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Honeywell ControlEdge 900 platform Hardware Planning And Installation Manual

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ControlEdge 900 Platform
Hardware Planning and Installation
Guide
HWDOC-X430-en-J
November 2018
ControlEdge PLC
ControlEdge UOC
Table of Contents
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Summary of Contents for Honeywell ControlEdge 900 platform

  • Page 1 ControlEdge 900 Platform Hardware Planning and Installation Guide HWDOC-X430-en-J November 2018 ControlEdge PLC ControlEdge UOC...
  • Page 2 In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The information and specifications in this document are subject to change without notice.

  • Page 3: Table Of Contents

    Contents CONTENTS Contents Chapter 1 - About this guide Chapter 2 - Overview Chapter 3 - ControlEdge PLC PLC I/O Network Topology Hardware Configuration of CPM Hardware Configuration of EPM Hardware Configuration of IO Device Replacement Chapter 4 - ControlEdge UOC UOC I/O Expansion Network Topology HSR Ring to 900 I/O Non-Redundant or Redundant Star to 900 I/O...

  • Page 4: Table Of Contents

    Contents Expansion Processor Module Serial Communication Module ControlEdge 900 I/O Terminal block styles Terminal Block-to-Field (Signal) Wiring Chapter 6 - Wiring and cabling planning Electrical considerations Wiring and cabling distance guidelines Chapter 7 - Maintenance Safety considerations - PLAN AHEAD! Periodic checks Removal and Insertion Under Power (RIUP) Replacing the power supply...

  • Page 5: Table Of Contents

    Contents CE LVD and EMC Compliance Standards UL Compliance Standards Appendix A - Installing RTP Overview of RTPs RTP Dimension Using the RTP to field wire the IOMs Using an RTP to field wire the UIO Using an RTP to field wiring the UAI Using Dual RTPs to field wiring the 16 Point AI Using an RTP to field wiring the 16 Point AC DI Using an RTP to field wiring the 16 Point DC DI...
  • Page 6 Contents...

  • Page 7: Chapter 1 - About This Guide

    CHAPTER ABOUT THIS GUIDE Scope This guide describes how to set up the ControlEdge 900 platform and install UOC or PLC. Revision history Revision Date Description September Initial release of document 2016 November Update for PLC R130.2 Release including: 2016 Delete the Self-powered 3–wire transmitter for UIO AI,...
  • Page 8 Quadrature Input and Pulse Output Serial Communication Module EtherNet/IP Intended audience This guide is primarily intended for Honeywell field personnel who do hardware planning, installation, operation, and maintenance for the Honeywell ControlEdge™ 900 Controller. Related documents The following list identifies publications that may contain information relevant to the information in this document.
  • Page 9 Chapter 1 - About this guide PLC document Doc Name ControlEdge Builder User’s Guide RTDOC-X283 ControlEdge Builder Function and Function Block Configuration RTDOC-X286 Reference Guide ControlEdge Builder Protocol Configuration Reference Guide RTDOC-X288 ControlEdge PLC and ControlEdge RTU Network and Security RTDOC-XX75 Planning Guide ControlEdge EtherNet/IP User's Guide...
  • Page 10 Chapter 1 - About this guide Item Description ControlEdge ControlEdge 900 controllers running the Honeywell control execution environment (CEE) configured with Experion Control Builder. Special Terms The following table describes the commonly used industry-wide and Honeywell-specific terminology: Terminology Description Analog Input...
  • Page 11 Chapter 1 - About this guide Terminology Description Human Machine Interface High Availability Seamless Redundancy I/O Rack ControlEdge 900 form factor rack with 4, 8, or, 12 I/O slots and one slot for non-redundant CPM or EPM. Programmable Logic Controller Power Status Module Power Supply Unit Printed Wiring Assembly...
  • Page 12 Chapter 1 - About this guide...

  • Page 13: Chapter 2 - Overview

    ControlEdge platform, both PLC and UOC. How to Use this Guide The following table outlines the tasks involved in planning and installing a Honeywell ControlEdge 900 Controller. The links provided will navigate the user through those tasks.
  • Page 14 Chapter 2 - Overview Revision PLC Specific UOC Specific Check the model number of See the section Spare parts and model numbers the hardware components Plan the architecture of the See the section System See the section System system architectures planning architectures Understand and plan the See the section...

  • Page 15: Chapter 3 - Controledge Plc

    CHAPTER CONTROLEDGE PLC Honeywell ControlEdge 900 family comprises a set of hardware and software enabling users and OEMs to assemble a system that fits a broad range of requirements. Any configuration can be readily modified or expanded as requirements dictate.
  • Page 16 Modbus TCP Slave OPC UA Server HART IP ControlEdge Builder Controller Configuration protocol Privacy protocol SNTP (if NTP server is enabled) Destination DHCP for uplink Modbus Master and OPC UA Client that configured in the relative function blocks CDA Responder The port number can be configured in ControlEdge Builder, and see the following table for the default port numbers.
  • Page 17 I/O Network In the I/O network used to connect the PLC-CPM to expansion I/O racks via the EPM, two network topologies are supported in the network: Ring and Star. Up to 144 I/O modules can be configured. Rationale: 12 racks x 12 modules per rack.
  • Page 18 Figure 3-2: System architecture with redundant PLC-CPM Physical cabling/connection of the nodes forming the ring, applicable to the purple HSR/Ring topology on the right side of the above illustration, must be connected as follows: CPM port 3 (ETH3) must be connected to CPM port 4 (ETH4) or EPM port 2 (ETH2).
  • Page 19 Power Status Module (PSM) on 8- and 12-slot I/O rack. A Power Status Module (PSM) is required with redundant power supplies. Redundant CPM Honeywell 1 Redundant Controller Rack Rack 2 Power Supplies 2 CPMs: Redundancy is provided by two CPMs operating in a Redundant Controller Rack;...
  • Page 20 (Optional) 900 Controllers, and other networks from (including Internet). Typically includes HMI Honeywell or operating software which includes from third- configuration tool from Honeywell. party supplier. Configuration Connects from ETH1/ETH2 of the certain Configuration Station CPM or network switch linking CPMs.
  • Page 21 Component Item Description Source Name Switch or 100Base-T Ethernet devices in an Ethernet Router/Firewall network. Devices include other ControlEdge 900 Controller, HMIs, and includes routers, servers, and other devices in wider networks. Use of a properly configured firewall provides a more robust network limiting exposure to uncontrolled network traffic.

  • Page 22: Hardware Configuration Of Cpm

    Hardware Configuration of CPM Control Processor Module A Redundant Controller Rack contains two CPMs. Either CPM can be primary. The CPM is shown in the following figure: Figure 3-3: Control Processor Module As indicated in this figure, CPM includes: Table 3-4: CPM Components Item Description Status LED indicator for the CPM.
  • Page 23 Item Description ETH1 and ETH2 host ports to PC applications and/or other CPMs, or other devices. ETH3 and ETH4 ports connect to the Ethernet ports of EPM, switch (for star topology), or CPM. Ethernet LED status indicators for communications functions. For more information, see CPM Indicators section.
  • Page 24 in REMOTE position, the operating modes can be configured in the Configuration tool. For more information for the operating modes, see “Selecting operating modes” in ControlEdge Builder User’s Guide. ATTENTION: For redundant controller system, the position of mode switch in primary PLC-CPM in this box determines the system operating mode.
  • Page 25 PLC-CPM Indicators The following diagram displays the location of the LED indicators on the CPM. The following table explains the meaning of each LED state. Figure 3-6: LED Indicators on PLC-CPM...
  • Page 26 Table 3-5: LED Indications on PLC-CPM Item LED Description State/Color Status No Power is applied to CPM. On/Green The controller is working normally. On/Red The controller is stopped. On/Orange The controller is in power-up process. Blinking Red The controller is running with error. @ 1HZ Blinking Red The controller is accessible via online...

  • Page 27: Hardware Configuration Of Epm

    Item LED Description State/Color 4, 6, Ethernet Port Green On for connection; Off for no Link/ Active ( On/Off/ connection; and blinking for activity Lower LED) Blinking Hardware Configuration of EPM Refer to the common section. Hardware Configuration of IO Refer to the I/O module type section.
  • Page 28 current configuration is available. It is recommended to bring the process to a safe and orderly shutdown. You will need a #2 Phillips screwdriver. To replace a non-redundant or unsynchronized primary PLC-CPM 1. If a process is currently in operation, bring it to the safe mode, and orderly shutdown if it is required.
  • Page 29 PLC/RTU" in ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information. 14. Optional-for IPsec enable system, enable the IPsec in the PC installed the ControlEdge Builder. See "Enable IPsec policy on PCs" in ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.
  • Page 30 8. Set the new CPM’s mode switch position to STOP (to enable firmware update). 9. Using an external (user-supplied) switch, re-connect the power supply in the rack (associated with the new CPM) to the source main power. 10. Optional-for IPsec enable system, setup certificates and IPsec policy in the CPM.
  • Page 31 Replacing a synchronized primary PLC-CPM 1. [Optional] It is recommended to first transition the synchronized primary CPM into the secondary role by issuing the redundancy switchover command from ControlEdge Builder. This step {1} transitions the synchronized secondary (redundant partner) CPM into the primary role and {2} the CPM to be replaced restarts into the secondary role.
  • Page 32 Following section provides information about replacing EPM, I/O Module and Spare parts that are common to both PLC and UOC. Table 3-6: Component Replacement Reference Component Reference replacement For information about replacing EPM, see the section device replacement. I/O Module For information about replacing I/O Module, see the section module replacement.

  • Page 33: Chapter 4 - Controledge Uoc

    SD card slot on CPM is currently not utilized and is reserved for use in future. The CPM Mode switch is not utilized by UOC firmware. Honeywell recommends that it be covered using (HW part number, if available) after conversion of the PLC CPM into a UOC CPM.

  • Page 34: Uoc I/O Expansion Network Topology

    Hardware configuration of EPM Hardware configuration of I/O module type Device Replacement UOC I/O Expansion Network Topology UOC has four Ethernet ports. Port 3 and 4 are used to connect to I/O network, used for I/O. Table below shows UOC supported these network topologies.
  • Page 35 following diagram for the case of a redundant UOC rack with two UOC CPMs connecting to two, 4-I/O slot, non-redundant racks, each with its own EPM. Also shown are the CPM’s connection of ETH1 to the A, Yellow FTE network tree and ETH2 to the B, Green FTE network tree.

  • Page 36: Non-Redundant Or Redundant Star To 900 I/O

    Component Comments Type EPMs be set to indicate I/O network connectivity. This is done by setting it to position 3. The IP address of the EPM is assigned by the UOC CPM based on the module number set on the 10X and 1X rotary switches. Ensure that the values within the range of 1-12 are used, as these are the valid values.
  • Page 37 Redundant Star Network The UOC does not support star topologies which mix redundant and non-redundant connectivity. Downlink star networks must be set up as exclusively redundant or exclusively non-redundant. Considerations for components that connect to a UOC’s downlink non-redundant or redundant star network are summarized in the following table.

  • Page 38: Dlr Direct Connection To 900 I/O And Eip Devices

    DLR network contain a maximum 50 IP address nodes (This is Honeywell specification). DLR network should have at least one node configured as ring supervisor. If there are multiple nodes configured as supervisor, then the node with highest supervisor precedence value becomes active supervisor, others will be backup Supervisors.

  • Page 39: Dlr Etap Connection To 900 I/O And Eip Devices

    Downlink DLR Network DLR ETAP Connection to 900 I/O and EIP Devices As an alternative to an HSR ring network with only ControlEdge 900 I/O, UOC can optionally be connected to an EtherNet/IP-based I/O, device and PLC ring network through its ETH3 downlink port. Under that configuration a UOC can communicate simultaneously with ControlEdge 900 I/O and third party devices attached to the same EtherNet/IP network.
  • Page 40 Installation and maintenance practices for the UOC’s downlink EtherNet/IP network generally follow those described in (EtherNet IP User's Guide) for topology 2, “C300 Through EIM To EtherNet/IP”. Additional considerations for components that connect to the EtherNet/IP network are summarized in the following table. Component Comments Type...

  • Page 41: Non-Redundant Star To 900 I/O And Eip Devices

    Component Comments Type connects to UOC. All device IP addresses must be statically assigned. For further information, see EtherNet IP User's Guide_EPDOC-X399- en-510A.pdf. Allen Bradley The Rockwell Allen Bradley OPC Server from MatrikonOPC can be OPC Server installed on the Experion Server in systems which incorporate UOC. from The Matrikon OPC Server enables one of two methods whereby MatrikonOPC...
  • Page 42 UOC CPM to 900 I/O and EIP Devices Installation and maintenance practices for the UOC’s downlink EtherNet/IP network generally follow those described in EtherNet IP User's Guide_EPDOC-X399-en-510A.pdf for topology 2, “C300 Through EIM To EtherNet/IP”. Additional considerations for components that connect to the EtherNet/IP network are summarized in the following table.

  • Page 43: Hardware Configuration Of Uoc-Cpm

    Component Comments Type EPMs while its ETH2 port is left disconnected. Before it is inserted into its slot, the 100x rotary switch on the EPM board must be set to indicate the type of network connectivity in use. This is done by setting it to position 4.
  • Page 44 Control Processor Module A Redundant Controller Rack contains two CPMs. Either CPM can be primary. The CPM is shown in the following figure. Figure 4-1: Control Processor Module As indicated in this figure, CPM includes: Table 4-2: Control Processor Module Components Item Description Status LED indicator for the CPM.
  • Page 45 Item Description downlink network for ControlEdge 900 Expansion I/O racks or third party I/O. Only ring network topologies are supported. Ethernet LED status indicators for communications functions. Refer to UOC User’s guide for detailed information. CAUTION: Do not remove or insert the Ethernet connection when the CPM is powered unless the installation is in a hazardous area.

  • Page 46: Hardware Configuration Of Uoc Epm

    The secondary controller of a redundant controller pair is configured with the even Device Index that is consecutive with its primary partner’s Device Index (i.e. primary controller Device Index plus 1) Set the Device Index (FTE DEVICE INDEX) by turning the three rotary decimal switches (range 001 to 509).

  • Page 47: Device Replacement

    Modules Types Currently, only the ControlEdge 900 UIOM is supported. Refer to the I/O module type section. Device Replacement CAUTION: Explosion hazard. Removal and Insertion Under Power is not supported in Division 2/ Zone 2. CPM and/or EPM removal under power is not supported. The up/down rocking motion required to remove the module causes intermittent communications to other modules resident in the same rack.
  • Page 48 To replace a non-redundant or unsynchronized primary CPM: 1. If a process is currently in operation, bring it to the safe mode, and orderly shutdown if it is required. 2. Using an external (user-supplied) switch, disconnect the power supply in the rack from the source main power. 3.
  • Page 49 1. [Optional] It is recommended to disable and prevent synchronization first by issuing the redundancy disable synchronization command from Control Builder. 2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power.
  • Page 50 replaced component through Control Builder. Wear an ESD wrist strap and observe static precautions.  You will need a #2 Phillips screwdriver. To replace an unsynchronized primary UOC-CPM: It is recommended to first establish redundancy synchronization between the redundant controllers (when possible) and follow the procedure to replace a synchronized primary UOC-CPM below.
  • Page 51 9. Use the Firmware Manager to laod firmware to the new CPM to match the version that is running in the primary redundant partner CPM. 10. Check the redundancy synchronization state by monitoring the role LED of the primary or secondary CPM. To replace an unsynchronized primary CPM,: Refer to Replacing a non-redundant UOC-CPM section for this information.

  • Page 53: Chapter 5 - Controledge 900 Common Reference Information

    CHAPTER CONTROLEDGE 900 COMMON REFERENCE INFORMATION This section is applicable to both UOC and PLC systems and provides the following information: Installation Wiring and cabling planning Maintenance Diagnostics and Troubleshooting Special Condition of Use and Approved Standards Installation The topics covered in this chapter are: See "Rack options"...
  • Page 54 8-slot or 12-slot I/O rack with non-redundant power supply 8-slot or 12-slot I/O rack with redundant power supply A Power Status Module is required if the I/O rack with redundant power supply is used. Figure 5-1: Rack Options Additionally, to eliminate single point of failure, you can also use the dual rack redundancy solution.

  • Page 55: Rack Types

    You can also use two Fiber Optics modules between the Redundancy Modules to extend the distance to 500m (Multi-mode Transmission Distance) or 10Km (Single-mode Transmission Distance). Rack Types ControlEdge 900 Controller supports the following types of racks: Redundant Controller Rack Non- redundant Rack, containing 4, 8 or 12 I/O slots (Containing 1 CPM or EPM and 4, 8, or, 12 I/O slots) –...
  • Page 56 Figure 5-2: Rack Types Installation Category II, Pollution Degree 2, IEC 60664-1, UL840 Installation coordination.
  • Page 57 One Slot Rack, 1 CPM/1 EPM, 1 P/S, 1 RM...
  • Page 58 Redundant Controller Rack Redundant Controller Rack is shown in the following figure. Figure 5-3: Redundant Controller Rack Components As indicated in Redundant Controller Rack Components section, the Redundant Controller Rack includes: Item Description Redundant Controller Rack Redundant Switchover Module Slot Filler Two CPMs (Redundant Primary and Secondary) Two Power Supplies...
  • Page 59 One Slot Rack...
  • Page 60 I/O rack I/O rack can include a topology with; either a non-redundant power supply or with redundant power supplies, accommodate a CPM or an EPM, and additional input/output modules. The I/O rack inserted with an EPM enables I/O modules to be located close to the field devices and remote from the CPM.
  • Page 61 Table 5-1: I/O Rack Componets Item Description Rack, available in 4-, 8- or 12-slot versions Power Supply CPM or EPM with Security Cover Grounding bars (for I/O wiring; optional; required for safety applications) Input/Output modules I/O Terminal Blocks Power Status Module (PSM) (required if using redundant power supply) Rack orientation and mounting Racks must be mounted horizontally and must never be mounted with the backplane flat on a horizontal panel or tabletop.
  • Page 62 Figure 5-7: Rack dimensions with redundant power supply...
  • Page 63 Table 5-2: Rack size I/O Slot Option Height Width Depth Comments 4-slot 5.4" 10.5" 6.0" Rear mounting plate extends height to 6.9” (175mm) 8-slot 5.4" 16.5" 6.0" 8-slot with redundant 5.4" 20.9" 6.0" power supply 12-slot 5.4" 22.5" 6.0" 12-slot with redundant 5.4"...

  • Page 64: Rack Installation

    Rack installation This section contains procedures for installing the racks. It is recommended that the information in this section be reviewed before beginning the installation to help to prevent errors and promote efficiency. Pre-requisites Before the installation of the racks and modules, check that the required tools and equipment’s are prepared.
  • Page 65 Table 5-3: Installation tools Types Item Description Common Wire strippers For Power Supply and for I/O tools Wiring Crimper For Terminal Lugs on Power Supply wiring and on I/O wiring shields Screwdrivers Small flat-tip For Euro-style Terminal Blocks Small/medium flat-tip or #2 For Barrier style Terminal blocks;...
  • Page 66 For more Step Procedure information, see Installing I/O Install (or verify correct installation of): modules section External disconnect switches Fuses at the power source associated with input sensor or output devices for I/O modules Arrange and organize items to be installed at or near enclosures.
  • Page 67 Dimensions and drill patterns are shown here: b. Drill and tap for # 10 (or M4) screws. c. Start the mounting screws (supplied by the user) in the drilled holes. d. Hang the Rack on the screws at the top. e.
  • Page 68 included, attach them with two M3 screws (supplied with grounding bars in plastic bag), as shown below. ATTENTION: The plastic bag also includes four M4 screws for attaching the grounding wire lugs, which are attached later. Attach the M4 screws loosely to the grounding bars for safe keeping.
  • Page 69 4. Repeat for each rack in the system. Module Insertion When inserting a module, carefully align the card with the rack. Press the module to ensure that the backplane connector is fully inserted. Secure the module to the rack using the top and bottom screws. Ensure that the screws are properly secured.
  • Page 70 1. Carefully place the Power Supplies in the slots in the Rack. 2. Make sure that the connector at the back seats properly. Insert a flat blade in the slots at the top and bottom of the power supply cover while pulling backward to open the cover. 3.
  • Page 71 ATTENTION: It is recommended each power supply should be powered from a separate power source and a power switch should be installed to allow for servicing of each Processor/Supply separately. 4. Ensure that wiring to the Power Supply is disconnected from the site source, and then connect the AC or DC wiring to the power supply as shown below.
  • Page 72 ATTENTION: The Yellow/Green wire is supplied with the power supply. The nuts (w/star washers) for the grounding stud are on the stud. For AC power supply use 3.0A, slow- blow for 115V AC operation for each line; 2.5A, slow-blow for 230V AC operation. For DC power supply use 7.0A slow- blow.
  • Page 73 CAUTION: Ensure that AC power to the rack is disconnected. Insert the Filler plate in the middle slot and attach with screws at top and bottom. 6. Insert the Filler block cover in the middle slot and attach with screws at top and bottom. Assembling I/O rack To assemble the I/O rack assembly: 1.
  • Page 74 4. Install EPM or CPM as required. Install EPM: a. Set the EPM address and network topology for the I/O rack using the rotary switches, as shown below. TIP: Set the 10x and 1x switches to the two digit address ranging from 01 to 99. The lower switch (10x) is used to set the tens digit and the upper switch (1x) sets the ones digit.
  • Page 75 c. Insert the Ethernet cables, and mount the security cover for the EMP.
  • Page 76 Optional, mount a wire security seal. The user should get a wire security seal themselves.

  • Page 77: Power Supply

    Install CPM: insert CPM to the right of the power supply, and secure it in place with the two captured screws in the faceplate. Set the mode switch, insert the SD card and the Ethernet cables, and mount the security cover for the EMP. Optional, mount a diameter 0.6 mm wire security seal.
  • Page 78 Figure 5-10: AC Power Supply Figure 5-11: DC Power Supply As indicated in the figures, the power supplies include:...
  • Page 79 Table 5-5: Power Supply Components Item Description Voltage test points AC/DC Input terminal block Wiring label Grounding lug (Reference; lug is not part of power supply; it is mounted to bottom of rack.) Table 5-6: Specification of power supplies Item AC power supply DC power supply Input voltage...
  • Page 80 B: Max C: Max Calculate A: Enter Calculate Module Current Current Quantity 5V current @ 5V @ 24V current (E (D = A * B) = A * C) 500mA 0mA ( 0 ) 22 mA 0 mA ( 0 ) 0 mA* ( 0 ) 40 mA...

  • Page 81: Environmental Considerations

    The product is only used indoors. The CPM must be mounted in suitable equipment enclosures. That is, all components such as the Redundant Controller Rack and I/O rack manufactured by Honeywell must be mounted in approved furniture designed for industrial applications.

  • Page 82: Power Status Module

    Power Status Module The Power Status Module (PSM), shown in the following figure, sits between redundant power supplies on the I/O rack. It is a status module for both power supplies and indicates which are powered, PS- 1 (left) or PS-2 (right) or both (typical). When the status indicator for either or both of the power supplies is lit, it is reporting that the status of the associated power supply is good and that the outputs are within specified limits.
  • Page 83 It is installed in the expansion I/O rack and provides the link between the CPM and remote I/O modules. Features at the front of the module include: Table 5-9: Expansion Processor Module Components Item Description Status LED indicator for EPM functions. For more information, see Indicators section.

  • Page 84: Serial Communication Module

    Serial Communication Module The rack-slot based serial communication module is used to communicate to serial based controllers. The module can be used to communicate to Modbus RTU Slave, Modbus RTU Master, Modbus ASCII Slave, Modbus ASCII Master and user defined protocol type devices.
  • Page 85 Item Description Communication Module Indicators" on page 1 for more information. RS485 Ports (two) CAUTION: Do not remove or insert the serial communication connection when the Serial Communication Module is powered unless the area is known to be non-hazardous. Table 5-11: RS485 Pin definition Type Description Output...
  • Page 86 Figure Definition Type Description Input Date carrier detect Input Receive data Output Transimit data Input Data terminal ready GND_ISO1 Input Isolated ground Input Data set ready Output Request to send Input Clear to send Male DB9 Input Ring Input Application cable: RS232 port connect to Male DB9 connector: As below figure shows, cable require Female-Female cross connection:...

  • Page 87: Controledge 900 I/O

    The application cables are not supplied by Honeywell, and you could prepare them by yourself. ControlEdge 900 I/O The configuration and operation of the I/O expansion network is automatic, it is entirely under control of built-in private software that resides in the CPM and in each EPM included in the ControlEdge 900 Controller system.
  • Page 88 Each slot in a rack includes a set of guides that locate the circuit board in the rack, and a pin socket in the backplane that receives the associated pin plug at the back of the I/O module. At the front of each I/O module, a pin plug receives the associated socket on the back of a terminal block.
  • Page 89 I/O Module Specification ControlEdge PLC supports various input/output modules. This section provides technical information to configure ControlEdge PLC IO Modules. The following IO modules are included: Universal Input/output module, 16 channel Universal AI – RTD,TC,V 8 Channel Analog Input High Level, 16 Channel Analog Output, 4 Channel Analog Output, 8 Channel Digital Input 120/240 VAC, 16 Channel...
  • Page 90 Reverse polarity protection is limited to max of Field Supply Voltage. Module I/O configuration and maximum power delivery by I/Os, depends on number of channels, configuration Type and the environment. 20 pin EURO style terminal block 20 position Barrier style terminal block HART Support (AI and AO) RTP support.
  • Page 91 Universal Analog Input Module (UAI) One UAI module provides a 20-terminal block with 8 channels, it supports inputs mixed on a module. Each channel can be configured mV, V, mA Ohms Input impedance: 10 megohm for T/C and mV inputs; >1 megohm for volts and 250 ohms for mA inputs;...
  • Page 92 OFF to ON Response Time: 4 ms maximum with 1.5 lines cycle maximum ON to OFF Response Time: 4 ms maximum with 2 lines cycle maximum Power Supply Loading: 5 V: 130 mA max and 24 V: 0 mA RTP support. For more information, see Using an RTP to field wiring the 16 Point AC DI section.
  • Page 93 Current Rating: 4 A at 240 VAC or 30 VDC resistive load; 0.5 A at 240 VAC or 30 VDC incandescent lamp load OFF to ON response time: 11 ms Max ON to OFF response time: 8 ms Max Maximum Leakage Current: 1 mA @ 350 VDC Power Supply Loading: 5V- 110mA maximum;...
  • Page 94 Channel Used: Any one of the channels can be used for Pulse Output. However, the use of a particular channel for outputting pulses will render the particular input channel unusable for either of pulse, frequency or quadrature input. Digital Output Type: Open Collector, 5 to 24V, 30 mA max Frequency Range: 25 Hz –...
  • Page 95 Minimum Pulse Width: 2.25 μsec Quadrature Counter: 32 bits signed Quadrature Modes: For variable resolution there are three count modes for the Pulse/Quadrature input: X1: rising edges of signal A are counted (increment); falling edges of signal A (decrement) X2: rising and falling edges of signal A are counted X4: rising and falling edges of signals A and B are counted Quadrature LEDs: Two LEDs indicate UP and DOWN direction of...
  • Page 96 Configurable failsafe behavior between failsafe value and hold last value. Failsafe Value: A user-configurable failsafe value to allow predictable in the event of communication between the module and the controller is interrupted or controller exception stop. Hold Last value: AO channel hold last value when module is in failsafe state.
  • Page 97 ATTENTION: When the DIP switch is set to be off , while the external power is down, the open wire detection is not available. External Power Source requirement: Vin:18 to 36 VDC Current: 350 mA per module Digital Input Module-AC DC Voltage type The AC/DC Input Module provides 16 individually isolated, inputs that are powered externally.
  • Page 98 Input Impedance : >1 megohm for volts and 250 ohms for mA inputs Galvanic Input Isolation: 400 VDC point to point, solid state switching; 1K VDC to logic. Noise Rejection: Series Mode >31dB Common Mode >90dB at 120VAC Over-range limit: +/- 10% for linear ranges Accuracy: Factory configured accuracy = ±...
  • Page 99 Update Rate: 6 ms Maximum Switching current: 2.6mA norminal Galvanic Isolation: Between Field wiring (input or output) and Module Power supply Loading: 5 V; 130 mA maximum 24v; 40 mA maximum Digital Output Module (8 Channels) - AC Voltage Type DO AC Voltage type module supports: Channel Density: 8 Channels Output Type: Triac (Zero switching voltage)

  • Page 100: Terminal Block Styles

    Channel Density: 32 Channels Input voltage range: 10.5 V DC to 32V DC. Isolation: Galvanic ally isolated in 2 groups of 16 channel to rack Overload Current Protection: Active Current Limiting is integrated into the output driver as 4 groups of 8 channels each. Power cycling is not required to reset the module after a fault condition.
  • Page 101 Terminal blocks have an embossed numbering “key” that shows the numbering pattern of the 20/36 connections. The frame associated with the terminal block has a transparent hinged door. The hinged door is a tool secured cover. To open the door, insert a flat screwdriver into the slot at the top and bottom of the door while pulling out.
  • Page 102 Terminal Block Colors Both the barrier style and the Euro style are available in two colors (red and black). Black terminal blocks, which have gold contacts, are used for low-voltage, low-energy signals such as analog inputs, contact inputs and low DC voltages. Red terminal blocks, which have tin contacts, are used for higher voltages such as 120/240 VAC.
  • Page 103 Installing I/O modules 1. Write the tag names of each configured I/O Module on the label. 2. Place the label supplied with each module (tag name side out) into the hinged door for that I/O Module. Use the slotted tabs, molded into the door, to hold the label in place.
  • Page 104 3. For each configured and labeled I/O Module, ONLY break off the "key-tabs" in the pattern that matches that module type. (For a diagram of each key-tab pattern, use the I/O Modules or UIO keying example diagram shown below). CAUTION: In the diagram below, the white cut-outs represent the cut- outs on the modules that accommodate tabs on the Terminal Block.
  • Page 105 4. Secure the field cable in place with a cable tie at top or bottom of the terminal block. Form a bend in each wire to provide strain relief, and secure the wire bundle with the tie. 5. Install all I/O modules in the racks. 6.

  • Page 106: Terminal Block-To-Field (Signal) Wiring

    ATTENTION: For CE conformity, the optional grounding bar should be installed. 7. In each slot location not occupied by an I/O module, install a Filler Block cover. (Part number 900TNF-0200). CAUTION: The Filler Block Cover looks much like an I/O Terminal Block assembly, except that it does not include the wire terminating block (screw terminals).
  • Page 107 Wiring rules and recommendations For analog input and analog output channels, twisted-pair wiring with shielded cable is recommended and it will improve noise immunity if wire routing is suspect. ATTENTION: For CE conformity, all signal wire must use shielded cable. Wire Gauge Observe all local codes when making power connections.
  • Page 108 Signal grounding The shield for each analog input and analog output should be grounded at the grounding bar at the top or bottom of each rack as indicated in the following figure. For low-frequency noise rejection, I/O wiring shields should be grounded only at the ControlEdge 900 Controller end.
  • Page 109 Figure 5-21: Wire-Shield Grounding To facilitate module replacement, it is advisable in most cases to route all wiring through either the top or the bottom of the terminal block. This allows the terminal block to pivot up or down, allowing ready access to the module, and is the preferred method for a limited number of wires.
  • Page 110 In above diagram, each power supply source supplies power to the whole module. If redundant power supply are provided, the UIO module still can work in case of failure on one power source. At least one power supply is required, otherwise UIO module cannot work and "External power"...
  • Page 111 Hardware Version Item Hardware Version B AO and DO Channel Maximum DO module current 1.5 A. (3 Maximum module Specs channels at 500 ma or 6 at 250 ma) current 4.2 A DI and AI Channel Maximum 16 per channel Specs DO Channel Specs In 60 Degree C and use High voltage...
  • Page 112 Devices that supply current, which is not first supplied by the external 24V to the device. For example, a device that creates current (even if referenced to Honeywell ground). Standard 2-wire transmitter with UIO Figure 5-23: Standard 2-wire transmitter with UIO (Loop Powered)
  • Page 113 Self-powered 3-wire transmitter with system ground This can be applied to any channels from 1 through 16. The simplest wiring is to have the 'common' wire and the 'current source' wire under the same terminal blocks screw. If the site wiring does not permit this method, then a separate external terminal block must be used.
  • Page 114 Self-powered 4-wire transmitter This wiring method can be applied to any of the channels 1 through Figure 5-25: Self-powered 4-wire isolated sourcing type transmitter with UIO...
  • Page 115 Figure 5-26: Self-powered 4-wire sinking type transmitter with UIO UIO does not support the following input types: Self-powered 4-wire transmitter with ground-referenced current source: This is because the current return path is on the negative...
  • Page 116 side of the wire-pair. Voltage input: This is because UIO supports only current measurements. Slide wire: This is because UIO supports only current measurements. Allowable field wiring resistance - UIO - Analog Input channel The maximum allowable field wiring resistance between the transmitter and the connection terminal is dependent upon the voltage requirement of the transmitter.
  • Page 117 Field wiring for Digital Input (Dry Contact) A UIO channel configured as a Digital Input. See the following table for DI specification: Table 5-17: UIO for DI(Dry Contact) Specifiction Item Description Signal type Dry contact With Open Wire Detection Short circuit detection I >...
  • Page 118 Item Description Open contact detection I < 2.4mA +/-5mA Input filter First-order low-pass 100Hz See the following wiring diagram of the UIO channel configuration. Figure 5-28: Digital input When the DI channel is configured with open wire detection (OWD), a 15K shunt resistor is required in the field near the switch contact as displayed in the above figure.
  • Page 119 A 15K shunt resistor and a 7.5K series resistor are required closed to the contact in field side. Refer to the following block diagram of this channel configuration, and a field wiring example. ATTENTION: For Channels that are configured with a debounce, the UIO will declare that the channel has changed state if all the consecutive samples are in the new state for the configured debounce time period.
  • Page 120 See the following figure for the channel configuration. Figure 5-29: UIO_DO channel configuration The UIO-DO channel supports ganging. A set of two, three, or four DO channels can be configured to deliver up to 1 Ampere, 1.5 Amperes, or 2 Amperes current respectively to the field.
  • Page 121 The field wire must be connected with one of the following OUT pins (together with the branch). One of the OUT pins can be used for connecting the return field wire. Two DO channels with a two pin branch Three DO channels with a three pin branch Universal Analog Input Module (UAI) Wiring The Universal Analog Input Module has eight inputs, which can include any combination of the following input types: RTD, TC, Ohms,...
  • Page 122 Type S Type R Type Type Diameter Type Type Type Type T inches PT110 PT113 0.0100 5.984 3.551 3.043 7.169 1.85 1.91 2.38 2.03 Table values are shown as a reference only; actual values may vary. Consult manufacturer specifications. Isolation This module has eight inputs, which are isolated except for RTD current sources.
  • Page 123 OHMs Inputs Ohms inputs are wired similar to 2-wire RTD inputs. That is, they require a current source, and thus must use one of the IRTD current sources. Also, two terminals are jumpered together as they are for two-wire RTD inputs. Analog channels wired for Ohms inputs differ from RTD inputs in these aspects: Ohms inputs connect to variable resistance devices other than...
  • Page 124 Figure 5-31: Universal Analog Input Wiring Figure 5-32: Examples of RTD Input Wiring...
  • Page 125 Figure 5-33: Analog Input Wiring - Eight TCs Figure 5-34: Analog Input Wiring - Eight Resistance Inputs...
  • Page 126 Figure 5-35: Analog Input Wiring - Eight RTDs Digital Input Module (16 channels)-AC Voltage Type Wiring The AC Input Module has sixteen inputs. An example of AC Input Module wiring is shown in the AC Input Module Wiring Diagram Specifications for this module, see Digital Input Module (16 channels)-AC Voltage Type section.
  • Page 127 power sources before servicing. - Failure to comply with these instructions could result in death or serious injury. Figure 5-36: AC Input Module Wiring Diagram Figure 5-37: AC Input Module Jumper...
  • Page 128 Digital Input Module (32 Channels)-DC Voltage Type Wiring The 32-point DC Digital Input module below provides two groups of 16 inputs, each with a pair of terminals for connection to common. DC power applied between the common terminal and an input cause the input to turn ON.
  • Page 129 Digital Output Module (8 Channels) - AC Voltage Type Wiring The AC Output Module provides eight output circuits. Each output is isolated from the other outputs. An example of AC output wiring is shown below. Specifications for this module, see Digital Output Module (8 Channels)-AC Voltage Type section.
  • Page 130 required) to connect the high-current loads to every other output - for example, outputs 1, 3, 5, 7 or 2, 4, 6, 8. This distributes heat more evenly across the heat sink. Jumper Comb A ten-position jumper comb is available for inter-connecting all L1 (Hot) terminals (1, 3, 5, 7, 9, 11, 13, 15, 17, 19).
  • Page 131 Digital Output Module (32 Channels)-DC Voltage Type Wiring The DC digital Output module provides 32 externally powered outputs in 2 groups of 16 (Figure below). The outputs are high side switching (current sourcing) type. Over-current protection is provided for each channel, in 4 groups of 8 channels.
  • Page 132 Relay Output Module Wiring The Relay Output Module provides eight individually isolated, electromechanical relay outputs. Four of the outputs are Form-C, and the other four are Form-A. A schematic showing the relationship of individual Form-A relays and Form-C relays to external (user) connections is given below.
  • Page 133 Maximum current per module: No de-rating per module, but ensure compliance with maximum ratings for each output. TIP: specified relay life is 1,000,000 cycles. For applications requiring constant cycling of output, Honeywell recommends using a solid state AC or DC output module. Required Output Fusing Outputs are not fused in the Relay module.
  • Page 134 CAUTION: exist at terminal blocks. Hazardous voltages Using switches at field devices disconnect the field wiring from power sources before servicing. Failure to comply with these instructions could result in death or serious injury. Figure 5-43: Relay Output Module Wiring Diagram Figure 5-44: Relay Output Module Jumpers...
  • Page 135 Pulse/Frequency/Quadrature Module (4 Channels) Wiring The 4 Channel Pulse/Frequency/Quadrature Module provides four different functionalities in the form of Pulse Input, Frequency measurement, Quadrature encoder input and Pulse Output. Each of the 4 channels can be configured for any one of these four functionalities;...
  • Page 136 Settings(using input 1 as example) Single ended (factory setting): Differential: Figure 5-46: Pulse Counting Wiring...
  • Page 137 Figure 5-47: Pulse Outing Wiring Figure 5-48: Frequency Wiring...
  • Page 138 Figure 5-49: Quadrature, Differential, External Power Wiring Figure 5-50: Quadrature, Single Ended, External Power Wiring...
  • Page 139 Figure 5-51: Quadrature, Differential, ControlEdge 900 Power Wiring Figure 5-52: Quadrature, Differential, ControlEdge 900 Power Wiring...
  • Page 140 Analog Output Module (4 Channels) Wiring An example of Analog Output Module wiring is shown below. Isolation The four outputs are isolated from each other. Shield Grounding Shields must be grounded as described under Shield Grounding at the beginning of this section. CAUTION: exist at terminal blocks.
  • Page 141 Analog Output Module (8 Channels) Wiring CAUTION: Hazardous voltages exist at terminal blocks. AO8 modules require at least one channel to be configured prior to a cold start for the module to work properly. Subsequent channels then may be added with a hot start. Failure to comply with these instructions could result in death or serious injury.
  • Page 142 CAUTION: exist at terminal blocks. Hazardous voltages Using switches at field devices disconnect the field wiring form power sources before servicing. Failure to comply with these instructions could result in death or serious injury. If installing 8 channel Analog Output module, set its DIP switch as follows.
  • Page 143 High Level Analog Input Module (16 Channels) Wiring Be sure to set the module DIP switches for voltage or current mode. See the following diagram. This requires Low Voltage Euro style 36- terminal terminal block. Requires Low Voltage Euro style 36-terminal terminal block.
  • Page 144 Figure 5-57: 16 point High Level Analog Input Wiring...
  • Page 145 Digital Input Module-Contact Type (16 Channel) Wiring The Contact Input Module has sixteen inputs in one group. An example of Contact Input wiring is shown below. Internally Powered Input Channels The Contact Input Module provides voltage to the field contacts. CAUTION: Do not apply any external power to the field device or to the input terminals.
  • Page 146 AC/DC Isolated Input Module Wiring The AC/DC Input Module has sixteen isolated inputs. An example of AC Input and DC input Module wiring is shown below. And it requires Low Voltage Euro style 36-terminal terminal block. Isolation Inputs must be powered from external voltage sources. Inputs are isolated from each other and from controller power.
  • Page 147 Figure 5-60: AC/DC Isolated Input Module Wiring...

  • Page 149: Chapter 6 - Wiring And Cabling Planning

    CHAPTER WIRING AND CABLING PLANNING Before wiring and cabling, the electrical environment including grounding and distance should be considered. This section provides wiring and cabling diagrams and specifications to assist with the planning. Electrical considerations Racks must be mounted and wired using following good industrial practices, such as proper grounding, shielding, local and national electrical codes to ensure proper operation, safety, electrical and EMC compliance.
  • Page 150 See the following figure for the protective electrical enclosure wiring with single rack: Figure 6-1: Protective electrical enclosure wiring, Single Rack For 2 phase power source, external circuit breaker must be included in both L1 and L2. See the following figure for the protective electrical enclosure wiring with multiple racks:...
  • Page 151 Figure 6-2: Protective electrical enclosure wiring, Multiple Racks For 2 phase power source, external circuit breaker must be included in both L1 and L2 for each rack. See the following figure for redundant power supplies each with external circuit breaker:...
  • Page 152 Figure 6-3: Redundant power supplies each with external circuit breaker For 2 phase power source, external circuit breaker must be included in both L1 and L2. See the following table for the slow-blow fuse of the two power supplies. Table 6-1: Slow-blow of power supplies Power supply Input rating Slow-blow...

  • Page 153: Wiring And Cabling Distance Guidelines

    Use suppression devices for additional noise protection. The suppression devices can be added at the external source. Appropriate suppression devices are commercially available. Grounding wires for routing Wires that carry relatively high electrical energy can produce unwanted noise in wires that transmit signals of relatively low energy, particularly when they are placed parallel in long wiring runs.
  • Page 154 Fiber Optics Recommendations Honeywell recommends to use the fiber optic cable for distances longer than 100m. Equipment tested with the fiber optic cable is listed in the following table:...

  • Page 155: Chapter 7 - Maintenance

    CHAPTER MAINTENANCE This section contains procedures for removing and replacing the active components of a ControlEdge 900 Controller. It also includes recommendations, suggestions, and hints as they apply to the circumstances under which the procedures are used. Safety considerations - PLAN AHEAD! When using the procedures in this section, plan the sequence of procedural actions so as to ensure: The safety of personnel...
  • Page 156 CAUTION: Most of the modules available for use in the ControlEdge PLC have an REMOVAL AND INSERTION UNDER POWER designation. That is, they can be Removed and Inserted Under Power, where "power" refers to DC power at the backplane of the rack. (It does not refer to power for field wiring at the terminal board associated with the I/O module, which must be disconnected (using a user-supplied switch) at the field device before removing or inserting the module.

  • Page 157: Periodic Checks

    SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2/ZONE 2. EXPLOSION HAZARD Class I, Division 2/Zone 2 Installations DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN NOT TO BE HAZARDOUS. Periodic checks Check .

  • Page 158: Replacing The Power Supply

    completely shutting down a running system. However, it must be recognized that removing or inserting an I/O module under power is potentially hazardous to property and to personnel. CAUTION: Explosion hazard. Removal and Insertion Under Power is not supported in Division 2/ Zone 2. Removal and Insertion Under Power : Potential Hazards and Recommended Actions Hazard...
  • Page 159 TIP: The power supply includes an internal fuse, rated at 5 amperes. This fuse is not replaceable in the field. The user must provide an external fuse that has a current rating lower than that of the internal fuse. See step Replacing the power supply on page of the section Assemble Redundant Controller Rack, Assembly.

  • Page 160: Replacing An Epm

    For AC: L1, L2 /N and Ground For DC: 24V DC +, 24V DC – and Ground 7. Ensure power can be applied safely, and use the external (user- supplied) switch to re-connect power to the power supply. 8. If the AC power supply is used, using a meter and the test points on the face of the power supply, ensure that voltages (measured on the backplane) are within specifications.

  • Page 161: Replacing An I/O Module

    Replacing an I/O module CAUTION: Read and understand all of the following information regarding Removal and Insertion Under Power (RIUP) before attempting to remove and/or replace any I/O module, particularly in a system that is actively controlling a process. All of the I/O module types in the ControlEdge 900 controller include the Removal and Insertion Under Power feature.
  • Page 162 but if operating circumstances permit, disconnecting power from the rack is the preferred option. Plan and develop an action sequence before beginning the replacement procedure. Primary considerations include: When replacing I/O module, the voltages to the modules must be disconnected at the field device before removing the terminal block from the module.
  • Page 163 5. Insert the screwdriver tip into the extraction tab on the front of the module cover, and rotate the screwdriver handle toward the back, using the top edge of the rack as a fulcrum. 6. Verify that the replacement module is of the proper type. Then, carefully insert it into the slot in the rack so as to make proper contact with the connector in the backplane.

  • Page 164: Spare Parts And Model Numbers

    Spare parts and model numbers Use the model numbers in the following table if there is a need to purchase spare parts for the ControlEdge 900 Controller system. Table 7-1: Spare parts and model numbers Description Model Number Processor Module Control Processor Module (CPM), ControlEdge 900 900CP1-0200 Expansion Processor Module (EPM), ControlEdge 900...
  • Page 165 Description Model Number Jump 10 Postion HC900 PKG of 10 900J10-0001 Redundancy Module 900E01-0100 Racks 1 I/O Slot Rack 900R01-0100 4 I/O Slot Rack 900R04-0200 8 I/O Slot Rack 900R08-0200 12 I/O Slot Rack 900R12-0200 8 Slot Rack - Red. Power 900R08R-0200 12 Slot Rack - Red.
  • Page 166 Description Model Number Low Voltage RTP Cable (2.5m, 8.2ft.) 900RTC-L225 Low Voltage RTP Cable (5.0m, 16.4ft.) 900RTC-L250 High Voltage RTP Cable (1.0m, 3.28ft.) 900RTC-H210 High Voltage RTP Cable (2.5m, 8.2ft.) 900RTC-H225 High Voltage RTP Cable (5.0m, 16.4ft.) 900RTC-H250 Low Power RTP Cable,16/32 Channel (1.0M, 3.28ft ) 900RTC-3410 Low Power RTP Cable,16/32 Channel (2.5M, 8.2ft ) 900RTC-3425...
  • Page 167 Description Model Number Fiber Optic convertor 50135395-001 Ethernet to Single-Mode Fiber Converter 50135395-002 MOXA MGate MB3180 Modbus Gateway TIP: Kits & Accessories are not in the scope of the certification we mentioned in the Special Condition of Use and Approved Standards section.

  • Page 169: Chapter 8 - Diagnostics And Troubleshooting

    CHAPTER DIAGNOSTICS AND TROUBLESHOOTING Diagnostics have two functions: Automatically alter system operation to react appropriately to operating conditions (particularly in the event of a system fault). Provide external indications that enable operating and maintenance personnel to react appropriately when external actions are required.
  • Page 170 Chapter 8 - Diagnostics and Troubleshooting Figure 8-1: EPM Indicators Table 8-1: LED Indications on EPM Item Description State/Color Status No power is applied to EPM. On/Green EPM is working normally. On/Orange EPM is in power-up process. Blink Red @ 1 EPM is running with error Blink Red @ EPM is not configured.

  • Page 171: Serial Communication Module Indicators

    Chapter 8 - Diagnostics and Troubleshooting Item Description State/Color Role Green Other situation except booting EPM is booting 3, 5 Ethernet Port Yellow On/Off OFF for 10Base-T; ON for Speed ( Upper 100Base-TX. LED) 4, 6 Ethernet Port Green OFF for no connection; ON Link/ Active ( On/Off/ for connection;...

  • Page 172: I/O Indicators

    Chapter 8 - Diagnostics and Troubleshooting Figure LED State/Color Description Item Module Solid Orange Boot Status LED Blinking Red at 1 Hz System in running state with error Blinking Red at 0.5 Hz Module offline or unconfigured Solid Green System good in running state without error.
  • Page 173 Chapter 8 - Diagnostics and Troubleshooting Table 8-3: IOM Indicator Definition Figure Description Item State/Color Module No Power Status LED Solid Red Hardware Failure Blinking [LED Failure Definition]section Solid Cold start with passing diagnostics Green Blinking Normal scanning Green Channel Green ON For Inputs, indicates On status of the field input LEDs...
  • Page 174 Chapter 8 - Diagnostics and Troubleshooting LED Failure Definition Number Applies Failure Description User Action strobes Failsafe The module is in 1. If expansion I/O rack, go to step the failsafe state modules 2. If non expansion I/O rack, go because it is not to step 3.
  • Page 175 Chapter 8 - Diagnostics and Troubleshooting Bad I/O Channel Diagnostics Individual channels on I/O modules indicate their diagnostics by 6 flashes on the EPM and CPM; the channel’s LED does not indicate a diagnostic. Table below is a list of conditions that can cause a bad channel diagnostic.

  • Page 176: Uio Indicators

    Chapter 8 - Diagnostics and Troubleshooting Refer to section "I/O module diagnostics" of ControlEdge Builder User Guide for conditions that can cause a bad channel diagnostic and corresponding action. UIO Indicators The following diagram displays the location of the LED indicators on the UIO.
  • Page 177 Chapter 8 - Diagnostics and Troubleshooting Item LED Description State/Color Module Solid Green Power on with self-test passed Status Solid Red In power-up process or hardware failure or firmware corrupt Blink Green Normal scanning (@ 4 Hz) Blink Red Firmware upgrade (@ 0.5 Hz) Blink Red Communication error...
  • Page 178 Chapter 8 - Diagnostics and Troubleshooting...

  • Page 179: Chapter 9 - Special Condition Of Use And Approved Standards

    CHAPTER SPECIAL CONDITION OF USE AND APPROVED STANDARDS Approval Rating Table 9-1: Approval Rating Certification Approval Rating Nonincendive for use in Class I, Division 2, Groups A, B, C & D Class I, Zone 2, IIC T* Class I, Division 2, Groups A, B, C & D T* ATEX II 3 G Ex nA IIC T* Gc Temperature class...

  • Page 180: For Canada

    Chapter 9 - Special Condition of Use and Approved Standards Equipment shall be installed in compliance with the enclosure, mounting, spacing and segregation requirements of the ultimate application. For installation with a second active phase (L-L) instead of neutral (L-N) connection both phases must be protected externally with circuit breaker adequately rated for 3 A maximum and 250 V AC minimum.

  • Page 181: Approved Standards For Division 2/Zone 2 Hazardous Location

    Chapter 9 - Special Condition of Use and Approved Standards Approved Standards for Division 2/Zone 2 Hazardous Location US Approval Standards Issue Item Number Date Electrical Equipment for Use in Hazardous (Classified) FM 3600 2011 Locations, General Requirements Non-incendive Electrical Equipment for Use in Class I and II, FM 3611 2004 Division 2 and Class III, Division 1 and 2, Hazardous...

  • Page 182: Ce Lvd And Emc Compliance Standards

    Chapter 9 - Special Condition of Use and Approved Standards European Standards (Zone 2) ATEX Standards Issue Title Number Date Electrical apparatus for explosive gas atmospheres. EN 60079- 2012 Part 0: General Requirements Electrical apparatus for explosive gas atmospheres EN 60079- 2010 Construction, test and marking of type of protection “n”...
  • Page 183 Chapter 9 - Special Condition of Use and Approved Standards Issue Title Number Date Electromagnetic compatibility (EMC) – Part 3-2: Limits – IEC 61000-3-2 2014 Limits for harmonic current emissions (equipment input current ≤ 16A per phase) Electromagnetic compatibility (EMC) – Part 3-3: Limits – IEC 61000-3-3 2013 Limitation of voltage changes, voltage fluctuations and...

  • Page 184: Ul Compliance Standards

    Chapter 9 - Special Condition of Use and Approved Standards UL Compliance Standards Issue Title Number Date Safety requirements for electrical equipment for measurement, ANSI/UL Third control, and laboratory use – Part 1: General requirements 61010-1 Edition...

  • Page 185: Appendix A - Installing Rtp

    APPENDIX INSTALLING RTP CAUTION: Do not insert or remove the RTP when the system is powered unless the area is known to be non-hazardous. In this section: Overview of RTPs RTP Dimension Using the RTP to field wire the IOMs Using an RTP to field wire the UIO Using an RTP to field wiring the UAI Using Dual RTPs to field wiring the 16 Point AI...

  • Page 186: Overview Of Rtps

    Appendix A - Installing RTP Overview of RTPs The Remote Termination Panel (RTP) provides an easy way to connect the ControlEdge 900 controller to the field wiring. The RTP integrates some of the typical externally connected components, reducing wiring and setup time. It also minimizes the need for multiple wires under a single screw connection by expanding the connectivity of the shared terminals of the I/O modules.

  • Page 187: Rtp Dimension

    Appendix A - Installing RTP Terminal Terminal RTP required per module I/O Module Block Block Cable (only for RTP not for Cable) (Euro) (Barrier) AO 4 CH 900TEK- 900TBK- 900RTS- 900RTC- (900B01-0301) 0200 0200 0001 L2xx DI Contact 16 CH 900TEK- 900TBK- 900RTS-...

  • Page 188: Using The Rtp To Field Wire The Ioms

    Appendix A - Installing RTP Using the RTP to field wire the IOMs In this section: Using an RTP to field wire the UIO Using an RTP to field wiring the UAI Using Dual RTPs to field wiring the 16 Point AI Using an RTP to field wiring the 16 Point AC DI Using an RTP to field wiring the 16 Point DC DI Using Dual RTPs to field wiring the 32 Point DC DI...

  • Page 189: Using An Rtp To Field Wire The Uio

    Appendix A - Installing RTP Using an RTP to field wire the UIO ATTENTION: The maximum current load on RTP cable series 900RTC-L12xx is 2.8A and 900RTC-H12xx is 4.2A per module for UIO. RTP and cables are intended for permanent installation within their own enclosure.
  • Page 190 Appendix A - Installing RTP b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-H1210 Remote Termination Low Voltage Cable Assembly, 1.0 meters long 900RTC-H1225 Remote Termination Low Voltage Cable Assembly, 2.5 meters long 900RTC-H1250 Remote Termination Low Voltage Cable Assembly, 5.0 meters long c.

  • Page 191: Using An Rtp To Field Wiring The Uai

    Appendix A - Installing RTP 4. Connect field wiring, as shown below. ATTENTION: Short connect terminal 30 and 31 as shown in the diagram above. See "Terminal Block-to-Field (Signal) Wiring" on page 106 for more information. Using an RTP to field wiring the UAI ATTENTION: RTP is not for use with thermocouples.
  • Page 192 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-L1210 Remote Termination Low Voltage Cable Assembly, 1.0 meters long 900RTC-L1225 Remote Termination Low Voltage Cable Assembly, 2.5 meters long...
  • Page 193 Appendix A - Installing RTP 3. Set DIP siwtch position SW1 through SW8. Set each input’s DIP switch positions according to the input type. For Input n use Switch n. For example, for Input 1 use Switch 1, for Input 2 use Switch 2, etc.
  • Page 194 Appendix A - Installing RTP Figure A-4: Two–wire transmitter connections with common 24 VDC supply Figure A-5: Milliamp input connections with 250 ohm shunt resistance...
  • Page 195 Appendix A - Installing RTP Figure A-6: Volt, millivolt input connections Figure A-7: Three-wire RTD input connections Figure A-8: Two-wire RTD or ohm input connections Figure A-9: Slidewire feedback connections for actuators...

  • Page 196: Using Dual Rtps To Field Wiring The 16 Point Ai

    Appendix A - Installing RTP Table A-2: Analog Input accuracy specification Range AI Module Accuracy RTP + Cable Accuracy AI Module + RTP Accuracy 100Ω Plat. RTD ±0.1% of Range ±0.04% Range (0.357°C) ±0.14% of Range JIS RTD ±0.1% of Range ±0.12% Range (0.824°C) ±0.22% of Range 10Ω...
  • Page 197 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-3410 Remote Termination High Voltage Cable Assembly, 1.0 meters long 900RTC-L3425 Remote Termination High Voltage Cable Assembly, 2.5 meters long...
  • Page 198 Appendix A - Installing RTP 3. Set/verify jumper positions on each RTP as shown. Module Removal / Insertion Under Power (RIUP) is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc.

  • Page 199: Using An Rtp To Field Wiring The 16 Point Ac Di

    Appendix A - Installing RTP Inputs 9 and 10 are connected across RTP A and RTP B. Figure A-11: Current connections with 2-wire transmitter TIP: Recommended external current loop fuses. Additionally, on RTP A connect the following terminals: 3-22, 4-23, 7-24, 8-25, 15-26, 16-27, 19-29, 20-30 On RTP B connect the following terminals: 1-22, 2-23, 5-24, 6-25, 13- 26, 14-27, 17-28, 18-29...
  • Page 200 Appendix A - Installing RTP 1. Mount the RTP cable assembly to ControlEdge 900 Controller. See the following figure for the example installation diagram. a. Remove the relevant key tabs from the terminal block to allow connection with the module. b.
  • Page 201 Appendix A - Installing RTP b. Connect the cable to the RTP. 3. Set/verify jumper positions as shown. Module Removal / Insertion Under Power (RIUP) is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc.

  • Page 202: Using An Rtp To Field Wiring The 16 Point Dc Di

    Appendix A - Installing RTP Using an RTP to field wiring the 16 Point DC DI ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. The RTP combines the two groups of 8 inputs into one group of 16. To wire the 16 Point AC DI using an RTP 1.
  • Page 203 Appendix A - Installing RTP 900RTC-L225 Remote Termination High Voltage Cable Assembly, 2.5 meters long 900RTC-L250 Remote Termination High Voltage Cable Assembly, 5.0 meters long c. Install the module label onto the module connector cover. d. Connect shield drain wire to the grounding bars at the base of the ControlEdge 900 Controller rack.

  • Page 204: Using Dual Rtps To Field Wiring The 32 Point Dc Di

    Appendix A - Installing RTP ATTENTION: SDC+ in the wiring figure below refers to power that is disconnected from these screw terminals when switch SW1 is open (0). Using Dual RTPs to field wiring the 32 Point DC DI ATTENTION: RTP and cables are intended for permanent installation within their own enclosure.
  • Page 205 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-3410 Remote Terminal Cable assembly, 1.0 meters long 900RTC-3425 Remote Terminal Cable assembly, 2.5 meters long c.
  • Page 206 Appendix A - Installing RTP 3. Set/verify jumper positions on each RTP as shown. Module Removal / Insertion Under Power (RIUP) is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc.

  • Page 207: Using An Rtp To Field Wiring The 8 Point Ac Do

    Appendix A - Installing RTP SDC+ refers to switched positive side of the DC supply. Terminals 9 and 11 (DC-) are connected through the RTP cable. Same for terminals 10 and 12 (DC-). Using an RTP to field wiring the 8 Point AC DO ATTENTION: RTP and cables are intended for permanent installation within their own enclosure.
  • Page 208 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-H210 Remote Termination High Voltage Cable Assembly, 1.0 meters long 900RTC-H225 Remote Termination High Voltage Cable Assembly, 2.5 meters long...
  • Page 209 Appendix A - Installing RTP 3. Set/verify jumper positions as shown. Module Removal / Insertion Under Power (RIUP) is supported by turning off Switch SW1 to allow removal of the module from the rack without causing an arc. ATTENTION: SW1 only disconnects L1, not both sides of the AC powerline.

  • Page 210: Using Dual Rtps To Field Wiring The 32 Point Dc Do

    Appendix A - Installing RTP Using Dual RTPs to field wiring the 32 Point DC DO ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. 32 point DC Digital Output is limited to 6A per RTP and 0.5A per output. To wire the 32 Point DC DO using dual RTPs: 1.
  • Page 211 Appendix A - Installing RTP d. Connect both shield drain wires to the grounding bars at the base of the ControlEdge 900 Controller rack. All field-wiring shields must be grounded as described in the shield grounding section. 2. Mount the RTP to the DIN rail. a.

  • Page 212: Using An Rtp To Field Wiring 4 Channel Analog Output

    Appendix A - Installing RTP SDC- refers to the switched negative side of the DC supply. Terminals 9 and 11 (DC-) are connected through the RTP cable. Same for terminals 10 and 12 (DC+). Using an RTP to field wiring 4 Channel Analog Output ATTENTION: RTP and cables are intended for permanent installation within their own enclosure.
  • Page 213 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-H210 Remote Termination High Voltage Cable Assembly, 1.0 meters long 900RTC-H225 Remote Termination High Voltage Cable Assembly, 2.5 meters long...

  • Page 214: Using An Rtp To Field Wiring The 8 Channel Analog Output

    Appendix A - Installing RTP b. Connect the cable to the RTP. 3. Set/verify jumper positions as shown for use with an analog output module. Switch SW1 is not used. Module RIUP is not affected by using the RTP. See "RTP Cable wire positions, colors, and internal schematic" on page 1 for more information.
  • Page 215 Appendix A - Installing RTP a. Remove the relevant key tabs from the terminal block to allow connection with the module. b. Connect the appropriate cable to the module at ControlEdge 900 Controller. Possible options are: 900RTC-H210 Remote Termination High Voltage Cable Assembly, 1.0 meters long 900RTC-H225 Remote Termination High Voltage Cable Assembly, 2.5 meters long...
  • Page 216 Appendix A - Installing RTP 2. Mount the RTP to the DIN rail. a. Secure the RTP to the rail. See "Securing the RTP to the DIN rail" on page 228 for more information. for details. b. Connect the cable to the RTP. 3.

  • Page 217: Using An Rtp To Field Wiring Relay Output

    Appendix A - Installing RTP Using an RTP to field wiring Relay Output ATTENTION: RTP and cables are intended for permanent installation within their own enclosure. To wire the 8 Channel Relay Output using an RTP: 1. Mount the RTP cable assembly to ControlEdge 900 Controller. See the following figure for the example installation diagram.
  • Page 218 Appendix A - Installing RTP 900RTC-H250 Remote Termination High Voltage Cable Assembly, 5.0 meters long ATTENTION: Cable power is limited to 24 Amps per module at 60 C° (140 degrees F) and 32 Amps at 54 C°(129 degrees F). c. Install the module label onto the module connector cover. d.

  • Page 219: Rtp Cable Wire Positions, Colors, And Internal Schematic

    Appendix A - Installing RTP ATTENTION: As shown in the schematic, each switch is SPST and opens and closes one lead of the relay wiring. If your application requires opening and closing both sides of the load wiring, then an external DPST switch is required.
  • Page 220 Appendix A - Installing RTP Twisted Pair Number Module TB Position RTP J1 Plug Connector Color Black Blue Black Yellow Black Brown Black Orange White Green Blue RTP Internal schematic (Applies to UIO, 4 AO, 16 DI and 8 DO) See the figure below for RTP Internal schematic (Applies to UIO, 16 DI and 8 DO).
  • Page 221 Appendix A - Installing RTP RTP Internal schematic (Applies to UAI) Figure A-13: Analog Input RTP Internal schematic...
  • Page 222 Appendix A - Installing RTP...
  • Page 223 Appendix A - Installing RTP RTP Cable wire positions and colors(Applies to 16 AI, 32 DI and 32DO) See the table below for RTP Cable wire positions and colors(Applies to 16 AI, 32 DI and 32 DO) : Table A-4: RTP A Cable wire positions and colors (Applies to 16 AI, 32 DI and 32 DO) Twisted Pair Number of Cable A Module TB Position RTP J1 Plug Connector...
  • Page 224 Appendix A - Installing RTP Table A-5: RTP B Cable wire positions and colors (Applies to 16 AI, 32 DI and 32 DO) Twisted Pair Number of Cable A Module TB Position RTP J1 Plug Connector Color Black Black White Black Green Black...
  • Page 225 Appendix A - Installing RTP Twisted Pair Number of Cable A Module TB Position RTP J1 Plug Connector Color White Green Blue RTP Cable wire positions and colors (applies Relay Output) Twisted Pair Number Module TB Position RTP J1 Plug Connector Color Black Black...
  • Page 226 Appendix A - Installing RTP Twisted Pair Number Module TB Position RTP J1 Plug Connector Color Black Blue Black Yellow Black Brown Black White Green Blue...
  • Page 227 Appendix A - Installing RTP Relay Output RTP Internal schematic...

  • Page 228: Securing The Rtp To The Din Rail

    Appendix A - Installing RTP Securing the RTP to the DIN rail 1. Secure mounting screws at each end of the mounting rail with additional screws approx. every 8"(203mm) to prevent the rail from twisting. 2. Insert one side of the DIN rail at position A, as shown below. 3.
  • Page 229 Documentation feedback You can find the most up-to-date documents on the Honeywell Process Solutions support website at: http://www.honeywellprocess.com/support If you have comments about Honeywell Process Solutions documentation, send your feedback to: [email protected]...
  • Page 230 To report a potential security vulnerability against any Honeywell product, please follow the instructions at: https://honeywell.com/pages/vulnerabilityreporting.aspx Submit the requested information to Honeywell using one of the following methods: Send an email to [email protected]; or. Contact your local Honeywell Process Solutions Customer Contact Center (CCC) or Honeywell Technical Assistance Center (TAC).

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