I/O components ............................................................................... 3

5. SERIES C IOTA PINOUTS............................................................ 3 5.1 Analog Input IOTA Models CC-TAIX01, CC-TAIX11 .....................................3

Analog Input wiring................................................................................................................ 3 5.2 Analog Output IOTA Models CC-TAOX01, CC-TAOX11...............................3 5.3 Low Level Analog Input Mux (LLMUX) IOTA Models CC-TAIM01...............3

Field wiring and module protection........................................................................................ 3 IOTA board and connections................................................................................................. 3

5.4 Digital Input High Voltage IOTA Models CC-TDI110, CC-TDI120, CC-TDI220, CC-TDI230....................................................................................................................3

Field wiring and module protection........................................................................................ 3 IOTA board............................................................................................................................ 3

5.5 Digital Input 24V IOTA Models CC-TDIL01, CC-TDIL11 ...............................3

Contents

R311.2 Experion Series C I/O User's Guide xi May 2009 Honeywell

Field wiring and module protection.........................................................................................3 Using DI channels to report system alarms............................................................................3 To connect the Power System alarm cable for RAM Charger Assembly 51199932-100 .......3 To connect the Power System alarm cable for RAM Charger Assembly 51199932-200 .......3

5.6 Digital Output 24V IOTA Models CC-TDOB01, CC-TDOB11 ....................... 3 Field wiring and module protection.........................................................................................3 IOTA board and connections..................................................................................................3

5.7 Digital Output Relay Module IOTA Models CC-TDOR01, CC-TDOR11....... 3 5.8 Digital Output Relay Extender board Models CC-SDOR01......................... 3

DO Relay Cover .....................................................................................................................3 To mount the DO Relay Cover ...............................................................................................3

5.9 Upgrading firmware in Series C I/O components ........................................ 3

6. SERIES C I/O CONFIGURATION FORM REFERENCE................3 6.1 Overview .......................................................................................................... 3 6.2 Determining Series C I/O block redundancy................................................ 3

Main tab checkbox invokes redundancy ................................................................................3 6.3 Switchover and Secondary readiness .......................................................... 3 6.4 Failure conditions and switchover................................................................ 3 6.5 Configuration tools ......................................................................................... 3

Using Control Builder to create control strategies ..................................................................3 6.6 Configuring the Main tab - IOM block ........................................................... 3

Configuring modules - Main tab .............................................................................................3 6.7 Configuring the Status Data tab - IOM block................................................ 3

Configuring modules - Status Data tab ..................................................................................3 6.8 Configuring the Maintenance tab - IOM block.............................................. 3

Configuring modules - Maintenance tab.................................................................................3 6.9 Configuring Box Soft Failures tab - IOM block ............................................ 3

Configuring modules - Box Soft Failures tab ..........................................................................3 6.10 Configuring Channel Soft Failures tab - IOM block ................................. 3

Configuring modules - Channel Soft Failures tab...................................................................3 6.11 Configuring Server History tab - IOM block.............................................. 3

Configuring modules - Server History tab...............................................................................3 6.12 Configuring Server Displays tab - IOM block ........................................... 3

Configuring modules - Server Displays tab ............................................................................3

Contents

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6.13 Configuring Control Confirmation tab - IOM block ..................................3 Configuring modules - Control Confirmation tab.................................................................... 3

6.14 Configuring Identification tab - IOM block ................................................3 Configuring modules - Identification tab ................................................................................ 3

6.15 Configuring QVCS tab - IOM block.............................................................3 Configuring modules - QVCS tab .......................................................................................... 3

6.16 Configuring the Calibration tab - IOM block..............................................3 Configuring modules - Calibration tab ................................................................................... 3

6.17 Configuring HART Status tab - IOM block.................................................3 Configuring modules HART - Status tab ............................................................................... 3

6.18 Configuring the Configuration tab - Channel block .................................3 Configuring modules - Identification tab ................................................................................ 3

6.19 Configuring HART Configuration tab - Channel block.............................3 Configuring modules - HART Configuration tab .................................................................... 3

6.20 Configuring HART Device Status tab - Channel block.............................3 Configuring modules - Identification tab ................................................................................ 3

6.21 Configuring HART Identification tab - Channel block..............................3 Configuring modules - Identification tab ................................................................................ 3

6.22 Configuring HART Variables tab - Channel block ....................................3 Configuring modules - Identification tab ................................................................................ 3

6.23 Configuring HART Notifications tab - Channel block ..............................3 Configuring modules - Identification tab ................................................................................ 3

6.24 Configuring Dependencies tab - Channel block.......................................3 Configuring modules - Dependencies tab ............................................................................. 3

6.25 Configuring Template Defining tab - Channel block ................................3 Configuring modules - Identification tab ................................................................................ 3

7. SERIES C I/O CONFIGURATION ................................................. 3 7.1 Adding an IOM to Project................................................................................3

Using the File menu method ................................................................................................. 3 Using the drag and drop method ........................................................................................... 3

7.2 Assigning an IOM to an IOLINK in the Project tab .......................................3 Using the Assignment dialog box .......................................................................................... 3

7.3 Adding an IOC block to a Control Module ....................................................3 Using the Project tab drag and drop...................................................................................... 3 Using the Library tab - drag and drop.................................................................................... 3

Contents

R311.2 Experion Series C I/O User's Guide xiii May 2009 Honeywell

7.4 Assigning an IOC block to an IOM ................................................................ 3 IOC block assignment ............................................................................................................3

7.5 Unassigning an IOC block from an IOM ....................................................... 3 IOC block unassignment ........................................................................................................3 To unassign an IOC from an IOM using the Function Block Assignment Dialog Box:............3

7.6 Field Calibration of the AI and AO modules................................................. 3 To field calibrate the AI-HL, AI-HART, AO and AO HART modules: ......................................3

7.7 Defining Channel blocks ................................................................................ 3 Overview ................................................................................................................................3 Common features of I/O channel blocks ................................................................................3 Defining Mode and Attribute settings .....................................................................................3 Enabling HART ......................................................................................................................3 Comparing parameters between Series C and PMIO ............................................................3 Using Block Copy...................................................................................................................3

7.8 Defining AI Channel Blocks ........................................................................... 3 Overview ................................................................................................................................3 Determining PV Characterization ...........................................................................................3 Determining Linear Conversion..............................................................................................3 Determining Square Root Conversion....................................................................................3 Determining Thermal Conversion...........................................................................................3 Open Wire Detection..............................................................................................................3 Checking and Filtering PV Range ..........................................................................................3 Comparing parameters between Series C and PMIO that support AI ....................................3

7.9 Defining AO Channel Blocks ......................................................................... 3 Overview ................................................................................................................................3 Determining Direct/Reverse Output .......................................................................................3 Determining Output Characterization .....................................................................................3 Determining Calibration Compensation..................................................................................3 Determining Modes ................................................................................................................3 Determining Output Verification .............................................................................................3 Comparing parameters between Series C and PMIO that support AO ..................................3

7.10 Defining DI Channel Blocks........................................................................ 3 Overview ................................................................................................................................3 Determining Status Digital Input channel ...............................................................................3 Determining Latched Digital Input channel.............................................................................3 Comparing parameters between Series C and PMIO that support DI....................................3 Open Wire Detection..............................................................................................................3

7.11 Defining DO Channel Blocks...................................................................... 3 Overview ................................................................................................................................3 Determining Status Output type .............................................................................................3 Determining Pulse Width Modulated (PWM) Output type.......................................................3 Determining On-Pulse and Off-Pulse Output type..................................................................3 Determining Initialization Request Flag..................................................................................3

Contents

xiv Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Determining Modes ............................................................................................................... 3 Determining Output Verification............................................................................................. 3 Determining Over-current protection ..................................................................................... 3 Comparing parameters between Series C and PMIO that support DO ................................. 3

7.12 Electronic Short-Circuit Protection (DO-24V only)...................................3 Non-redundant Configuration ................................................................................................ 3 Redundant Configuration ...................................................................................................... 3 Electronic Short-Circuit Fault Recovery................................................................................. 3 To clear the short-circuit fault: ............................................................................................... 3

8. SERIES C I/O OPERATIONS........................................................ 3 8.1 Overview...........................................................................................................3 8.2 Reviewing the Control Builder icons.............................................................3

Series C I/O block icons ........................................................................................................ 3 IOLINK icons ......................................................................................................................... 3 Block icons ............................................................................................................................ 3 Channel icons........................................................................................................................ 3

8.3 Series C I/O LED Descriptions .......................................................................3 8.4 Powering up the IOM.......................................................................................3 8.5 Activating a control strategy from the Monitoring tab ................................3

Starting an IOM ..................................................................................................................... 3 Issuing Shutdown command ................................................................................................. 3

8.6 Activating HART ..............................................................................................3 Assigning a channel to HART - Series C............................................................................... 3 To assign a channel to HART................................................................................................ 3 Enabling HART Alarm and Events - Series C ....................................................................... 3

8.7 IOM configuration values not copied during Block Copy operation..........3 8.8 SOE Scenarios .................................................................................................3

Input chatter scenario............................................................................................................ 3 PVCHGDLY scenarios .......................................................................................................... 3 PV State Change event Regeneration .................................................................................. 3

8.9 SOE Events & Configuration ..........................................................................3 SOE Event Configuration ...................................................................................................... 3 SOE Events........................................................................................................................... 3

8.10 DIMODE and OWDENBL related scenarios...............................................3 DIMODE Parameter Changes............................................................................................... 3 Low Latency Mode ................................................................................................................ 3 OWDENBL changes in Project View ..................................................................................... 3

Contents

R311.2 Experion Series C I/O User's Guide xv May 2009 Honeywell

9. SERIES C I/O LOADING................................................................3 9.1 Loading Series C I/O components................................................................. 3

Load order guidelines.............................................................................................................3 9.2 Loading an IOLINK.......................................................................................... 3

IOLINK Load with Contents....................................................................................................3 9.3 Loading the IOM block the first time............................................................. 3

Loading the IOM block present on the IOLINK.......................................................................3 Loading with the IOM block missing on the IOLINK ...............................................................3 Reloading the IOM block from Project or Monitoring..............................................................3 Reviewing IOM reconfiguration rules .....................................................................................3

9.4 Common I/O block load activities.................................................................. 3 Uploading the I/O block..........................................................................................................3 Update to Project ...................................................................................................................3 Using IOM Checkpoint ...........................................................................................................3

9.5 Loading a CM................................................................................................... 3 Loading the CM the first time .................................................................................................3 Reloading the CM from Project or Monitoring ........................................................................3

9.6 Setting Priority IOMs....................................................................................... 3 To set the Priority IOM ...........................................................................................................3

10. SERIES C I/O LINK FIBER OPTIC EXTENDERS (FOE)...............3 10.1 Overview....................................................................................................... 3

Fiber Optic Extender assembly ..............................................................................................3 FOE features..........................................................................................................................3 Fiber Optic redundancy..........................................................................................................3 Hazardous environment .........................................................................................................3

10.2 FOE Installation ........................................................................................... 3 Handling components - ESD..................................................................................................3 Work practices .......................................................................................................................3 Hazardous areas....................................................................................................................3

10.3 Component mounting sequence................................................................ 3 Mounting the FOE module onto the IOTA ..............................................................................3 Connecting the FOE module's power cable to the module.....................................................3 Removing the FOE IOTA F1 fuse ..........................................................................................3 Mounting the FOE module/IOTA assembly to the carrier .......................................................3 Connecting the IOLINK interface cable to the FOE module ...................................................3 Re-installing the FOE IOTA F1 fuse.......................................................................................3 Connecting the fiber optic cables to the FOE module ............................................................3 FOE connection rules.............................................................................................................3 LED indicators........................................................................................................................3

Contents

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10.4 Defining the Fiber Optic topology ..............................................................3 FOE capacity......................................................................................................................... 3 Required hardware................................................................................................................ 3 FOE topologies...................................................................................................................... 3 Fiber optic budget considerations.......................................................................................... 3 I/O link extender cable selection............................................................................................ 3

11. SERIES C I/O MIGRATING FROM PMIO TO SERIES C I/O ........ 3 11.1 Determining Series C I/O vs. PMIO functionality ......................................3

Label ..................................................................................................................................... 3 11.2 Migrating channels blocks from PMIO to Series C I/O.............................3

12. SERIES C I/O TROUBLESHOOTING ........................................... 3 12.1 Initial checks.................................................................................................3

Checking Control Builder error code reference ..................................................................... 3 Checking front panel display and LEDs................................................................................. 3 Upgrading Firmware in Series C I/O components ................................................................. 3

12.2 Self-test diagnostics at power-up ..............................................................3 Powerup diagnostics ............................................................................................................. 3

12.3 Communication problems...........................................................................3 IOLINK - loss of communications .......................................................................................... 3 IOLINK - re-establishing communications ............................................................................. 3

12.4 FOE Troubleshooting ..................................................................................3 Loss of power ........................................................................................................................ 3 Loss of communication.......................................................................................................... 3

13. SERIES C I/O MAINTENANCE ..................................................... 3 13.1 Series C recommended spares ..................................................................3

IOM removal and installation under power ............................................................................ 3 13.2 Replacing a Series C IOTA..........................................................................3

To replace a Series C IOTA .................................................................................................. 3 13.3 Replacing an I/O module .............................................................................3

Prerequisites ......................................................................................................................... 3 To replace an I/O module...................................................................................................... 3

13.4 FOE recommended spares..........................................................................3 Spare parts............................................................................................................................ 3

13.5 FOE Maintenance .........................................................................................3

Contents

R311.2 Experion Series C I/O User's Guide xvii May 2009 Honeywell

FOE Repair ............................................................................................................................3 Replacing the FOE IOTA F1 fuse...........................................................................................3 Replacing the FOE module on the IOTA................................................................................3 Removing the FOE assembly from the carrier .......................................................................3 Cable considerations..............................................................................................................3

14. SERIES C POWER SUB-SYSTEM CONNECTIONS AND ALARM INDICATIONS .........................................................................................3

14.1 Series C DC Power Connections and Indicators...................................... 3 14.2 Series C Power Sub-System LED Indications .......................................... 3 14.3 Series C Power Sub-System Alarm Contacts and LED Activation Levels 3

15. SERIES C I/O ALARMS AND FAILURES .....................................3 15.1 Reviewing IOM alarms generated by the C300......................................... 3

IOM alarms.............................................................................................................................3 HART alarms/events ..............................................................................................................3

15.2 Reviewing IOM soft failures........................................................................ 3 IOM soft failures .....................................................................................................................3 01 STCOVRUN ...............................................................................................................3 02 REQOFLOW ..............................................................................................................3 06 FTAMISSG.................................................................................................................3 07 EECKSMER ...............................................................................................................3 08 EECNTERR ...............................................................................................................3 09 EEFLAGER ................................................................................................................3 21 INPTFAIL ...................................................................................................................3 23 OUTPUTFL ................................................................................................................3 24 STCKLIM....................................................................................................................3 26 DIAGCTFL .................................................................................................................3 31 FTAMSMCH...............................................................................................................3 32 VZERO-FL .................................................................................................................3 33 BADRJVAL.................................................................................................................3 36 FTA1FAIL...................................................................................................................3 37 FTA2FAIL...................................................................................................................3 38 CALBABRT ................................................................................................................3 39 BADCALRF ................................................................................................................3 41 VREFFAIL ..................................................................................................................3 42 ADOUTUDF ...............................................................................................................3 43 ADOUTCAL................................................................................................................3 44 BADFLREG................................................................................................................3 45 BDSNDLTC................................................................................................................3 46 BDOUTBFR ...............................................................................................................3

Contents

xviii Experion Series C I/O User's Guide R311.2 Honeywell May 2009

47 VCALFAIL ................................................................................................................. 3 48 F1NOTCAL................................................................................................................ 3 49 F2NOTCAL................................................................................................................ 3 50 F1COM_FL................................................................................................................ 3 51 F2COM_FL................................................................................................................ 3 52 F1_IDERR................................................................................................................. 3 53 F2_IDERR................................................................................................................. 3 54 F1VREFFL ................................................................................................................ 3 55 F2VREFFL ................................................................................................................ 3 56 F1CAL_FL ................................................................................................................. 3 57 F2CAL_FL ................................................................................................................. 3 58 LOSTSYNC............................................................................................................... 3 59 WRITENBL................................................................................................................ 3 60 MLTINPFL................................................................................................................. 3 61 REDNDIAG ............................................................................................................... 3 63 WRONG_HW ............................................................................................................ 3 64 HWFIFOFL................................................................................................................ 3 65 PRVRAMFL............................................................................................................... 3 66 SOECLKFL................................................................................................................ 3 67 PVVALDFL ................................................................................................................ 3 68 SOECNTFL ............................................................................................................... 3 69 DTPATHFL................................................................................................................ 3 70 DTPATHTO............................................................................................................... 3 71 STMACHFL............................................................................................................... 3 72 PIFAULTY ................................................................................................................. 3 161 HMODEM1................................................................................................................ 3 162 HMODEM2................................................................................................................ 3 163 HMODEM3................................................................................................................ 3 164 HMODEM4................................................................................................................ 3 165 HDIAGTO.................................................................................................................. 3 166 HSTACKHI ................................................................................................................ 3 167 FTA3FAIL .................................................................................................................. 3 168 FTA4FAIL .................................................................................................................. 3 169 F3NOTCAL................................................................................................................ 3 170 F4NOTCAL................................................................................................................ 3 171 F3COMFL.................................................................................................................. 3 172 F4COMFL.................................................................................................................. 3 173 F3IDERR................................................................................................................... 3 174 F4IDERR................................................................................................................... 3 175 F3VREFFL ................................................................................................................ 3 176 F4VREFFL ................................................................................................................ 3 177 F3CALFL ................................................................................................................... 3 178 F4CALFL ................................................................................................................... 3 179 OPENWIRE............................................................................................................... 3 180 DOVRCRNT .............................................................................................................. 3 181 FTAPOWFL............................................................................................................... 3 182 DPADIAFAIL ............................................................................................................. 3 183 RDBKRGDIAGFL ...................................................................................................... 3

Contents

R311.2 Experion Series C I/O User's Guide xix May 2009 Honeywell

184 WDTDIAGFAIL...........................................................................................................3 185 RLYEXTBDMSSNG ...................................................................................................3 186 REDHWFAIL ..............................................................................................................3 187 HARTCHANFAIL........................................................................................................3

15.3 Reviewing IOM hard failures ...................................................................... 3 IOM hard failures....................................................................................................................3 To recover from an IO module hard failure ............................................................................3 IOM Behavior during Hard Failures........................................................................................3

15.4 Getting further assistance .......................................................................... 3 Other troubleshooting sources ...............................................................................................3 Guidelines for requesting support ..........................................................................................3

16. SERIES C I/O GALVANICALLY ISOLATED / INTRINSICALLY SAFE HARDWARE.................................................................................3

16.1 GI/IS IOTA models ....................................................................................... 3 Galvanically Isolated IOTAs ...................................................................................................3 Line-Fault Detection (LFD) - Digital Input GI/IS only ..............................................................3 Hazardous environment .........................................................................................................3

17. GI/IS POWER AND GROUNDING REQUIREMENTS ...................3 17.1 Introduction.................................................................................................. 3

IOTA fusing ............................................................................................................................3 Temperature and humidity parameters ..................................................................................3

17.2 Grounding and power considerations -GI/IS IOTA boards ..................... 3 Attaching the GI/IS IOTA board..............................................................................................3 Testing for power for GI/IS .....................................................................................................3

18. GI/IS INSTALLATION ....................................................................3 18.1 GI/IS Shield Connection Options ............................................................... 3 18.2 Installing the GI/IS IOTA onto the carrier .................................................. 3

Mounting the IOTA .................................................................................................................3 18.3 Installing the IOM onto the GI/IS IOTA ...................................................... 3

Mounting the IOM on a GI/IS IOTA ........................................................................................3 18.4 Installing the Isolator .................................................................................. 3

Precautions ............................................................................................................................3 Preparing the isolator for installation ......................................................................................3 To prepare the isolator for installation ....................................................................................3 Installing the isolator ..............................................................................................................3

Contents

xx Experion Series C I/O User's Guide R311.2 Honeywell May 2009

To install the isolator: ............................................................................................................ 3 18.5 Setting isolator DIP switches......................................................................3

Setting Operation mode via Digital Input isolator DIP switches............................................. 3 To set the DIP switches:........................................................................................................ 3

18.6 MTL4510........................................................................................................3 18.7 MTL4511 / 4516 / 4517..................................................................................3 18.8 Field Wiring Connections............................................................................3

Typical Galvanic Isolation Module ......................................................................................... 3 To install the terminal plug into the isolator ........................................................................... 3 Isolator plug-in capability....................................................................................................... 3 Isolator removal..................................................................................................................... 3 Screw-clamp terminals .......................................................................................................... 3

18.9 Screw-terminal wiring..................................................................................3 Terminal wiring connections.................................................................................................. 3

19. GI/IS IOTA PINOUTS .................................................................... 3 19.1 GI/IS Analog Input IOTA Model CC-GAIX11...............................................3

Description ............................................................................................................................ 3 CC-GAIX11 Analog Input IOTA connection diagram............................................................. 3

19.2 GI/IS Analog Input IOTA Model CC-GAIX21...............................................3 Description ............................................................................................................................ 3 CC-GAIX21 Analog Input IOTA connection diagram............................................................. 3 Analog Input supported isolators ........................................................................................... 3 Configuration using PCS45/PCL45 ....................................................................................... 3 Field Wiring Input Signals...................................................................................................... 3 Field Wiring Input Signals...................................................................................................... 3

19.3 Analog Output GI/IS IOTAs .........................................................................3 Description ............................................................................................................................ 3

19.4 GI/IS Analog Output IOTA Model CC-GAOX11..........................................3 CC-GAOX11 Analog Output IOTA ........................................................................................ 3 CC-GAOX11 Analog Output IOTA connection diagram ........................................................ 3

19.5 GI/IS Analog Output IOTA Model CC-GAOX21..........................................3 CC- GAOX21 Analog Output IOTA ....................................................................................... 3 CC-GAOX21 Analog Output IOTA connection diagram ........................................................ 3 Analog Output supported isolators ........................................................................................ 3

19.6 24 Vdc Digital Input GI/IS IOTAs.................................................................3 Description ............................................................................................................................ 3 Input signal phase and IOTA features ................................................................................... 3

19.7 GI/IS Digital Input IOTA Model CC-GDIL01................................................3

Contents

R311.2 Experion Series C I/O User's Guide xxi May 2009 Honeywell

CC-GDIL01 Digital Input IOTA ...............................................................................................3 CC-GDIL01 Digital Input IOTA connection diagram ...............................................................3

19.8 GI/IS Digital Input IOTA Model CC-GDIL11 ............................................... 3 Description .............................................................................................................................3 CC-GDIL11 Digital Input IOTA ...............................................................................................3 CC-GDIL11 Digital Input IOTA connection diagram ...............................................................3

19.9 GI/IS Digital Input IOTA Model CC-GDIL21 ............................................... 3 CC-GDIL21 Digital Input IOTA ...............................................................................................3 Model CC-GDIL21 Digital Input IOTA connection diagram ....................................................3 Digital Input supported isolators .............................................................................................3

19.10 ............................................................................................................................ 3 19.11 ............................................................................................................................ 3 19.12 GI/IS Digital Output IOTA Model CC-GDOL11........................................... 3

CC-GDOL11 Digital Output IOTA...........................................................................................3 CC-GDOL11 Digital Output IOTA...........................................................................................3 Digital Output supported isolators ..........................................................................................3

19.13 GI/IS Digital I/O Expander Model CC-SDXX01 .......................................... 3 Description .............................................................................................................................3

20. PCS45 CONFIGURATION SOFTWARE........................................3 20.1 Description................................................................................................... 3

Accessing the software ..........................................................................................................3 20.2 PCS45 features ............................................................................................ 3

Operating Modes....................................................................................................................3 Data format ............................................................................................................................3 Data flow ................................................................................................................................3 Temperature converter...........................................................................................................3 PC-link - PCL45 and PCL45USB ...........................................................................................3 Export and Print file................................................................................................................3 Damping and smoothing ........................................................................................................3 Alarm signals..........................................................................................................................3 Trip output value ....................................................................................................................3 Menus ....................................................................................................................................3

20.3 Troubleshooting the PSC45 software ....................................................... 3 Interface error.........................................................................................................................3 Configuration error .................................................................................................................3 Device defective or causing problems error ...........................................................................3

21. GI/IS MAINTENANCE ....................................................................3

Contents

xxii Experion Series C I/O User's Guide R311.2 Honeywell May 2009

21.1 GI/IS recommended spares.........................................................................3 21.2 Repair ............................................................................................................3 21.3 Replacing an GI/IS IOTA..............................................................................3

To replace an GI/IS IOTA...................................................................................................... 3 21.4 Replacing an IOM on the GI/IS IOTA ..........................................................3 21.5 Replacing the isolator..................................................................................3

To remove the isolator:.......................................................................................................... 3 21.6 Replacing fuses on a GI/IS IOTA ................................................................3

To replace fuses on a GI/IS IOTA: ........................................................................................ 3

22. GI/IS TROUBLESHOOTING.......................................................... 3 22.1 Loss of power...............................................................................................3

23. ATEX INFORMATION ................................................................... 3 23.1 General ..........................................................................................................3

Installation ............................................................................................................................. 3 Inspection and maintenance ................................................................................................. 3 Repair.................................................................................................................................... 3 Marking ................................................................................................................................. 3

23.2 Isolators safety parameters ........................................................................3

Contents Tables

R311.2 Experion Series C I/O User's Guide xxiii May 2009 Honeywell

Tables Table 1 Terms and conventions ...................................................................................... 3 Table 2 Series C features................................................................................................ 3 Table 3 Topology rules .................................................................................................... 3 Table 4 Available I/O modules......................................................................................... 3 Table 5 Series C I/O channel function blocks ................................................................. 3 Table 6 Transmission rate of data on an I/O Link ........................................................... 3 Table 7 Link Unit utilization rates..................................................................................... 3 Table 8 I/O parameters scanned when the IOM is loaded.............................................. 3 Table 9 Series C I/O cable types..................................................................................... 3 Table 10 IOM types and ancillary hardware.................................................................... 3 Table 11 IOMs, IOTAs, and ancillary cards..................................................................... 3 Table 12 AI 6 inch, non-redundant - terminal block 1...................................................... 3 Table 13 AI 6 inch, non-redundant - terminal block 2...................................................... 3 Table 14 Jumpers to support Analog Input connections ................................................. 3 Table 15 Custom wiring to support Analog Input ............................................................ 3 Table 16 Summary - Analog Input wiring connections .................................................... 3 Table 17 AO 6 inch, non-redundant - terminal block 1.................................................... 3 Table 18 LL MUX FTA connections................................................................................. 3 Table 19 LL MUX FTA jumper unit positions................................................................... 3 Table 20 DI HV 12 inch, redundant - terminal block 1..................................................... 3 Table 21 DI HV 12 inch, redundant - terminal block 2..................................................... 3 Table 22 DI 9 inch, non-redundant - terminal block 1 ..................................................... 3 Table 23 DI 9 inch, non-redundant - terminal block 2 ..................................................... 3 Table 24 DI 9 inch, non-redundant - terminal block 3 ..................................................... 3 Table 25 24V DO 9 inch, non-redundant - terminal block 1 ............................................ 3 Table 26 24V DO 9 inch, non-redundant - terminal block 2 ............................................ 3 Table 27 24V DO 9 inch, non-redundant - terminal block 3 ............................................ 3 Table 28 DO Relay Extender board- terminal block 1..................................................... 3 Table 29 DO Relay Extender board- terminal block 2..................................................... 3 Table 30 Redundancy state and module readiness ........................................................ 3 Table 31 Failure conditions that result in switchover....................................................... 3 Table 32 Main tab parameters......................................................................................... 3 Table 33 Server History tab parameters.......................................................................... 3 Table 34 Server Display tab parameters ......................................................................... 3 Table 35 Identification tab parameters ............................................................................ 3 Table 36 HART Configuration tab parameters ................................................................ 3 Table 37 HART Device Status tab parameters ............................................................... 3 Table 38 HART Identification tab..................................................................................... 3 Table 39 HART Variables tab parameters....................................................................... 3 Table 40 HART Notifications tab parameters.................................................................. 3

Contents Tables

xxiv Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Table 41 I/O Channel block type......................................................................................3 Table 42 Mode parameter - channel block ......................................................................3 Table 43 Mode Attribute parameter - channel block ........................................................3 Table 44 Channel block fault conditions and results........................................................3 Table 45 AO fault handling...............................................................................................3 Table 46 DO fault handling ..............................................................................................3 Table 47 FAULTOPT parameter settings ........................................................................3 Table 48 IOM hard failure and output state .....................................................................3 Table 49 PV Source settings............................................................................................3 Table 50 PVSRCOPT settings .........................................................................................3 Table 51 REDTAG settings..............................................................................................3 Table 52 HART parameters .............................................................................................3 Table 53 AI engineering unit conversions........................................................................3 Table 54 RTD lead wire characteristics ...........................................................................3 Table 55 Status Output settings.......................................................................................3 Table 56 Setting DOTYPE to ONPULSE or OFFPULSE.................................................3 Table 57 DO channel initialization....................................................................................3 Table 58 Channel block icons ..........................................................................................3 Table 59 IOLINK icons .....................................................................................................3 Table 60 Block icons ........................................................................................................3 Table 61 Channel icons ...................................................................................................3 Table 62 I/O LED descriptions .........................................................................................3 Table 63 Sequence of activating components - Monitoring tab.......................................3 Table 64 Sequence of activating components - Project tab ............................................3 Table 65 IOM reconfiguration rules..................................................................................3 Table 66 FOE module and IOTA summary......................................................................3 Table 67 FOE LED descriptions......................................................................................3 Table 68 Comparing Series C and PM I/O functionality ..................................................3 Table 69 Comparing Series C and PM I/O parameters ...................................................3 Table 70 Recommended spare parts...............................................................................3 Table 71 Recommended spare parts...............................................................................3 Table 72 IOM alarms displayed by the C300 controller ...................................................3 Table 73 IOM hard failures...............................................................................................3 Table 74 - GI/IS IOTAs and Isolators ...............................................................................3 Table 75 MTL4510 isolator DIP switch settings...............................................................3 Table 76 Module input/output operation ..........................................................................3 Table 77 MTL4511 isolator DIP switch settings...............................................................3 Table 78 MTL4516 isolator DIP switch settings...............................................................3 Table 79 MTL4517 isolator DIP switch settings...............................................................3 Table 80 Terminal wiring connections..............................................................................3 Table 81 AI IOTAs and their supporting isolators ............................................................3 Table 82 MTL4575, power and status information...........................................................3 Table 83 AO IOTAs and their supporting isolators ..........................................................3

Contents Tables

R311.2 Experion Series C I/O User's Guide xxv May 2009 Honeywell

Table 84 DI IOTAs and their supporting isolators ........................................................... 3 Table 85 DO IOTA and its supporting isolator................................................................. 3 Table 86 GI/IS Recommended spare parts ..................................................................... 3 Table 87 MTL4500 safety parameters............................................................................. 3

Contents Figures

xxvi Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Figures Figure 1 Series C I/O and C300 topology ........................................................................3 Figure 2 Series C I/O library.............................................................................................3 Figure 3 Execution State..................................................................................................3 Figure 4 Point Execution State.........................................................................................3 Figure 5 Series C board connections...............................................................................3 Figure 6 Series C cabling.................................................................................................3 Figure 7 Grounding and power connections ....................................................................3 Figure 8 Series C Analog Input 6 inch, non-redundant IOTA ..........................................3 Figure 9 Series C Analog Input 6 inch, non-redundant IOTA and field wiring connections

..................................................................................................................................3 Figure 10 Series C Analog Input 12 inch, redundant IOTA .............................................3 Figure 11 Series C Analog Output 6 inch, non-redundant IOTA .....................................3 Figure 12 Series C Analog Output 6 inch, non-redundant IOTA and field wiring

connection.................................................................................................................3 Figure 13 Series C Analog Output 12 inch, redundant IOTA...........................................3 Figure 14 Series C Low Level 6 inch, non-redundant IOTA ............................................3 Figure 15 Series C Low Level Analog Input IOTA and field wiring connections..............3 Figure 16 Series C Digital Input High Voltage 9 inch, non-redundant IOTA....................3 Figure 17 Series C Digital Input High Voltage 12 inch, redundant IOTA.........................3 Figure 18 Series C Digital Input High Voltage 120 Vac and field wiring connections......3 Figure 19 Series C Digital Input High Voltage 240 Vac and field wiring connections......3 Figure 20 Series C 24V Digital Input 9 inch, non-redundant IOTA..................................3 Figure 21 Series C 24V Digital Input 9 inch, non-redundant IOTA and field wiring

connection.................................................................................................................3 Figure 22 Series C 24V Digital Input 12 inch, redundant IOTA .......................................3 Figure 23 Alarm cable connection to the power supply and 24V DI IOTA for RAM

Charger Assembly 51199932-100 ............................................................................3 Figure 24 Alarm cable connection to the power supply and 24V DI IOTA for RAM

Charger Assembly 51199932-200 ............................................................................3 Figure 25 Series C 24V Digital Output 9 inch, non-redundant IOTA ...............................3 Figure 26 Series C 24V Digital Output 9 inch, non-redundant IOTA and field wiring

connections ...............................................................................................................3 Figure 27 Series C 24V Digital Output 12 inch, redundant IOTA ....................................3 Figure 28 Series C Digital Output Relay, non-redundant IOTA .......................................3 Figure 29 Series C Digital Output Relay, non-redundant IOTA .......................................3 Figure 30 Series C Digital Output Relay, redundant IOTA ..............................................3 Figure 31 Series C Digital Output Relay Extender board ................................................3 Figure 32 Series C Digital Output Relay Extender board and field wiring connections...3 Figure 33 Series C Digital Output Relay Cover ...............................................................3 Figure 34 Defining redundancy from the Main tab...........................................................3 Figure 35 Main tab ...........................................................................................................3

Contents Figures

R311.2 Experion Series C I/O User's Guide xxvii May 2009 Honeywell

Figure 36 Status Data tab................................................................................................ 3 Figure 37 Maintenance tab.............................................................................................. 3 Figure 38 Box Soft Failures tab ....................................................................................... 3 Figure 39 Channel Soft Failures tab................................................................................ 3 Figure 40 Server History tab............................................................................................ 3 Figure 41 Server Display tab ........................................................................................... 3 Figure 42 Control Confirmation tab ................................................................................. 3 Figure 43 Identification tab .............................................................................................. 3 Figure 44 QVCS tab ........................................................................................................ 3 Figure 45 Calibration tab ................................................................................................. 3 Figure 46 HART Status tab ............................................................................................. 3 Figure 47 Configuration tab ............................................................................................. 3 Figure 48 HART Configuration tab .................................................................................. 3 Figure 49 HART Device Status tab ................................................................................. 3 Figure 50 HART Identification tab ................................................................................... 3 Figure 51 HART Variables tab......................................................................................... 3 Figure 52 HART Notifications tab .................................................................................... 3 Figure 53 Dependencies tab ........................................................................................... 3 Figure 54 Template Defining tab ..................................................................................... 3 Figure 55 AO and DO fault state (FAULTST) transitions ................................................ 3 Figure 56 Series C I/O AI or AO - HART tabs ................................................................. 3 Figure 57 Analog Input conversion.................................................................................. 3 Figure 58 Analog Output conversion ............................................................................... 3 Figure 59 Determining fixed endpoint.............................................................................. 3 Figure 60 Digital input conversion ................................................................................... 3 Figure 61 Digital output conversion ................................................................................. 3 Figure 62 Pulse Width Modulated Output........................................................................ 3 Figure 63 On-Pulse and Off-Pulse Output types............................................................. 3 Figure 64 Series C I/O LED indicators ............................................................................ 3 Figure 65 : SOE PV Change Delay Scenario.................................................................. 3 Figure 66 Loading the IOM block the first time................................................................ 3 Figure 67 Reloading the IOM block ................................................................................. 3 Figure 68 Loading the CM ............................................................................................... 3 Figure 69 Setting Priority IOM ......................................................................................... 3 Figure 70 Fiber Optic Extender assembly ....................................................................... 3 Figure 71 Example of possible FOE usage..................................................................... 3 Figure 72 Typical dc power and battery backup connections in Series C cabinet with

RAM Charger 51199932-100 ................................................................................... 3 Figure 73 Typical dc power and battery backup connections in Series C cabinet with

RAM Charger 51199932-200 ................................................................................... 3 Figure 74 Location of hard failure message .................................................................... 3 Figure 75 GI/IS board assembly...................................................................................... 3

Contents Figures

xxviii Experion Series C I/O User's Guide R311.2 Honeywell May 2009

Figure 76 GI/IS Grounding and power connections.........................................................3 Figure 77 Mounting a module onto an IOTA....................................................................3 Figure 78 DI module switch setting..................................................................................3 Figure 79 Inserting the terminal plug into the isolator ......................................................3 Figure 80 CC-GAIX11 Analog Input IOTA .......................................................................3 Figure 81 CC-GAIX11 Analog Input IOTA connection diagram.......................................3 Figure 82 CC-GAIX21 Analog Input IOTA .......................................................................3 Figure 83 CC-GAIX21 Analog Input IOTA connection diagram.......................................3 Figure 84 Transmitter Field Wiring to CC-GAIX11/GAIX21 IOTAs..................................3 Figure 85 Analog Input - MTL4541 and MTL4544 isolator LED indicators......................3 Figure 86 Temperature - MTL4575 isolator LED indicators.............................................3 Figure 87 CC-GAOX11 An

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