User Manuals: Honeywell 900U02-0100 IO Modules

Manuals and User Guides for Honeywell 900U02-0100 IO Modules. We have 1 Honeywell 900U02-0100 IO Modules manual available for free PDF download: User And Installation Manual

Honeywell 900U02-0100 User And Installation Manual (286 pages)

Process & Safety Controller

Brand: Honeywell | Category: Controller | Size: 5.96 MB

Notices and Trademarks
2
Symbol Definitions
6
Table of Contents
8
Introduction
15
Purpose
15
Model Selection Guide
16
Functional Description
22
Figure 1 - Small Controledge HC900 Controller Configuration
22
Figure 2 - Expanded Controledge HC900 Controller Configuration (C50/C70 CPU Only)
23
Figure 3 - Single Process with Redundancies
24
Feature Summary
26
Components and Architecture
29
Overview
29
Components
29
Figure 4 - Configuration with Multiple Controllers
30
Table 1 - Descriptions of Major Components (Figure 4)
31
Redundant Components
32
Figure 5 - Redundant Configuration with Multiple I/O Racks (Star Topology)
32
Figure 6 Redundant Configuration with Multiple I/O Racks (Ring Topology)
33
Table 2 - Descriptions of Major Redundancy Components
34
Hardware Components
35
Figure 7 - Controller Rack Components
35
Figure 8 - Redundant Controller Rack Components
36
Figure 9 - I/O Expansion Rack Components
37
Figure 10 - Rack Options
38
Figure 11 - Power Supply
39
Figure 12 - Power Status Module (PSM)
40
Figure 13 - Controller Module
41
Figure 14 - Redundancy Switch Module
42
Figure 15 - Scanner 1 Module
42
Figure 16 - Scanner 2 Module
43
Figure 17 - I/O Module Terminal Block
43
Figure 18 - RS-232 Modem Devices
44
I/O Network
45
Figure 19 - Controledge HC900 Controller Configurations
45
I/O Implementation Requirements Include
46
Ethernet Open Connectivity Network
46
Figure 20 - Modular Network Structure
48
Figure 21 - Modbus/Tcp Framing
49
Figure 22 - Typical Installation Using a Cable Modem
51
Serial Ports
52
Figure 23 - Controller Serial Ports
52
Table 3 - Serial Port DIP Switch Settings
53
Figure 24 - Serial Ports DIP Switch Default Settings
53
Network and Security Planning
54
Overview
54
Security Checklists
54
Backup and Restore
56
Physical and Environmental Considerations
57
Security Updates
58
Network Security
58
Figure 25: System Architecture
59
Figure 26: System with Safety Peer Communication
61
Controledge HC900 Security Features
62
Figure 27: Communication from Remote Location
62
Notices
63
Pre-Installation Planning
64
Overview
64
AC Power Supply Selection for Racks with I/O
64
DC Power Supply
66
Rack Orientation and Mounting
66
Figure 28 - Rack Dimensions
66
Figure 29 - Rack Dimensions with Reserve Power Supply
67
Figure 30 - Vertical Spacing of Racks (All Models)
68
Remote Termination Panels
69
Environment
69
Heat Rise De-Ratingpage
69
Installation in Hazardous Location
70
Table 4 - Power Applied, by Module Type
71
Figure 31 - AC Input Module De-Rating
72
Figure 32 - Power Supply De-Rating
72
Cable/Wiring Distance Planning
73
Electrical Considerations
74
Figure 33 - Cabinet Wiring, Single Chassis
75
Figure 34 - Cabinet Wiring, Multiple Chassis
76
Figure 35 - Redundant Power Supplies each with External Fuse and Switch
77
Table 5 - Guidelines for Grouping Wires
78
Figure 36 - Master Control Relay Wiring Example
80
Hardware and Wiring Requirements for Safety Configuration
81
Figure 37 - IO-V Function Block Connections
81
Figure 38 - Individual Series DO Connections
82
Figure 39 - Common Series DO Connections
82
System Monitor Function Blocks
83
Figure 40 - Series Relay for Analog Outputs
83
Rack Installation
84
Overview
84
Table 6 - Installation Tools
84
Table 7 - Site and Equipment Preparation
85
Mount Racks
87
Table 8 - Mount Racks
87
Assemble Controller Rack
89
Table 9 - Assemble C30/C50/C70 Controller Rack
90
Table 10 - Assemble C75 Controller Rack
93
Assemble I/O Expansion Racks
94
Table 11 - Assemble I/O Expansion Racks
94
I/O Module Installation and Wiring
96
Overview
96
Module Placement in Racks
96
Figure 41 - I/O Module Installation
96
Figure 42 - Terminal Block Styles
97
Remote Termination Panel (RTP)
98
Terminal Block-To-Field (Signal) Wiring
98
Table 12 - Minimum Recommended Wire Sizes
98
Figure 43 - Signal-Wire Grounding
99
Figure 44 - Wire-Shield Grounding
99
Figure 45 - Terminal Block Jumper Installation
100
Removal and Insertion under Power (RIUP)
101
Table 13 - RIUP: Potential Hazards and Recommended Actions
101
I/O Module Installation Procedures
102
Table 14 - Connect Input/Output Wiring
102
I/O Terminal Block Wiring Diagrams
109
Table 15 - Typical Thermocouple Resistance in Ohms Per Double Foot @ 68 Degrees F
109
Figure 46 - RTD Inputs
110
Figure 47 - Universal Analog Input Wiring Diagram
111
Figure 48 - Examples of RTD Input Wiring
112
Figure 49 - Analog Input Wiring - Eight Tcs
113
Figure 50 - Analog Input Wiring - Eight Resistance Inputs
114
Figure 51 - Analog Input Wiring - Eight Rtds
115
Figure 52 - Analog Input Wiring - Slidewire (Position Proportion Block)
116
Figure 53 - 16 Point High Level Analog Input Wiring
117
Figure 54 - 4 Channel Analog Output Wiring Diagram
118
Figure 55 - 8 Channel Analog Output Wiring Diagram
119
Figure 56 - 16 Channel Analog Output Wiring Diagram
120
Figure 57 - DC Input Module Wiring Diagram
121
Figure 58 - DC Input Module Jumper
122
Figure 59 - 32 Point DC Input Module Wiring
123
Figure 60 - AC Input Module Wiring Diagram
124
Figure 61 - AC Input Module Jumper
125
Figure 62 - AC/DC Isolated Input Module
126
Figure 63 - AC/DC Isolated Input Module Wiring
127
Figure 64 - Contact Input Wiring Diagram
128
Figure 65 - DC Output Module Wiring Diagram
130
Figure 66 - DC Output Jumpers
130
Figure 67 - 32 Point DC Output Module Wiring
131
Figure 68 - AC Output Module Wiring Diagram
133
Figure 69 - AC Output Module Jumper
133
Figure 70 - Schematic Example: Relay Output and External Wiring
134
Figure 71 - Relay Output Module Wiring Diagram
135
Figure 72 - Relay Output Module Jumpers
136
Figure 73 - Pulse Counting Wiring
137
Figure 74 - Pulse Output Wiring
138
Figure 75 - Frequency Wiring
138
Figure 76 - Quadrature, Differential, External Power Wiring
139
Figure 77 - Quadrature, Single Ended, External Power Wiring
139
Figure 78 - Quadrature, Differential, Controledge HC900 Power Wiring
140
Figure 79 - Quadrature, Single Ended, Controledge HC900 Power Wiring
140
Figure 80: Safety UIO with Power Wiring
141
Table 16 - AI Channel
143
Figure 81 - Standard 2 Wire Transmitter with UIO
144
Figure 82 - Self-Powered 3-Wire Transmitter with System Ground
145
Table 17 - Field Wiring for Analog Output
147
Overview
153
Wiring and Cabling
153
Table 18 - Connect Communications Wiring and Cabling
153
Table 19 - Links to Controller Communication Ports
154
Connecting the Operator Interface to the Controller
156
Table 20 - Parts Needed to Make RS-485 Cable
157
Table 21 - Null Modem Cable Connections
159
Connecting the Controledge HC900 Controller to Modbus Device(S)
176
Operating Characteristics
179
Introduction
179
Overview
179
Power down / Power up
179
Controller Modes
182
Table 24 - Controller Operating Modes
185
Table 25 - Mode Switch Functions
189
Table 26 - Controller Behavior in Mode Transition
190
File Download/Upload Functions
191
Table 27 - Configuration File Downloading
192
Redundant Operating Characteristics
193
Overview
193
Start-Up
193
Modes of Operation (Figure 100)
193
Steady State Operations
195
Failover
197
File Download/Upload Functions
197
Diagnostics and Troubleshooting
199
Overview
199
External Indications of Diagnostic Information
199
Controller CPU Indicators
200
Table 29 - Controller Status LED Diagnostics
203
Scanner Indicators
211
Table 30 - LED Indications on Scanner Module
212
Table 31 - Scanner LED Diagnostics
212
I/O Module Indicators
216
Table 32 - LED Indications on I/O Module
216
Table 33 - I/O Module LED Diagnostics
217
Table 34 - Bad I/O Channel Diagnostics
218
Table 35 - LED Indications on Ethernet Switch
220
Analog Calibration
221
Overview
221
Removal and Replacement Procedures
225
Overview
225
Safety Considerations - PLAN AHEAD
225
Table 36 - Power Supply Replacement (All Except C75)
226
Table 37 - Controller Module Replacement
227
Table 38 - Scanner Module Replacement
228
Table 39 - RIUP: Potential Hazards and Recommended Actions
229
Table 40 - I/O Module Replacement
230
Figure 106 - Battery Life in Months
232
Table 41 - Installing Backup Battery (CPU Not Initialized)
233
Table 42 - Replacing a Backup Battery (CPU Powered))
234
Specifications
235
General Specifications (Refer to Specification Manual)
235
Table 43 - Controledge HC900 PV Input Types and Ranges
235
System Sizing and Availability Summary
238
Table 44 - System Size and Availability Summary
238
Extended Distance Configuration with Fiber Optics
239
Figure 107 - Extended Distance Example #1
239
Figure 108 - Extended Distance Example #2
240
Appendix - Installation of Remote Termination Panels (Rtps)
241
Overview
241
Analog Input
241
Relay Output
241
Figure 109 - Example Installation
241
Analog Input/Digital Input/Digital Output/Analog Output
242
Figure 110 - Analog Input Terminals
244
Figure 111 - Two-Wire Transmitter Connections with Common 24 VDC Supply
244
Figure 112 - Milliamp Input Connections with 250 Ohm Shunt Resistance
245
Figure 113 - Volt, Millivolt Input Connections
245
Figure 114 - Three-Wire RTD Input Connections
246
Figure 115 - Two-Wire RTD or Ohm Input Connections
246
Figure 116 - Slidewire Feedback Connections for Actuators
246
Figure 117 - Voltage Input Connections
270
Figure 118 - Current Connections with 2-Wire Transmitter
271
Declaration of Conformity
279
ATEX Certification
280

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User Manuals: Honeywell 900U02-0100 IO Modules

Honeywell 900U02-0100 User And Installation Manual (286 pages)

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