HC900 Process & Safety Controller User and Installation Manual

Functional Description

All Controllers

The Honeywell HC900 Process Controller is an integrated loop and logic controller that is designed specifically for small-and medium-scale unit operations

It comprises a set of hardware and software modules that can be assembled to satisfy any of a broad range of process control applications. The HC900 Process Controller can consist of a single rack, as indicated in Figure 1, or can be can be networked with other controllers via Ethernet links to expand the dimensions of control over a wider range of unit processes, as indicated in Figure 2.

Although the HC900 E1/E2 ports provide protection against Cyber-security/DOS type attacks, additional protection is required for safety applications using a firewall device configured to prevent uncontrolled messages into the controller. Please refer to Ethernet Devices/Considerations Section in this manual for further information. The figures in this manual assume the firewall is installed properly above the controller's Ethernet connection(s) E1 and E2.

The HC900 Controller design enables users and OEMs who are adept in system integration to assemble a system that fits a broad range of requirements. Any configuration can be readily modified or expanded as requirements dictate. In initial configuration and in subsequent modifications, the HC900 Controller affords an optimum balance of performance and economy.

Configurations such as those shown in Figure 1 and in Figure 2, as well as many variations, can be assembled from modular components. Many of the components are available from Honeywell, and some are available from third-party suppliers. These modular components are available in any quantity and mix that make the most sense for a given application.

As indicated in Figure 3, the HC900 Controller includes provisions for communication via Ethernet with host systems such as the Honeywell Experion HMI and other HMI software that supports Ethernet Modbus/TCP protocol. Also, the communication structure of the HC900 Controller enables remote placement of input/output components, allowing significant economies in cabling and wiring.

 Redundant CPUs - Redundancy is provided by two C75 CPUs operating in a controller rack; this rack has no I/O. A Redundancy switch module (RSM) sits between the CPUs.

 Redundant CPU Power - Two power supplies, P01 and P02 one for each C75 CPU. Model numbers are 900P01-0101, 900P01-0201, 900P02-0101, 900P02-0201

 Redundant CPU-I/O connection – Each CPU has its own 100 base-T Ethernet physical communication link with one or more racks of I/O. Multiple I/O racks require Ethernet switches.

 I/O racks – 5 racks shown, top to bottom: 4-slot w/1 power supply, 8-slot w/1 power supply, 12-slot w/1 power supply, 8-slot w/redundant power supplies, 12-slot w/redundant power supplies. A Power Status Module (PSM) is required with redundant power supplies. High and low capacity power supplies are available.

 Dual Networks for Host communications - Dual Networks for Host communications are provided on the C75 CPU. Both network ports are continuously active on the Lead controller. The network ports on the Reserve CPU are not available for external communications. Experion HS and the 900 Control Station (15 inch model) support Dual Ethernet communications and automatically transfer communications to the opposite E1/E2 port during a network failure. Connections to these ports are to be considered part of the control network layer and as such care must be taken to reduce exposure to uncontrolled/ unknown network communications. A properly configured firewall such as the MOXA EDR-810 is recommended to help mitigate the exposure.

 Scanner 2 module – has 2 ports, one for each CPU connection to I/O. This IO network between the controllers and scanners is considered proprietary with no other Ethernet traffic.

Feature Summary

Hardware

 Modular rack structure; components are ordered individually as needed

 CPU with Ethernet and isolated RS485 communications

 Easy to assemble, modify, and expand

 C30 and C30S controllers provide local I/O connections while C50/C70 and C50S/C70S Controllers provide for remote input/output rack connections over a private Ethernet-linked network

 Parallel processing - a microprocessor in each I/O module performs signal processing, to preserve update rates

 Power supplies - provide power to CPU rack and Scanner I/O racks

Redundancy

 Redundant C75 CPU

 Redundancy Switch Module (RSM) – required between redundant CPUs

 Redundant Power Supply – provides redundant power to any CPU rack or Scanner2 I/O rack

 Power Status Module (PSM) – required when using a second power supply in Scanner2 I/O rack

Communications

All CPUs (except where noted):

 Serial Ports:

 Legacy

 Two serial ports, configurable for RS-232 or galvanically isolated RS-485 communications.

 RS232 port can be used for link to PC for 900 Designer configuration tool (up to 50ft/12.7 Meters) or via modem. Also can be configured for Modbus RTU, master or slave.

 RS 485 port used for 2 wire link to legacy operator interface (ELN protocol) or can be configured for Modbus RTU, master or slave communications (up to 2000 Ft /600 Meters).