Honeywell CC-TCNT01 Controller Module

The Honeywell CC-TCNT01 is a powerful process controller module designed for use in Honeywell's distributed control systems (DCS), particularly within the Experion platform. Engineered for high availability and deterministic performance, this module executes control strategies, manages I/O communication, and ensures continuous operation even in the most demanding industrial environments. Its robust architecture and advanced features make it a cornerstone of modern process automation.

Overview and Core Architecture

The CC-TCNT01 controller is built around a high-performance processor optimized for real-time control applications. It runs a hardened real-time operating system that guarantees deterministic execution of control loops, logic sequences, and data handling tasks. The module includes substantial onboard memory for application storage, historical data buffering, and firmware. Its design supports redundant configurations, where two identical controllers operate in parallel to provide bumpless failover, ensuring uninterrupted process control.

Key Technical Specifications

Communication and Networking

The CC-TCNT01 features multiple high-speed communication interfaces for seamless integration:

• Two independent Gigabit Ethernet ports supporting industrial protocols: PROFINET, EtherNet/IP, Modbus TCP, and OPC UA

• Redundant Ethernet support for fault-tolerant network connections

• Serial ports for legacy device connectivity (Modbus RTU, ASCII protocols)

• USB port for local programming, data transfer, and firmware updates

• Backplane interface for high-speed communication with I/O modules and other controllers

Redundancy and High Availability

Designed for mission-critical processes, the CC-TCNT01 supports full controller redundancy. In a redundant pair, both controllers run identical programs and maintain synchronized data. The primary controller executes control, while the secondary tracks its state. Upon detection of a fault, the secondary assumes control without any bump or interruption. This feature is essential for applications where downtime is unacceptable, such as refining, power generation, and chemical production.

Software and Engineering

The controller is fully supported by Honeywell's Experion engineering suite, including Control Builder and SCADA tools. Engineers can develop control strategies using IEC 61131-3 languages (LD, FBD, ST, IL, SFC) and advanced function blocks for PID, motor control, and valve positioning. The module also supports Honeywell's Profit Loop and other advanced process control (APC) algorithms. Configuration is straightforward, with automatic discovery of I/O modules and built-in simulation capabilities for offline testing.

Applications

The CC-TCNT01 is deployed across a wide range of industries for various control tasks:

• Oil and gas – wellhead control, pipeline monitoring, refinery process units

• Chemical – batch reactors, continuous distillation, blending systems

• Power – boiler control, turbine management, emissions control

• Pharmaceutical – fermentation, purification, CIP/SIP sequences

• Pulp and paper – digesters, paper machines, wastewater treatment

• Food and beverage – pasteurization, mixing, packaging lines

It can function as a standalone controller or as part of a larger DCS network, coordinating with other controllers, HMIs, and historians.

Reliability and Diagnostics

The CC-TCNT01 incorporates extensive diagnostic features to maximize uptime. It continuously monitors its own health, including CPU load, memory usage, and communication integrity. Any anomaly is logged and reported to the system console. The module also performs cyclic checks on configuration data and firmware integrity. For redundancy, both controllers continuously exchange heartbeat signals and status information. In case of a detected fault, the system automatically initiates failover and alerts operators.

Installation and Maintenance

The module installs into a standard Honeywell Series 8 I/O rack. It is hot-swappable, allowing replacement without powering down the rack (when used in redundant configuration or with proper precautions). Front-panel LEDs provide at-a-glance status: power, run, fault, and redundancy state. For non-redundant applications, the controller can be replaced during a scheduled outage. The module's rugged design meets ISA-S71.04 Class G3 for harsh environments, ensuring long-term reliability.

Certifications and Compliance

The Honeywell CC-TCNT01 carries necessary certifications for global deployment:

• CE – EMC and Low Voltage Directives

• UL/cULus – UL 61010-1, UL 61010-2-201

• FM – Class I Division 2 (optional)

• RoHS, REACH compliant

• Marine certifications (ABS, DNV-GL) available on request

These certifications ensure compliance with safety and environmental standards worldwide.