Page 1
900 Control Station
For use with HC900 Controller
User Guide
Doc. No.: 51-52-25-148
Revision: 9
Date: May 2014
Honeywell Process Solutions
Page 2
Notices and Trademarks
Copyright 2014 by Honeywell
Revision 9, May 2014
Warranty/Remedy
Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact
your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of
coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole
remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is believed to be accurate
and reliable as of this printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the
customer to determine the suitability of the product in the application.
Honeywell Process Solutions
1250 W Sam Houston Pkwy S
Houston, TX 77042
HC900 is a U.S. registered trademarks of Honeywell
Other brand or product names are trademarks of their respective owners.
ii 900 Control Station User Guide Revision 9
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About This Document
About This Document
Abstract
This manual describes the installation and operation of the 900 Control Station Operator Interface.
References
The following list identifies all documents that may be sources of reference for material discussed in this
publication.
Document Title Doc ID
HC900 Control Station Installation 51-52-33-147
900 Control Station Specification 51-52-03-46
Legacy HC900 Controller Installation and User Guide 51-52-25-107
Abstract
Station Designer User Guide 51-52-25-149
HC900 Designer User Guide 51-52-25-110
Control Designer Function Block Reference Guide 51-52-25-109
HC900 Controller Communications User Guide 51-52-25-111
HC900 Controller Redundancy Overview & System Operation 51-52-25-133
Revision Information
Document Name
This manual … 51-52-25-148 900 Control Station
New
Languages added, IP address setup, model specific
notes
Summary Displays added, Alarms & Events added,
batch Logging and Download and upload
configurations + others
Variable Recipes added, Alarm & Events section
updated, Compact Flash Min/Max added
CS 15” USB conflict note added Revision 6 September 2011
“USB 3.0 support is only available for 900CS10”
note added
Information on I/O Safety Function block added
CE conformity updates Revision 9 May 2014
Revision Number Publication Date
Error! Unknown
document property
name.
Revision 2 October 2009
Revision 3 March 2010
Revision 4, 5 October 2010
Revision 7 March 2013
Revision 8 September 2013
April 2009
Revision 9 900 Control Station User Guide iii
May 2014
Page 4
http://www.honeywell.com
http://www.hpsweb.honewell.com/ps
http://hpsweb.honeywell.com/Cultures/en
US/Products/Instrumentation/hybrid/hc900/TechnicalTips
/documents.htm
Support & Contact Information
For Europe, Asia Pacific, North and South America contact details, refer to the back page of this manual
or the appropriate Honeywell Solution Support web site:
Honeywell Organization WWW Address (URL)
Corporate
Honeywell Process Solutions
HPS Technical tips
Telephone and Email Contacts
Area Organization Phone Number
United States and
Canada
Global Email Support Honeywell Process Solutions
Honeywell Inc.
-
1-800-343-0228 Customer Service
1-800-423-9883 Global Technical Support
Email: (Sales)
FP-Sales-Apps@Honeywell.com
or (TAC)
hfs-tac-support@honeywell.com
iv 900 Control Station Us er Guide Revision 9
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Symbol Definitions
The following table lists those symbols that may be used in this document to denote certain conditions.
Symbol Definition
This DANGER symbol indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
This WARNING symbol indicates a potentially hazardous situation, which, if
not avoided, could result in death or serious injury.
This CAUTION symbol may be present on Control Product instrumentation
and literature. If present on a product, the user must consult the
appropriate part of the accompanying product literature for more
information.
This CAUTION symbol indicates a potentially hazardous situation, which, if
not avoided, may result in property damage.
Contents
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,
42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these
instructions could result in death or serious injury.
ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices
Protective Earth (PE) terminal. Provided for connection of the protective earth
(green or green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.
Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requirements.
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Contents
Contents
Symbol Definitions ............................................................................................................................... v
Introduction ..................................................................................................................... 1
Overview.............................................................................................................................................. 1
What’s in this guide ......................................................................................................................................... 1
Typical readers of this guide ............................................................................................................................ 2
What you can do with the Control Station ......................................................................................................... 2
Specifications ....................................................................................................................................... 2
CE Conformity (Europe) ....................................................................................................................... 2
Components ........................................................................................................................................ 3
Preparation and startup ................................................................................................... 4
Site Preparation ................................................................................................................................... 4
Control Station Mounting ...................................................................................................................... 4
Noise Protection................................................................................................................................... 4
How to configure your Control Station .................................................................................................. 4
Startup ................................................................................................................................................. 5
Features .......................................................................................................................... 7
Overview.............................................................................................................................................. 7
Touch screen ....................................................................................................................................... 8
Navigation and data entry ................................................................................................................................ 9
Status bar ..................................................................................................................................................... 10
Keys .................................................................................................................................................. 11
CompactFlash .................................................................................................................................... 11
Status LEDs ....................................................................................................................................... 12
Ports .................................................................................................................................................. 13
900 Control Station 10 inch model ................................................................................................................. 13
900 Control Station 15 inch model ................................................................................................................. 13
USB Device .................................................................................................................................................. 14
USB Host ...................................................................................................................................................... 14
Ethernet ........................................................................................................................................................ 14
RS485 .......................................................................................................................................................... 14
RS232 .......................................................................................................................................................... 14
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Contents
Main Menu .................................................................................................................... 15
Overview............................................................................................................................................ 15
Access .......................................................................................................................................................... 15
Functions ...................................................................................................................................................... 15
Main menu tree ............................................................................................................................................. 16
Controller ........................................................................................................................................... 17
Controller Status ........................................................................................................................................... 17
Controller Setup ............................................................................................................................................ 19
Summary Displays ............................................................................................................................. 20
About Summary Displays .............................................................................................................................. 20
Communications ................................................................................................................................ 22
Menu Overview ............................................................................................................................................. 22
Serial Port S1/S2........................................................................................................................................... 22
Ethernet Port E1/E2 Status ............................................................................................................................ 27
Expansion Rack Communications .................................................................................................................. 29
Modbus Slave Devices .................................................................................................................................. 31
Host Connections .......................................................................................................................................... 32
Peer Connections .......................................................................................................................................... 33
Troubleshooting a Comm Quality problem ...................................................................................................... 35
Troubleshooting Data Link Errors ................................................................................................................... 35
Diagnostics ........................................................................................................................................ 36
Menu Overview ............................................................................................................................................. 36
Controller Diagnostics ................................................................................................................................... 37
I/O Module Diagnostics and I/O Calibration .................................................................................................... 42
Communication Diagnostics .......................................................................................................................... 48
Redundant Overview ..................................................................................................................................... 48
Lead/Reserve CPU Diagnostics ..................................................................................................................... 56
Station Settings .................................................................................................................................. 61
View Data ..................................................................................................................................................... 61
Delete Data ................................................................................................................................................... 61
Export Data to USB ....................................................................................................................................... 61
Format Memory Device ................................................................................................................................. 62
Station Setup ................................................................................................................................................ 62
Station Status................................................................................................................................................ 62
Station Comm Ports ...................................................................................................................................... 62
Change Passwords ....................................................................................................................................... 62
Language Menu Selection ............................................................................................................................. 62
Log On ............................................................................................................................................... 63
Alarms and Events ............................................................................................................................. 64
Alarm Access ................................................................................................................................................ 64
Alarm Definition ............................................................................................................................................. 64
Alarm Indicator .............................................................................................................................................. 64
Display Details .............................................................................................................................................. 64
Alarm Groups ................................................................................................................................................ 65
Alarm Group Indication .................................................................................................................................. 66
Alarm Group Overview .................................................................................................................................. 66
Alarm Point Indication.................................................................................................................................... 67
Alarm Point Detail ......................................................................................................................................... 67
Alarm Acknowledgement ............................................................................................................................... 67
Event Access ................................................................................................................................................ 68
Event Definition ............................................................................................................................................. 68
Event Indication ............................................................................................................................................ 68
Display Details .............................................................................................................................................. 68
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Contents
Data Logging ..................................................................................................................................... 69
View Alarm & Event Logs .............................................................................................................................. 69
View Data Logs ............................................................................................................................................. 70
View Audit Logs ............................................................................................................................................ 70
Export Data Logs to USB ............................................................................................................................... 71
View Batch Groups & View Batch Status ........................................................................................................ 71
Delete Data Logs .......................................................................................................................................... 74
Downloading and Uploading Controller Configuration ......................................................................... 75
Download Configuration Files ........................................................................................................................ 75
Upload Controller Configuration ..................................................................................................................... 77
Uploading Database Image ................................................................................................................ 79
Uploading and Downloading Recipe Files........................................................................................... 80
Download Recipe Files .................................................................................................................................. 80
Upload Recipe Files ...................................................................................................................................... 82
Uploading and Downloading Security Settings .................................................................................... 84
Upload Security Displays and Functionality .................................................................................................... 84
Download Security Displays and Functionality ................................................................................................ 86
Using Barcode Reader ....................................................................................................................... 86
Process Displays ........................................................................................................... 87
Overview............................................................................................................................................ 87
Access .......................................................................................................................................................... 87
Widget displays ............................................................................................................................................. 87
How to edit a parameter ................................................................................................................................ 89
Pushbuttons, signals and variables .................................................................................................... 90
AGA8DL & AGA8GS .......................................................................................................................... 91
AGA Detail Gas Components ........................................................................................................................ 95
AGA8 Gross Setup ........................................................................................................................................ 96
4-Selector Switch ............................................................................................................................... 97
Device Control ................................................................................................................................... 98
Device Control Setup..................................................................................................................................... 99
Hand/Off/Auto Switch ....................................................................................................................... 100
Stage ............................................................................................................................................... 101
Stage setup display ..................................................................................................................................... 102
Ramp ............................................................................................................................................... 103
Ramp setup display ..................................................................................................................................... 104
Alternator ......................................................................................................................................... 105
Alternator Setup display............................................................................................................................... 106
Alternator Edit Setup display ........................................................................................................................ 106
Calendar Event ................................................................................................................................ 109
Calendar Event Block Menu ........................................................................................................................ 110
Edit Event Setpoints .................................................................................................................................... 111
Set Active Setpoint Group............................................................................................................................ 111
Edit Special Days ........................................................................................................................................ 111
View Special Days Event Setup ................................................................................................................... 112
Wireless transmitters ........................................................................................................................ 113
XYR5000 Base Radio.................................................................................................................................. 113
XYR5000 Transmitter .................................................................................................................................. 114
XYR6000 Transmitter .................................................................................................................................. 115
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Contents
VARIABLE RECIPES .................................................................................................. 117
Overview.......................................................................................................................................... 117
Description .................................................................................................................................................. 117
Variable Recipe Load vs. Variable Recipe Upload/Download ........................................................................ 117
Setpoint Programmers ................................................................................................ 119
Overview.......................................................................................................................................... 119
Description .................................................................................................................................................. 119
Setpoint Programmer Overview widgets ....................................................................................................... 120
Setpoint programmer – Pre Plot Display ........................................................................................... 122
General Description ..................................................................................................................................... 122
Setpoint Programmer Pre-Plot Graph attributes ............................................................................................ 123
Process Variable Trend Plot attributes ......................................................................................................... 124
Special cases and actions ........................................................................................................................... 124
Auxiliary SP and PV Pre-plot ....................................................................................................................... 125
Setpoint programmer Operate .......................................................................................................... 125
View/Edit profile ............................................................................................................................... 129
View/Edit Profile Segments .............................................................................................................. 131
Edit Type and Value .................................................................................................................................... 131
Edit Events ................................................................................................................................................. 132
Setpoint Scheduler ...................................................................................................... 133
Overview.......................................................................................................................................... 133
Setpoint Scheduler Operate ............................................................................................................. 134
View/Edit schedule ........................................................................................................................... 137
View/Edit Schedule Segments.......................................................................................................... 138
Edit Setpoints .............................................................................................................................................. 138
Edit Auxiliary Setpoints ................................................................................................................................ 138
Edit Time & Recycles .................................................................................................................................. 139
Edit guarantee hold ..................................................................................................................................... 139
Edit segment events .................................................................................................................................... 139
Sequencers ................................................................................................................. 141
Overview.......................................................................................................................................... 141
Sequencer Operate .......................................................................................................................... 142
View/Edit Sequence ......................................................................................................................... 144
View/Edit Sequence Steps ............................................................................................................... 145
Edit Time/Events ......................................................................................................................................... 145
Edit Auxiliary ............................................................................................................................................... 146
View Outputs 1-8/9-16 ................................................................................................................................. 146
Loops .......................................................................................................................... 147
Overview.......................................................................................................................................... 147
Loop widgets ............................................................................................................................................... 147
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Contents
Loop Setup ...................................................................................................................................... 148
Overview..................................................................................................................................................... 148
Loop modes ................................................................................................................................................ 149
Loop control setup ....................................................................................................................................... 150
Loop Tuning ................................................................................................................................................ 151
Tuning constants ......................................................................................................................................... 155
Alarm setpoints ........................................................................................................................................... 156
High Output Limiting .................................................................................................................................... 157
I/O Calibration ............................................................................................................. 159
Menu Overview ................................................................................................................................ 159
Overview.......................................................................................................................................... 160
AI Calibration ................................................................................................................................... 161
Overview..................................................................................................................................................... 161
Calibration equipment.................................................................................................................................. 161
Calibrate AI channel .................................................................................................................................... 162
Cancel Calibration ....................................................................................................................................... 162
Restore AI factory calibration ....................................................................................................................... 162
CJ Calibration .................................................................................................................................. 163
Cancel Calibration ....................................................................................................................................... 163
Restore CJ factory calibration ...................................................................................................................... 163
AO Calibration ................................................................................................................................. 164
Cancel Calibration ....................................................................................................................................... 165
Restore AO factory calibration ..................................................................................................................... 165
PPO Motor Calibration ..................................................................................................................... 166
Overview..................................................................................................................................................... 166
Calibration Status Information ...................................................................................................................... 166
Cancel Calibration ....................................................................................................................................... 167
Calibration Errors ........................................................................................................................................ 167
Auto Calibration Procedure .......................................................................................................................... 168
Semi-Auto Calibration Procedure ................................................................................................................. 169
Hand Calibration Procedure ......................................................................................................................... 170
Motor Setup ..................................................................................................................................... 172
Maintenance ................................................................................................................ 173
Troubleshooting ............................................................................................................................... 173
What to do if the Control Station has difficulty starting up .............................................................................. 173
Performing a cold start ................................................................................................................................ 173
What to do if you want to change the IP Address at the Control Station ......................................................... 174
Changing or entering IP Address ................................................................................................................. 174
How to remove the rear cover and change the battery of the operator interface? ........................................... 175
Changing the battery of Control Station unit ................................................................................................. 175
Parts ................................................................................................................................................ 176
Index ........................................................................................................................... 177
Sales and Service ....................................................................................................... 180
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Contents
Tables
Table 1 Main menu functions............................................................................................................................... 15
Table 2 Main menu tree ....................................................................................................................................... 16
Table 3 Controller status details ........................................................................................................................... 17
Table 4 Controller Setup details ........................................................................................................................... 19
Table 5 Controller modes defined ......................................................................................................................... 19
Table 6 Serial Port S1/S2 Statistics (left side of display) ........................................................................................ 23
Table 7 Serial Port S1/S2: Port Diagnostic status.................................................................................................. 24
Table 8 Serial Port S1/S2 Settings (right side of display) ....................................................................................... 25
Table 9 Protocol selection versus setup parameters for the Serial Port S1/S2.......................................................... 26
Table 10 Ethernet Port E1/E2 details .................................................................................................................... 27
Table 11 Ethernet Port E1/E2: Port Diagnostic status ........................................................................................... 28
Table 12 Expansion Rack Communication details ................................................................................................. 29
Table 13 Expansion Rack Communication Status ................................................................................................. 30
Table 14 Modbus Slave Status .............................................................................................................................. 31
Table 15 Host Connections ................................................................................................................................... 32
Table 16 Host Connection Status Indicators .......................................................................................................... 32
Table 17 Peer Connections ................................................................................................................................... 33
Table 18 Peer Connection Status ........................................................................................................................... 34
Table 19 Rack n diagnostics ................................................................................................................................ 37
Table 20 I/O module diagnostics .......................................................................................................................... 42
Table 21 I/O module Details ................................................................................................................................ 43
Table 22 I/O Module Error Status ........................................................................................................................ 44
Table 23 Bad module details ................................................................................................................................. 46
Table 24 Bad Channel details ............................................................................................................................... 47
Table 25 Redundant Overview ............................................................................................................................. 48
Table 26 Details of Rack diagnostics error status messages .................................................................................. 51
Table 27 Details of Lead or Reserve CPU diagnostics error status messages ......................................................... 57
Table 28 AGA Parameters .................................................................................................................................... 92
Table 29 AGA Error Codes ................................................................................................................................. 92
Table 30 Device control display details ................................................................................................................ 98
Table 31 Device states .......................................................................................................................................... 99
Table 32 Stage setup details ............................................................................................................................... 102
Table 33 Ramp operator display details .............................................................................................................. 103
Table 34 Edit ramp display details ..................................................................................................................... 104
Table 35 SPP inputs and current state................................................................................................................. 119
Table 36 Setpoint Progammer Overview widget features ..................................................................................... 120
Table 37 SPS inputs and current state................................................................................................................. 133
Table 38 Loop modes ........................................................................................................................................ 149
Table 39 Calibration Errors................................................................................................................................. 167
Table 40 Auto Calibration Procedure ................................................................................................................ 168
Table 41 Semi-Auto Calibration Procedure ......................................................................................................... 169
Table 42 Hand Calibration Procedure................................................................................................................. 170
Table 43 Parts ................................................................................................................................................... 176
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Contents
Figures
Figure 1 900 Control Station menu ........................................................................................................................ 1
Figure 2 Home display........................................................................................................................................... 5
Figure 3 Features .................................................................................................................................................... 7
Figure 4 Examples of buttons and data entry fields .................................................................................................. 9
Figure 5 Status bar................................................................................................................................................ 10
Figure 6 Status LEDs............................................................................................................................................ 12
Figure 7 Main Menu ............................................................................................................................................ 15
Figure 8 Variable Recipe Selection Display ....................................................................................................... 118
Figure 9 Recipe Load ......................................................................................................................................... 128
Figure 10 Recipe Save ........................................................................................................................................ 128
Figure 11 IMAN loop mode ............................................................................................................................... 149
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Overview
What’s in this guide
This guide contains instructions on assembly, installation, wiring, and operation of the 900 Control Station,
shown in Figure 1.
Introduction
Figure 1 900 Control Station menu
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Introduction
Specifications
Typical readers of this guide
The typical users of this guide are:
• the technician who installs the Control Station,
• the engineer who configures the Control Station,
• the operator who views/controls/monitors the process.
What you can do with the Control Station
The Control Station lets you perform these tasks:
• Monitor and control a process.
• Load/Store/Run Recipes, Profiles, Schedules, Sequences.
• Display various process data such as trends, alarms, diagnostics, setpoint profiles, and control loops.
• Store process data to disk.
Specifications
Refer to 900 Control Station Specifications document #51-52-03-46.
CE Conformity (Europe)
This product is in conformity with the protection requirements of the following European Council
Directives:
this product with any other “CE Mark” Directive(s) shall not be assumed.
2006/95/EC
ATTENTION
The emission limits of EN 50081-2 are designed to provide reasonable protection against
harmful interference when this equipment is operated in an industrial environment. Operation
of this equipment in a residential area may cause harmful interference. This equipment
generates, uses, and can radiate radio frequency energy and may cause interference to radio
and television reception when the equipment is used closer than 30 meters to the antenna(e).
In special cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the electromagnetic
emissions of this equipment.
, the Low Voltage Directive, and
2004/108/EC
, the EMC Directive. Conformity of
2 900 Control Station User Guide Revision 9
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Components
PC 900 Control Station HC900 Controller
•
Honeywell’s HC Designer
application configures your
HC900 Controller’s process
•
Honeywell’s Station Designer
application configures how your
Control Station interfaces with
the HC900 Controller. Build
custom displays using preconfigured objects (called
“widgets”) for interfacing with
principal function blocks such as
loops and SPPs. Configure data
logs for storage and trend
viewing.
Components
•
Lets you monitor and adjust the
HC900’s process through
custom-built displays and preconfigured “widgets”
•
Load/store/run recipes, profiles,
data logs
•
Monitor alarms, diagnostics,
events
•
Store data logs
•
Integrate loops of control with
digital I/O
•
Setpoint programming
•
Setpoint scheduling
•
Sequencing
•
Recipe management
•
Alarm processing
•
PID control, Advanced control,
autotuning, fuzzy logic
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Preparation and startup
Site Preparation
Preparation and startup
Site Preparation
The cable that connects the Control Station to the controller module contains low voltages. Keep the cable
away from high voltage wires that can cause interference.
Control Station Mounting
See HC900 Control Station Installation document #51-52-33-157.
Noise Protection
See document 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise
Environments.
How to configure your Control Station
The Control Station is shipped from the factory unconfigured. Use Honeywell’s Station Designer
application to configure your Control Station.
The overall steps for configuration are as follows.
Step Action
1
Using Station Designer application, open .sds file, add device, update IP address and create
data tags from your HC900’s .cde configuration file.
2
In Station Designer, build custom displays to be used by Control Station for viewing and
interacting with your HC900 Controller process.
3
In Station Designer, assign data tags to the custom displays.
4
Save the Station Designer configuration as an .sds file.
5
Download the .sds file via USB or Ethernet to the Control Station.
6
Your Control Station is now configured and ready to use.
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Startup
After connecting the Controller and Control Station and downloading your .sds file to the Control Station,
the Home display appears with 16 buttons. (Actual button text may vary.)
Preparation and startup
Startup
Figure 2 Home display
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Preparation and startup
Startup
This page has been intentionally left blank.
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Overview
Features
1
3
2
Figure 3 Features
Item Feature Description Details
1 Touch screen Interactive touch screen shows menus and displays.
(Optional protective film available.)
2 Keys Key functions are more generic than button functions. See page 11
3 CompactFlash For data storage and booting up from an image file. See page 11
4 Status LEDs Status of power, CompactFlash and alarms. See page 12
5
See page 8
4
5 Ports Connections for data storage and communications. See page 13
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Features
Touch screen
Touch screen
1
Item Feature Description Details
1 Navigation and
data entry
A button is an onscreen object that when touched
causes an action. Shown here are the buttons on the
Main Menu. Buttons come in various shapes, sizes
and colors but a graduated blue background is the
most common.
2 Status bar Always visible. Shows status of:
•
Logs
•
Diagnostics
•
Alarms
•
Events
•
Controller
•
Language
2
See page 9.
See page 10.
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Navigation and data entry
A button is an object you touch on the display to go to another menu or display or to cause an action.
Buttons come in various shapes, colors and sizes.
Features
Touch screen
2
2
1
1
3
4
5
1
1
3
1
1
1
Figure 4 Examples of buttons and data entry fields
Item Description Function
1 Buttons with graduated blue background appear on
virtually every menu under the Menu key (page 11)
and on many displays. Various sizes, shapes and
functions.
2 Graduated blue background in the title bar of the
object indicates a link to additional displays related to
the object.
Touch to activate.
Touch light blue title bar of object to jump to
detailed displays for that object.
Example: Touch PID title bar to jump to loop
tuning, tuning constants, etc.
Example: Touch SPP title bar to jump to
setpoint programmer events, etc.
5
3 Black value or text on white unlined box. Read only. Read-only.
4 Black value or text on white lined box. Read/write. Touch to edit. A popup appears where you can
5 Grayed out text, field or button. Not accessible or
applicable under current conditions.
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enter a new value, type text, or select from a
list of choices. See page 89
Example: Loop output not adjustable in Auto
mode.
Example: Redundant Overview button is not
active for non-redundant HC900s.
Page 22
Features
2
Touch screen
Status bar
The status bar is always visible at the bottom of all menus and displays.
1
3
4
Figure 5 Status bar
Button Description Function
1 Data Log indicator/Data Log menu button.
Gray text when no data logging is occurring on the Control Station.
When data logging is occurring, the icon becomes colorful and the
text becomes black.
2 Diagnostic indicator.
Gray text when there is no controller diagnostic present.
When a controller diagnostic is present, the button flashes.
3 Alarm indicator.
Gray text when there are no active alarms.
When there is an active alarm present (either acknowledged or
unacknowledged), the white background turns red and the icon
becomes colorful and the text becomes white.
When there are any unacknowledged alarms, the button flashes.
When all alarms become acknowledged, the flashing stops.
Touch to go to Data Log
menu. See page 64.
Touch to go to System
Diagnostics page. See page
36.
Touch to go to Alarms
console or Alarm Group
display depending on how the
Control Station was
configured (see Station
Designer manual section on
Alarms). Here all alarms are
displayed, with buttons that let
you mute and acknowledge
alarms.
5
4 Event indicator/Alarm and Event Summary button.
Gray text when no event is present.
When an event occurs, a description appears in black text and the
background changes to a pale yellow.
5 Controller mode, time and date. Touch to go to Controller
6 Language of displayed text is indicated by flag icon. Touch to go to Language
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Note: To see alarm history, go
to Alarm and Event Summary.
Touch to go to Alarm and
Event Summary, where they
can be viewed or cleared.
Setup. See page 19.
Setup. See page 68
Page 23
Keys
Features
Keys
Unless otherwise noted, the membrane keys on the left side of the front panel always behave as described
here.
Press key For this result
•
Programmable function
•
Programmable function
•
Print contents of the display to a .bmp file on CompactFlash.
•
Log off current user.
•
Go to next display. Works only after Back key was pressed.
•
Go to previous display.
•
Go to Home display. This is the default display upon startup. It
contains links to displays for viewing your HC900’s process.
See page 87.
•
Go to main menu. See page 15.
CompactFlash
CompactFlash socket is on the left side. Use CompactFlash card for:
• storing data logs (.csv)
• storing print screen images (.bmp)
• loading image file (.sdi).
NOTE: Maximum Compact Flash memeory size is 2GB, minimum Compact Flash size is 4MB.
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Features
Status LEDs
Status LEDs
The Status LEDs indicate:
• Run status of the Control Station
• CompactFlash card status
• Alarm status.
Figure 6 Status LEDs
Green LED Indication
Flashing Unit is in the boot loader, no valid configuration is loaded.
Steady Unit is powered and running an application.
Yellow LED Indication
Off No CompactFlash card present.
Steady CompactFlash card present.
Flashing rapidly CompactFlash being checked.
Flickering Unit is writing to the CompactFlash, either because it is storing data, or
because the PC connected via the USB port has locked the drive.
Flashing slowly Incorrectly formatted CompactFlash card present.
Red LED Indication
Flashing A tag is in alarm state.
Steady Valid configuration is loaded and no alarms are present.
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Ports
900 Control Station 10 inch model
900 Control Station 15 inch model
Features
Ports
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Features
Ports
USB Device
The USB Device port is for downloading a configuration from Station Designer to the Control Station.
Type B connector. Note: USB 3.0 support is only available on the 900CS10.
USB Host
USB Host Port A is for exporting data logs to a USB storage device with Type A connector.
USB Host Port B is not used.
Ethernet
The Ethernet port is for fastest communication with your HC900 Controller, PC, or other devices. Use an
Ethernet switch to link multiple devices.
RS485
The RS485 port is for communication with HC900 Controller if Ethernet is not desired or available.
RS232
The RS232 ports are not recommended due to reduced performance. Port B may be used to connect to
HC900. Port A PGM Port may be connected to your PC.
NOTE: The 15" model has two Ethernet ports and two RS485 ports whereas the 10" model has one of
each.
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Overview
Access
To access the Main Menu, press the Menu key.
Main Menu
Functions
The Main Menu is for viewing and adjusting settings for your Control Station and HC900 Controller.
Process displays are accessed under the Home key.
Figure 7 Main Menu
Table 1 Main menu functions
Menu Item Function
Controller Controller status and setup.
Communications Controller communications. Serial ports, Ethernet ports, I/O, Modbus, Hosts,
Peers.
Diagnostics Diagnostic status of controller, I/O, communications.
Station Settings File management of CompactFlash and USB device. Adjust/calibrate/clean touch
screen. View status of communication ports. Set passwords.
Log On Security manager for logging on.
Data Logging File management of Data Logs.
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Main Menu
Overview Main menu tree
Main menu tree
Access the Main Menu by pressing
. The menu is organized as shown in Table 2.
Table 2 Main menu tree
See Page
17 Controller Controller Status
Controller Setup
Summary Displays Analog Input Summary
Analog Output Summary
Analog Variable Summary
Digital Input Summary
Digital Output Summary
Digital Variable Summary
20 Serial Port S1
Serial Port S2
Ethernet Port E1
Ethernet Port E2
Modbus Slave Devices Modbus Slave Device n Modbus Slave n Status
Modbus/TCP Slave Device n Modbus/TCP Slave n Status
Host Connections Host Connection n Host Connection n Status
Peer Connections Peer Connections n Peer Connection n Status
36 Diagnostics Controller Diagnostics Rack n I/O Module Module Details
Details
I/O Module Diagnostics Rack n I/O Modules Module Details
I/O Calibration
Motor Setup
Redundant Overview
Lead CPU Diagnostics
Reserve CPU Diagnostics
61 Station Settings View Data
Delete Data
Export Data to USB
Memory Device Utilities
Download Recipes
Upload Recipes
Download Security
Upload Security
Export Data Logs
Export Data to USB
Upload Database Image
Format Memory Device
Main menu button Submenu
Expansion Rack
Communications
Communication
Diagnostics
Controller Communications
Download Controller
Configuration
Upload Controller
Configuration
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Main Menu
Controller Status Controller
See Page
Cellular Modem
Station Setup Languages
Adjust Display Brightness
Touch Calibration
Touch Test
Soft Key Test
Clean Screen
Station Status
Station Comm Ports
Change Passwords
62 Log On
64 Data Logging View Alarm & Event Logs
View Data Logs
View Audit Logs
Export Data Logs to USB
View Batch Groups Batch Groups
View Batch Status
Delete Data Log
Main menu button Submenu
Batch Status (for all batch
groups)
Batch Header (if the
batch group selected is
not running a batch)
Batch Status (f the batch
group selected is running
a batch). The Batch
Status is for this batch
group only.
Controller
Controller Status
This is a read-only display giving the status of various controller parameters.
Controller Type 900C30, 900C50, 900C70 and 900C75
Controller Name Configured controller name
Local Alias A locally referenced alias for the controller.
Control Firmware
Revision Level
Table 3 Controller status details
Item Description
Revision level of the Controller software.
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Main Menu
Controller Controller Status
Item Description
Controller Mode Controller’s mode of operation:
RUN: Controller is running normally.
Note: (For C30S, C50S, C70S and C75S Controllers only)
Blinking RUN text on master slide on lower right hand corner indicates
controller is in invalid mode, which means there are some forced output(s)
present in Safety portion of the controller configuration and user changed the
controller mode to RUN-LOCKED mode from RUN-PRGM mode.
PROG: Controller is in Program mode.
OFLN: Controller is in Offline mode.
FAULT: A fault was found reading the Controller switch.
NO COMM: This is displayed if controller is not responding.
Frequency (Hz) Line frequency. Used for configuring the conversion time of the A/D converter.
Cycle Time (Sec) The analog control cycle time in seconds. This value is determined from the
execution time estimated from the configured control scheme. Cycle Time and
Fast Cycle Time increase (slow down) as the following increase: CPU % Used,
Fast CPU % Used, Dynamic Memory, Config Memory. Also, extensive use of
Free Form Logic blocks (as opposed to equivalent gate logic) can substantially
increase Fast Cycle Time.
CPU Percent used Calculation of percentage of time the CPU is active during the analog cycle time
Peak time (sec) Maximum time used to complete the analog cycle
Control Block
Overruns
Fast Logic Cycle Time
(Sec)
Number of times that the processing of the analog control blocks exceeds the
allocated analog cycle time
Cycle Time and Fast Cycle Time increase (slow down) as the following
increase: CPU % Used, Fast CPU % Used, Dynamic Memory, Config Memory.
Also, extensive use of Free Form Logic blocks (as opposed to equivalent gate
logic) can substantially increase Fast Cycle Time.
Fast Logic CPU Per
Cent Used
Fast Logic Peak Time
Calculation of percentage of time the CPU is active during the processing of
digital control blocks
Maximum time used to complete the digital control cycle
(Sec)
Fast Logic CB
Overruns
Number of times that the processing of the digital control blocks exceeds the
allocated digital cycle time
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Main Menu
Controller Setup Controller
Controller Setup
The current controller mode is indicated on the bottom right of the display.
Table 4 Controller Setup details
Item Description
Set Controller Time
and Date
Change mode of the
controller
Write To Flash Write controller database to Flash memory. Controller must be in the Run, Run Locked,
Set the controller time and date.
Run Mode: Select this to resume running the process.
Offline Mode: Select this before performing AI calibration.
Program mode: Select this:
•
Before performing AI and AO Calibration.
•
To turn off all of the controller outputs while reconfiguring a control strategy.
Cold Start: Refreshes the Flash memory of the controller so that if your battery goes
dead the data in Flash is up to date. Use the Program mode for changes whenever
possible.
or Offline Mode. Saves any parameters that you may have changed in the controller to
the controller’s non-volatile Flash memory. The affected parameters include:
Loop tuning parameters (gain, rate, reset, etc.)
Changes to Recipes, Profiles, Schedules, and Sequences.
If the write fails, upload the controller's configuration to the PC (using HC Designer) and
save the uploaded configuration to disk to make sure that you have captured all of the
non-volatile parameter changes.
Table 5 Controller modes defined
Mode Function Blocks Executed? Output status? Effect upon return to RUN mode?
RUN Yes Outputs updated None
OFFLINE No Outputs held Resume
PROGRAM No Outputs off Cold start
ATTENTION
You cannot change the controller mode from this display if the controller’s mode switch is in the
RUN LOCKED or PROGRAM LOCKED position. If the switch is in either of these locked
positions, this display will show the message “MODE MUST NOT BE LOCKED OR FAULT.”
TIP
• If the controller switch is set to RUN but the mode was set to PROGRAM or
OFFLINE here, following a power cycle the mode will return to RUN.
• Changing from Program to Run causes data in RAM (setpoint profiles, recipes,
schedules, sequences) to be copied to non-volatile (FLASH) memory.
• In a cold start, all data storage and display buffers are cleared and accumulated
values of some function blocks (such as totalizers) are reset.
• In a resume, all buffered data and values are retained and the process resumes
where it left off.
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Main Menu
Summary Displays About Summary Displays
Summary Displays
About Summary Displays
There are six summary displays to show the I/O blocks present in the Controller and the variables in the
configuration. The six summary displays are:
• Analog Input Summary
• Analog Output Summary
• Analog Variable Summary
• Digital Input Summary
• Digital Output Summary
• Digital Variable Summary
The Analog Input and Output Summary Displays show the following fields.
1. Physical Address of the Block (RMC)
• Rack Number
• Module Number
• Channel Number
2. Tag
3. Description
4. Value
5. Units
6. Error Status
The following additional fields are displayed when an I/O Safety Function block Analog Input Voting is
configured.
7. Channels A,B, and C
8. VFAIL
9. SFAIL
The following additional fields are displayed when an I/O Safety Function Block Analog Output Validated
is configured.
7. VFAIL
8. FBFAIL
The Analog Variable Summary Display shows the following fields:
1. Variable Number
2. Tag
3. Description
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Main Menu
About Summary Displays Summary Displays
4. Value
5. Units
The Digital Input Summary Display shows the following fields:
1. Physical Address of the DI Block (RMC)
• Rack Number
• Module Number
• Channel Number
2. Tag
3. Description
4. State
5. Error Status
The following additional fields are displayed when an I/O Safety Function block Digital Input Voting is
configured.
6. Channels A,B, and C
7. VFAIL
8. SFAIL
The following additional fields are displayed when an I/O Safety Function Block Digital Output Validated
is configured.
6. VFAIL
7. FBFAIL
The Digital Output Summary Display shows the same information as above plus the Type of the module.
The Digital Variable Summary Display shows following fields:
1. Variable Number
2. Tag
3. Description
4. Data
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Main Menu
Communications Menu Overview
Communications
Menu Overview
Menu Submenu
Serial Port S1 (p. 22)
Serial Port S2 (p. 22)
Ethernet Port E1 (p. 27)
Ethernet Port E2 (p. 27)
Expansion Port
Communications (p. 29)
Modbus Slave Devices (p. 31) Modbus Slave Device n Modbus Slave n Status
Host Connections (p. 32) Host Connection n Host Connection n Status
Peer Connections (p. 33) Peer Connections n Peer Connection n Status
Modbus/TCP Slave Device n Modbus/TCP Slave n Status
NOTE: The 15" control station can be programmed using only the Ethernet, serial and compact flash card.
The 900CS15's USB programming port conflicts with today’s PCs so it's advisable to use Ethernet ports for
configuration changes. This problem has been observed only with the 15" control station; the 10" control
station has not shown any problems with its USB ports.
Serial Port S1/S2
The Serial Port S1 and Serial Port S2 screens both show Statistics (Table 6) and Settings (Table 8) for those
controller serial ports.
Table 9 shows the relationship between the setup parameters and each protocol.
The controller’s Serial Port S1 can be set-up as an ELN Configuration port, a Modbus Master port, or a
Modbus Slave port. The ELN protocol allows the controller to communicate with the Process Control
Designer package on the PC using the proprietary ELN protocol. The Modbus Master protocols allow the
controller to act as a Modbus Master, retrieving data from other instruments that have been configured as
Modbus slave devices. The three Modbus Slave protocols allow the controller to act as a slave to various
host devices, including a PC running HC Designer.
The information presented in Table 6 and Table 9 also applies to Serial Port S1 when a Redundant
Controller is used.
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Main Menu
Serial Port S1/S2 Communications
Table 6 Serial Port S1/S2 Statistics (left side of display)
Item Description
Port Diagnostic
Port Status
Messages Received
Shows the overall condition of the Serial Port S1. See the list of Serial Port S1
diagnostic conditions in Table 7 on page 24.
This is the current status of the port. The possible status conditions are:
GOOD: the protocol is set to ELN.
REQUIRES SETUP: the protocol is set to one of the Modbus Slave protocols, and
the Slave Address is set to 255. Messages on the communication link are ignored
in this state.
OFFLINE: the protocol is set to one of the Modbus Slave protocols, and the Slave
Port Enable is set to DISABLE. Messages on the communication link are ignored
in this state.
ONLINE: the protocol is set to one of the Modbus Slave protocols, and the Slave
Port Enable is set to ENABLE. Messages on the communication link are being
processed in this state.
NO MODBUS SLAVE BLOCKS: the protocol is set to one of the Modbus Slave
protocols, but there are no Modbus slave function blocks present in the controller’s
configuration.
PROGRAM MODE: the protocol is set to one of the Modbus Slave protocols, but
the controller is in Program Mode. The controller does not scan the slave devices in
this state.
ELN SLAVE: the protocol is set to one of the Modbus Slave protocols, but the
controller is in Program Locked Mode. The port automatically reverts to ELN
protocol and the controller becomes a slave device whenever the mode selection
switch is placed in the Program Locked position.
SCANNING SLAVES: the protocol is set to one of the Modbus Slave protocols, and
the controller is actively scanning the slave devices attached to the port.
The number of messages that were received and processed correctly.
Data Link Errors
Application Errors
Clear Statistics
The number of basic link-level errors detected by the controller. If the protocol is
Modbus Master, the errors may be due to a slave device that does not reply when it
is scanned. Refer to the section “Troubleshooting Data Link Errors” (page 35) for
more information.
The number of messages that were responded to with an exception code. For
example, application errors can be caused by (a) writing to a read-only register, (b)
accessing a register that is not supported by the slave device, or (c) using a
Modbus function code that is not supported by the slave device.
This item resets the message counters for this port back to zero (Messages
Received, Data Link Errors, and Application Errors). Note: the counters will only be
reset if the controller is in Run Mode.
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Main Menu
Communications Serial Port S1/S2
Table 7 Serial Port S1/S2: Port Diagnostic status
Status Possible Cause Controller Action What to do
GOOD N/A N/A N/A
APPLICATION
ERROR
DATA LINK
ERROR
HARDWARE
FAILURE
Applies to Port S2
only. At least one
response to a host
resulted in an
exception code or
NAK.
A large number of
messages are
resulting in data link
errors.
The DUART is failing
to operate properly.
1. Rack 1 monitor block’s
COMPORT DIAG is set to
WARNING.
2. Rack 1 monitor block’s
RACK OK pin is turned off.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
1. Rack 1 monitor block’s
COMPORT DIAG is set to
FAILED.
2. Rack 1 monitor block’s
RACK OK pin is turned off.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
4. If configured as Modbus
Master port, associated
slave blocks have their
read pin values frozen to
the last value read.
Replace the controller CPU module.
At host, determine which message is
causing the exception code and fix it.
1. Check baud rate.
2. Check connectors.
3. Check cable polarity.
4. Isolate cable from electrical
interference.
5. If RS232-to-RS485 converter used,
check its power, switch/jumper settings,
and polarity.
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Main Menu
Serial Port S1/S2 Communications
Table 8 Serial Port S1/S2 Settings (right side of display)
Setting Description
Protocol
ELN: The default protocol, used to communicate with the HC Designer
configuration software.
MODBUS MASTER: The controller acts as a Modbus Master device on the
communication link.
MB MASTER ADVANCED: The controller acts as a Modbus Master device on the
communication link. This protocol provides enhanced data throughput for
applications where the HC900 is being used with a “Modbus-to-fieldbus” gateway
device.
MODBUS SLAVE MULTI: The controller acts as a Modbus Slave device. This
protocol allows more than one slave device to be present on the communications
link (multi-drop).
MODBUS SLAVE PTP: The controller acts as a Modbus Slave device. This
protocol can be used if the controller is the only slave device on the link (Point-topoint).
MODBUS SLAVE MODEM: The controller acts as a Modbus Slave device. This
protocol provides the extended delays that are needed to access the controller via
a modem.
Baud Rate (Bps) Select 9600, 19200, 38400, 57600 or 115200 bits per second.
Modbus Parity Select None, Odd, or Even parity.
Modbus Stop Bits Select 1 or 2 Stop Bits.
Slave Address (1-247 or
255)
This is the address of the controller on the Modbus link when one of the three
Modbus Slave protocols is selected. All devices on the link must have a unique
Modbus address. The address may be set to a value of 1 to 247, or it may be set
to 255. A value of 255 disables the port for this controller.
Slave Port Enable This item allows you to enable or disable the port:
ENABLE: The port will respond to communication requests.
DISABLE: The port will ignore communication requests.
Double Register Format
Under the Modbus protocol, each IEEE 32-bit floating-point number requires two
consecutive Modbus registers, for a total of four bytes. The stuffing order of the
bytes within these registers differs among Modbus devices. To provide
compatibility with the various hosts, the double-register format is configurable. The
selections are:
FP B Big Endian format Byte order: 4, 3, 2, 1
FP L Little Endian format Byte order: 1, 2, 3, 4
FP BB Big Endian with byte-swap Byte order: 3, 4, 1, 2
FP LB Little Endian with byte-swap Byte order: 2, 1, 4, 3
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Main Menu
Communications Serial Port S1/S2
Table 9 Protocol selection versus setup parameters for the Serial Port S1/S2
Setup parameter
ELN Modbus
Master or
Modbus
Protocol selection
Modbus
Slave
Modbus Slave
Point to Point
Multidrop
Modbus Slave
Modem
(PTP)
Master
Advanced
Baud Rate (BPS)
Modbus Parity
Modbus Stop Bits
Slave Address
Slave Port Enable
Double Register Format
Note:
When “Modbus Slave Modem” protocol is selected, the Modbus Parity and Modbus Stop Bits are fixed at
“None” and “1 Bit” respectively and cannot be changed.
X X X
X X
X X
X
X
X
X
X
X
X
X
X
X
NONE
1 BIT
X
X
X
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Main Menu
Ethernet Port E1/E2 Status Communications
Ethernet Port E1/E2 Status
The Ethernet Port E1 and Ethernet Port E2 screens both show the following details for each Ethernet port
on the controller.
Table 10 Ethernet Port E1/E2 details
Item Description
Port Diagnostic Shows condition of Ethernet port. See Table 11 for status details.
Controller Name Configured controller name
Network Name The network name to which the controller belongs.
Local Alias A locally referenced alias for the controller.
Mac Address The controller’s Media Access Control address.
IP Address The controller’s Internet Protocol address.
Subnet Mask The controller’s subnet mask address.
Gateway IP Address The Internet Protocol address for the controller’s gateway device.
Double Register Format Each IEEE 32-bit floating point number requires two consecutive registers (four bytes,
MSB=4, LSB=1 in byte order below) starting with the register defined as the starting
register for the information. The stuffing order of the bytes into the two registers differs
among Modbus hosts. To provide compatibility, the Double register format is
configurable. Selections are:
FPB
Floating Point Big Endian Format Byte order – 4, 3, 2, 1 (Default)
FP BB
Floating Point Big Endian with byte-swapped Byte order – 3, 4, 1, 2
FP L
FP LB
Floating Point Little Endian Format Byte order – 1, 2, 3, 4
Floating Point Little Endian with byte-swapped Byte order – 2, 1, 4, 3
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Main Menu
Communications Ethernet Port E1/E2 Status
Table 11 Ethernet Port E1/E2: Port Diagnostic status
Status Possible Cause Controller Action What to do
GOOD N/A N/A N/A
SETUP ERROR Controller/network
names determined on
network are illegal
NO IP ADDRESS IP address is not
configured
HARDWARE
FAILURE
Ethernet port tests
failed during power-up.
DHCP Failure DHCP is configured,
and no IP address has
been granted.
Rack 1 monitor block’s
Correct the setup problem.
COMPORT DIAG is set to
FAILED.
Rack 1 monitor block’s
RACK OK pin is turned off.
ASYS (SYSTEM
MONITOR) block’s HW OK
pin is turned off.
Same as above If a DHCP server is present,
download a configuration that
uses DHCP.
Enter an IP address.
Same as above Replace CPU module.
Same as above Check the DHCP server.
Download a configuration with
DHCP required.
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Main Menu
Expansion Rack Communications Communications
Expansion Rack Communications
Shows status of each controller expansion I/O rack.
Table 12 Expansion Rack Communication details
Item Description
Diagnostics Status Status of the rack’s communication port.
Message Count Number of message attempts to the rack.
Link Error Count Number of message attempts to the rack that resulted in failed response.
Total Count Total for all racks.
Clear Statistics Reset the messages and link error counters for all racks to zero.
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Main Menu
Communications Expansion Rack Communications
Table 13 Expansion Rack Communication Status
Status Possible Cause Controller Action What to do
GOOD
DATA LINK
FAILURE
Comm port is functioning
properly or comm port is
not used
The communications to a
particular rack is resulting
in a lot of communication
errors.
N/A N/A
1. Related rack monitor
block’s RACK OK pin is
turned off.
2. Depending on the nature of
the communication errors, the
associated rack monitor
block’s module diagnostics,
and pins could be affected.
3. Associated rack’s
COMPORT DIAGNOSTIC is
set to FAILED.
4. Rack 1 COMPORT
DIAGNOSTIC is set to
FAILED.
1. Use the OI to determine which
rack is experiencing the comm
errors. Verify that the expansion
rack should be in the
configuration
2. Verify that the jumpers on the
scanner are setup for the correct
rack address.
3. If a hub is used, check that all
cables are properly connected to
the hub, proper crossover cables
are used, and that hub is
powered.
4. Cycle power to the rack.
5. Cycle power to the hub.
6. Replace the expansion rack’s
power supply.
7. Replace the expansion rack.
8. Replace the expansion rack’s
scanner board.
9. Replace the main CPU.
HARDWARE
FAILURE
The power-up test of the
expansion rack Ethernet
controller failed.
1. All rack monitor block XIO
PORT DIAG are set to
HWFAIL and COMPORT
DIAGNOSTIC is set to FAIL.
2. All rack monitor block
RACK OK pins are turned off.
3. All modules in the
configuration have their
diagnostic set to
MOD_NOCOMM, their rack
monitor module fail pin is
turned on., and the rack
monitor block’s RACK OK pin
is turned off.
4. SYSTEM MONITOR
block’s HW OK pin is turned
off.
5. The statuses for the AO, AI,
DI, DO channels that are
affected are set to
BAD_CHANNEL.
Replace main-CPU module
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Main Menu
Modbus Slave Devices Communications
Modbus Slave Devices
This display gives you an overview of the individual Modbus or Modbus/TCP slave devices attached to the
controller. Navigate to the desired device to see its status.
Table 14 Modbus Slave Status
Item Description
Slave Name
Slave Address
Name of slave device.
For Modus: 1-247 or 255. For Modbus/TCP: IP address.
In Scan
Comm Quality
Messages Received
Data Link Errors
Application Errors
Scan Enabled
Current scan status of slave device.
YES
: The slave device is being scanned at its optimum rate. The scan rate is
computed by the controller.
NO:
The slave device is being scanned at a reduced rate, or it is not being scanned
at all. The possible reasons are:
•
SCAN ENABLED is set to NO.
•
COMM QUALITY is NONE or BAD.
•
the Modbus address of the slave device is set to 255.
•
the slave device is not defined in the controller configuration.
•
The RS-232 port protocol is not set to one of the Modbus Master protocols.
NONE:
This slave device is not defined in the controller configuration.
GOOD
: The slave device is being scanned at its optimum rate because its operation
on the communications link is acceptable.
BAD
: The slave device is being scanned at a reduced rate because it has
experienced an abnormal number of failed responses. Refer to the section
“Troubleshooting a Comm Quality Problem” below.
The number of messages that were received and processed correctly since the last
controller Cold Start.
The number of basic link-level errors generated by this slave since the last controller
Cold Start. Refer to the section “Troubleshooting Data Link Errors” for more
information.
The number of application errors generated by this slave since the last controller
Cold Start. Application errors are messages that the slave device responded to with
an exception code. For example, application errors can be caused by (a) writing to a
read-only register, (b) accessing a register that is not supported by the slave device,
or (c) using a Modbus function code that is not supported by the slave device.
YES
: Scanning has been enabled
NO
: Scanning has been disabled
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Main Menu
Communications Host Connections
Host Connections
Table 15 Host Connections
Item Description
Connection Status Shows condition of each virtual connection.
See Host Connection Diagnostics Status Indicators, Table 16
Protocol The protocol used by the host to communicate with the controller (Modbus TCP).
IP Address The IP address of the host device that is using this connection.
Messages Received Number of messages received without errors.
Application Errors Number of message requests that resulted in an exception.
Clear Statistics Resets to zero the number of messages received and application errors.
Table 16 Host Connection Status Indicators
Status Possible Cause Controller Action What to do
GOOD N/A N/A N/A
APPLICATION
ERROR
At least one response to
a host resulted in an
exception code.
1. Rack 1 monitor
block's COMPORT
DIAG is set to
WARNING.
2. Rack 1 monitor
block's RACK OK
pin is turned off.
3. ASYS block's HW
OK pin is turned off
At host, determine which message
is causing the exception code and
fix.
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Main Menu
Peer Connections Communications
Peer Connections
.
Table 17 Peer Connections
Item Description
Peer Controller Name Controller name of the peer device. All peer devices must have the same network
name. All peer devices that share a common network name must have unique
controller names.
IP Address IP address of the peer. The IP address is automatically determined when a peer
device is discovered via its network and controller names.
Peer Status See Peer Connection Status Indicators, Table 18.
Messages Received Number of messages received from the peer device.
Messages Transmitted Number of messages sent to the peer device.
Write Requests Number of write event messages sent to the peer device.
Write Request Failures Number of write event messages that have not been acknowledged by the peer device
within the scan rate configured for the peer data exchange. A non-zero value means
the network is congested and message transfer is being impeded.
Producer Failures Number of times the peer device has not responded to a data exchange connection
request. Non-zero value means the peer device is not available because the controller
is in Program mode, controller power is off, or controller name does not exist in the
network. The network is defined as all devices that:
•
are on the same physical network,
•
are within the IP address range per the configured IP mask,
•
share the same peer network name.
Clear Statistics Reset to zero the number of messages received and application errors.
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Main Menu
Communications Peer Connections
Table 18 Peer Connection Status
Status Possible Cause Controller Action What to do
GOOD N/A
APPLICATION
ERROR
The peer connection
could not be
established due to an
internal program
problem.
SETUP ERROR
The peer device
indicated that the one
or more data item is
not valid.
PEER FAIL
The assigned peer
could not be located on
the network.
Peer is connected and
updating normally
N/A
The error will occur when
an incompatibility exists
between peer devices with
regard to variable or signal
assignments.
This error should not
occur when exchanging
data between HC900
controllers.
N/A
N/A
1. Reset the controller to restart
the UDP/IP protocol stack and
reset buffer allocations.
2. Contact Honeywell Technical
Assistance if the problem
exists.
Contact Honeywell Technical
Assistance if the status occurs.
1. Check the controller name and
network name of the peer
device to assure that they
match that specific PDE block.
2. Check that the IP addresses of
the peer devices are all within
the range of the IP mask.
3. Check that the peer devices
have the same IP subnet mask.
See Network parameters for IP
mask setting.
PORT FAIL
NOT STARTED
The peer data
exchange IO
subsystem could not
be started due to
internal resource
problem.
The assigned peer IO
connection has not yet
been attempted.
Normal state during
startup and during
configuration mode.
This status should
automatically change
to GOOD after both
peer controllers are in
the RUN mode.
N/A
1. Reset the controller to restart
the Ethernet IO hardware and
reassign processor IO
mapping.
2. Contact Honeywell Technical
Assistance if the problem
exists.
1. If this status persists during run
time, check that the peer
device is properly connected
and that the control name and
network name is correct.
2. Check that the IP masks of all
peer devices to assure that all
IP addresses are within the
same subnet.
3. Check that all external network
components such as switches
and routers allow passing of
UDP packets on port 502.
4. Check that the peer device is
powered on and is in RUN
mode.
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Main Menu
Troubleshooting a Comm Quality problem Communications
Troubleshooting a Comm Quality problem
If a slave device is reporting a Comm Quality value of “BAD”, check the following items:
5. Verify that the slave device is powered-up.
6. Verify that the slave device is wired correctly.
7. Verify that the slave device has the correct slave address.
8. Verify that all slave devices on the link have a unique slave address.
9. Verify that the slave device has the correct baud rate and parity settings.
10. Verify that all slave devices on the link have the same baud rate and parity settings.
11. Verify that the slave is set-up for half-duplex operation.
12. If all slave devices report a BAD status, check the physical connection of the link to the controller’s
RS-232 port. If this connection is OK, check the connection to each slave device on the link.
13. If there is more than one slave device on the link, verify that the RS-232/RS-485 converter box is
working correctly.
14. Verify controller is set to unterminated for RS-485 communications.
Troubleshooting Data Link Errors
Data Link Errors can be caused by electrical noise, physical wiring problems, or incorrect configuration
settings. If a Master or Slave device is reporting Data Link Errors, check the following items:
15. Verify that the physical wiring of the communication link is correct.
16. Verify that the physical wiring is shielded from electrical noise.
17. Verify that all devices on the link have the correct baud rate and parity settings.
18. Verify that all terminating resistors are installed properly. Verify that the ohm-value of the
terminating resistors is correct.
19. Verify controller is set to unterminated for RS-485 communications.
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Main Menu
Diagnostics Menu Overview
Diagnostics
Touching the DIAGS indicator on the status bar will go to the System Diagnostics page so that you can see
at a glance the status of the H900 Controller. As the screen shot below shows, diagnostic information on
the CPU, Communications, and I/O Rack is displayed with green highlights indicating a good status or red
if there is a diagnostic. Touching the various buttons will direct you to the various detailed screens per the
menu tree below.
Menu Overview
Menu Submenu
Controller Diagnostics
I/O Module Diagnostics
Communication Diagnostics
This links to the main
Communications menu. See page
22.
Redundant Overview
Lead CPU Diagnostics
(p. 37)
Rack n Diagnostics I/O Module Diagnostics
(p. 42)
Rack n I/O Modules
(p. 48)
(p. 56)
(p. 42)
Details.
This links to the main
Communications menu.
See page 22.
(p. 42)
Module Details
I/O Calibration
Motor Setup
Controller Communications
(p. 159)
(p. 172)
(p. 43)
Module Details
43)
(p.
Reserve CPU Diagnostics
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Main Menu
Controller Diagnostics Diagnostics
Controller Diagnostics
Select a rack number to see its diagnostics. For I/O diagnostics and details, see pages 42 and 43.
Table 19 Rack n diagnostics
Item Status Possible Cause Controller Action What to do
Rack
Configured?
NO N/A N/A N/A
Controller
Status
FORCED OUTPUT
INVALID CONFIG.
SWITCH FAULT
YES N/A N/A N/A
GOOD N/A N/A N/A
NO MASTER
PORT
A block has an output
that is forced.
A configuration that
exceeds the loop
capacity of the
controller was
downloaded or an
invalid configuration
exists.
A failure is detected in
the switch reading.
The controller
configuration contains
at least one Modbus
slave block, but
neither the RS-232
nor the RS-485 port is
set up as a Modbus
Master port.
None Remove force on block output..
An empty database is
created.
1. All control blocks stop
running
2. All I/O scanning ceases.
This forces the modules
into failsafe.
The controller is not
scanning the Modbus
slave devices.
Download a valid configuration.
Replace CPU.
Select Modbus Master or Modbus
Master Advanced protocol for either the
RS-232 or RS-485 port.
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Main Menu
Diagnostics Controller Diagnostics
Item Status Possible Cause Controller Action What to do
CPU Status GOOD N/A N/A N/A
WATCHDOG
ERROR
Watchdog reset
resulting from
software failure
1. Associated rack monitor
block’s RACK OK pin is
turned off.
2. SYSTEM MONITOR
block’s HW OK pin is
1. Force a cold start.
2. Upgrade controller module software.
3. Replace CPU board.
4. Contact Honeywell Personnel.
turned off.
PREFETCH
ERROR
CPU failed when
attempting to fetch an
instruction from the
prefetch register.
1. Controller performs a
restart
2. Associated rack monitor
block’s RACK OK pin is
turned off.
1. Force a cold start.
2. Isolate system from noise and force
a cold start.
3. Replace CPU board.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
ADDRESS ERROR
The reserved
See PREFETCH ERROR. See PREFETCH ERROR.
exception occurred for
an unknown reason.
UNDEFINED
INSTR ERROR
DATA ABORT
ERROR
Bad Instruction
Detected
CPU failed when
attempting to access
See PREFETCH ERROR See PREFETCH ERROR.
See PREFETCH ERROR. See PREFETCH ERROR.
data.
S/W INTERRUPT
ERR
Software Interrupt
occurred which is not
See PREFETCH ERROR. See PREFETCH ERROR.
supported by the
software.
VECTOR ERROR
Memory
GOOD N/A N/A N/A
Corrupted interrupt
vectors in RAM.
Interrupt vectors were
restored.
See WATCHDOG ERROR.
Status
5 DAY BATTERY
WARNING
Estimated battery life
is less than 5 days.
1. Associated rack monitor
block’s RACK OK pin is
Replace battery.
turned off.
2. SYSTEM MONITOR
block’s HW OK pin is
turned off.
LOW BATTERY Battery voltage is low.
1. Associated rack monitor
Replace battery.
block’s RACK OK pin is
turned off.
2. SYSTEM MONITOR
block’s LOW BATTERY
pin is turned on.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
FLASH ERROR Flash failed to burn
1. Associated rack monitor
block’s RACK OK pin is
turned off.
1. Force a cold start.
2. Replace CPU board.
2. SYSTEM MONITOR
block’s HW OK pin is
turned off.
I/O Status GOOD N/A N/A N/A
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Main Menu
Controller Diagnostics Diagnostics
Item Status Possible Cause Controller Action What to do
MODULE ERROR
One of the module
diagnostics in the
associated rack is set
to MISMATCH, BAD
Select I/O from the menu
to see details on the faulty
module. See I/O Module
Diagnostics on page 42.
Select I/O from the menu to see details
on the faulty module. See I/O Module
Diagnostics on page 42.
MODULE, BAD
CHANNEL., or
MISSING/NO COMM
(if the
communications is
failing due to the
module not
installed—could occur
if the module is
installed but CPU
can’t communicate to
it).
MODULE HI CJ
TEMP
One of the module
diagnostics in the
associated rack is set
to HI CJ
Select I/O from the menu
to see details on the faulty
module. See I/O Module
Diagnostics on page 42.
Select I/O from the menu to see details
on the faulty module. See I/O Module
Diagnostics on page 42.
TEMPERATURE.
FAILURE
The Controller
module is unable to
successfully
communicate to any
modules that are in its
SPI backplane.
All associated module
diagnostics are set to
MISSING/NO COMM.
See MISSING/NO COMM
in Table 22 I/O Module
Error Status on page 44 for
further details.
1. Remove modules and check for bent
pins on connectors.
2. Reinsert modules one at a time and
note which module the diagnostic
reoccurs, and replace that module.
3. Cycle power to the rack.
4. Replace the power supply.
5. Replace the rack.
6. Replace the CPU board.
NO COMM
The Main CPU is
unable to successfully
communicate to an
expansion rack that is
in its configuration.
See FAILURE.
1. Verify that the expansion rack should
be in the configuration
2. Verify that the jumpers on the
scanner are setup for the correct rack
address.
3. Check that expansion rack is on.
4. Check the expansion rack’s status
LED for diagnostic information.
5. Check that cable is connected to
expansion rack.
6. If a hub is used, check that all cables
are properly connected to the hub,
proper crossover cables are used, and
that hub is powered.
7. Cycle power to the rack.
8. Cycle power to the hub.
9. Replace the expansion rack’s power
supply.
10. Replace the expansion rack.
11. Replace the expansion rack’s
scanner board.
12. Replace the main CPU.
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Main Menu
Diagnostics Controller Diagnostics
Item Status Possible Cause Controller Action What to do
BAD VERSION
The Main CPU
determined that its
software is not
compatible with the
scanner module.
All associated module
diagnostics are set to
MISSING/NO COMM.
Refer to MISSING/NO
COMM diagnostic for
further details.
1. Upgrade the scanner software either
by replacing the module or doing a
code-download.
2. Update Main CPU software either by
replacing the module or doing a code
download.
RTC Status GOOD N/A N/A N/A
NOT
RTC not programmed
PROGRAMMED
1. Time and date is set to
00:00:00, January 1, 1970.
Program RTC.
2. Associated rack monitor
block’s RACK OK pin is
turned off.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
BAD DATA Bad date and time
See NOT
PROGRAMMED.
1. Program RTC.
2. Cycle power.
3. Replace CPU.
4. Replace boards in rack.
5. Replace rack.
PROGRAMMING
RTC failed to program
FAILURE
READ FAILURE Unable to read RTC
See NOT
PROGRAMMED.
See NOT
See BAD DATA.
See BAD DATA.
PROGRAMMED.
Comm Port
Status (Rack
Good N/A N/A N/A
1)
IO Comm
Link Status
(Rack 2-5)
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Main Menu
Controller Diagnostics Diagnostics
Item Status Possible Cause Controller Action What to do
Data Link Failure The communications
to a particular rack is
resulting in a lot of
DLL errors.
1. Related rack monitor
block’s RACK OK pin is
turned off.
2. Depending on the
nature of the DLL errors,
the associated rack
monitor block’s module
diagnostics, and pins
could be affected.
1. Use the OI to determine which rack
is experiencing the DLL errors. Verify
that the expansion rack should be in
the configuration
2. Verify that the jumpers on the
scanner are setup for the correct rack
address.
3. If a hub is used, check that all
cables are properly connected to the
hub, proper crossover cables are
used, and that hub is powered.
4. Cycle power to the rack.
5. Cycle power to the hub.
6. Replace the HC900-C50 expansion
rack’s power supply.
7. Replace the HC900-C50 expansion
rack.
8. Replace the HC900-C50 expansion
rack’s scanner board.
9. Replace the main CPU.
Hardware Failure The power-up test of
the expansion rack
Ethernet controller
failed.
Port A/B Cable
Mismatch
C70R only. The I/O
cables from CPUA
and CPUB are
connected to the
wrong ports on the
I/O scanner CPU
1. All rack monitor block
XIO PORT DIAG are set
to HWFAIL.
2. All rack monitor block
RACK OK pin are turned
off.
3. All modules in the
configuration have their
diagnostic set to
MOD_NOCOMM, their
rack monitor module fail
pin is turned on., and the
rack monitor block’s
RACK OK pin is turned
off.
4. ASYS block’s HW OK
pin is turned off.
5. The statuses for the AO
and AI channels that are
affected are set to
BAD_CHANNEL.
Controller continues to run
but is not able to access
the I/O on the associated
rack
Replace main-CPU module
Swap the cables so that I/O A is
connected to I/O on CPUA and I/O B
is connected to I/O on CPUB
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Main Menu
Diagnostics I/O Module Diagnostics and I/O Calibration
Item Status Possible Cause Controller Action What to do
Protocol Mismatch C70R only. The
firmware version in
the controller CPU is
not compatible with
the firmware version
in the I/O scanner
Controller continues to run
but is not able to access
the I/O on the associated
rack
Upgrade the firmware in the CPU
and/or scanner to be compatible
versions
I/O Module Diagnostics and I/O Calibration
Select a rack to see its I/O module diagnostics. For I/O Calibration, see page 159.
Table 20 I/O module diagnostics
Item Description
MODULE
PHYSICAL TYPE
CONFIGURED AS
ERROR STATUS
Slot number in the rack.
NONE
AI UNIVERSAL 8-CHAN
AI LO-LEVEL 16-CHAN
AI HI-LEVEL 8-CHAN
AO CURRENT 4-CHAN
AO VOLTAGE 4-CHAN
DI DRY-CONTACT 16-CHAN
DI 120/240 VAC 16-CHAN
DI 24 VDC 16-CHAN
DO LO-CURRENT RLY 8-CHAN
DO HI-CURRENT RLY 4-CHAN
DO 120/240 VAC 8-CHAN
DO 24 VDC 16-CHAN
AI HI-LEVEL 16-CHAN
DI 24 VDC 32-CHAN
DO 24 VDC 32-CHAN
PULSE/FREQ/QUAD 4-CHAN
HIGH LEVEL AO 8 CHANNEL
HIGH LEVEL AO 16 CHANNEL
Analog Input, Analog Output, Digital Input, Digital Output, Pulse Frequency
Quadrature
See Table 22.
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Main Menu
I/O Module Diagnostics and I/O Calibration Diagnostics
Table 21 I/O module Details
Item Description
MODULE Slot number in the rack.
PHYSICAL TYPE NONE
AI UNIVERSAL 8-CHAN
AI LO-LEVEL 16-CHAN
AI HI-LEVEL 8-CHAN
AO CURRENT 4-CHAN
AO VOLTAGE 4-CHAN
DI DRY-CONTACT 16-CHAN
DI 120/240 VAC 16-CHAN
DI 24 VDC 16-CHAN
DO LO-CURRENT RLY 8-CHAN
DO HI-CURRENT RLY 4-CHAN
DO 120/240 VAC 8-CHAN
DO 24 VDC 16-CHAN
AI HI-LEVEL 16-CHAN
DI 24 VDC 32-CHAN
DO 24 VDC 32-CHAN
PULSE/FREQ/QUAD 4-CHAN
HIGH LEVEL AO 8 CHANNEL
HIGH LEVEL AO 16 CHANNEL
PART NUMBER The re-order part number of the module.
FIRMWARE REV. Revision level of the firmware running on this module.
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Main Menu
Diagnostics I/O Module Diagnostics and I/O Calibration
I/O Module Error Status
Table 22 I/O Module Error Status
Status Possible Cause Controller Action What to do
HI CJ TEMP
Possible causes of
this diagnostic are:
1. One of the two CJs
on the module is
indicating a
temperature reading
greater than 70
degrees C.
2. Both cold-junction
sensors are failing to
convert.
3. The CJs are
converting properly,
but their differential is
greater than 10
degrees C.
1. Associated AI blocks that are configured
as T/Cs set their fail pin on, their warn pin
off, and their output pin to the failsafe value.
2. Associated AI blocks that are configured
as T/Cs set their IO status to “CJ High
Temperature” for reason 1 or “CJ Failure”
for possible causes 2 and 3.
3. Associated rack monitor block’s module
fail pin is turned on.
4. Associated rack monitor block’s RACK
OK pin is turned off.
5. Associated rack monitor block’s
HITEMP pin is turned on.
6. SYSTEM MONITOR block’s HITEMP
pin is turned on.
1. Improve ventilation to rack
2. Replace AI module
MISMATCH
The installed module
does not agree with
the module required
for the control
strategy downloaded
in the configuration
file.
7. SYSTEM MONITOR block’s HW OK
pin is turned off.
1. Associated blocks set their fail pin on,
their warn pin off, and their output pin to the
failsafe value.
2. Associated blocks set their IO status to
“Channel No Comm”.
3. Associated rack monitor block’s module
fail pin is turned on.
4. Associated rack monitor block’s RACK
OK pin is turned off.
5. SYSTEM MONITOR block’s HW OK
pin is turned off.
1. Verify configuration
2. Replace module with the correct one.
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Main Menu
I/O Module Diagnostics and I/O Calibration Diagnostics
Status Possible Cause Controller Action What to do
MISSING/NO
COMM
Main CPU is unable
to communicate to
the module for one of
the following reasons:
See MISMATCH.
Action is based on the RACK STATUS
indication. If RACK STATUS is not
MODULE ERROR, then follow the
prescribed action defined for the RACK
STATUS diagnostic.
1. Module is not
installed
For MODULE ERROR, do the following:
BAD MODULE
BAD
CHANNEL
2. The module cannot
communicate with the
controller CPU or the
expansion rack CPU
because of a
backplane problem.
3. Module is on an
expansion rack and
the expansion rack
communications is
failing
Module is reporting a
diagnostic condition.
See
Table 23
.
See Table 24
See MISMATCH.
1. Associated block sets its fail pin on, its
warn pin off, and its output pin to the
failsafe value.
2. Associated block sets its IO status as
denoted in Table 24.
3. Associated rack monitor block’s module
fail pin is turned on.
4. Associated rack monitor block’s RACK
OK pin is turned off.
5. SYSTEM MONITOR block’s HW OK
pin is turned off.
1. Verify configuration
2. Install module.
User should inspect the module’s status
LED to determine the nature of the
problem. Table 23 describes the user
action for the various LED diagnostics.
See
Table 24
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Main Menu
status LED (see
Remove other modules and replace
Diagnostics I/O Module Diagnostics and I/O Calibration
Bad module details
When an I/O module’s error status is BAD MODULE, the module’s status LED on the controller is flashed
red with a number of quick strobes followed by a long off time. Table 23 outlines the potential module
diagnostics.
Table 23 Bad module details
Number of
Strobes
1 FAIL SAFE The module is in the failsafe state
2 EAROM EA ROM Failed its checksum
3 RAM
4 ROM
5 +24 V
6 FACTORY CAL CRC failure of primary and backup
7 FIELD CAL CRC failure of field calibration
8 HARDWARE General Hardware Failure
9 HW/SW Key The software residing on the
Failure Description AI AO DI DO PFQ User Action
because it is not receiving message
requests from the CPU or Scanner
at a rate that satisfies the configured
failsafe timeout.
factory calibration
values
(AI=convertor not working)
module does not match the module
type. This diagnostic should only
result in the factory.
Contact AC DC Relay AC DC
√ √ √ √ √ √ √ √ √
√ √
√ √ √ √ √ √ √ √ √
√ √ √ √ √ √ √
√ √ √
√ √
√ √
Replace module.
√
Replace module.
√ √ √ √
√
√
1. If expansion I/O rack, go to step 2. If
no expansion I/O rack, go to step 3.
2. Check the Scanner
Scanner Indicators in HC900
Process Controller manual, #51-5225-107).
If it’s flashing 6 times, proceed
with step 3.
If it’s flashing some other red
status code (refer to Scanner
Indicators in HC900 Process
Controller manual, #51-52-25-107)
to solve that problem first.
If it’s flashing green, the module
probably is not required in the
configuration.
If it’s not on or steady, cycle
power to the scanner.
3. Make sure the module is the correct
one for the configuration.
4. Remove the module and check for
a bent pin, then reinsert the module
5. Replace the module
6.
one at a time until the problem
reoccurs. Most likely the last module
inserted needs to be replaced.
7.
Replace the rack.
1. Remove/reinsert module.
2. Replace module.
1. Remove the module and check
for a bent pin, then reinsert the
module
2. Measure power supply voltage. If
not correct, replace power supply.
3. Replace module
4. Replace rack
1. Remove/reinsert module.
2. Replace module.
Replace module
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Main Menu
I/O Module Diagnostics and I/O Calibration Diagnostics
Number of
Strobes
11 Shift Register The loopback test of the shift
Failure Description AI AO DI DO PFQ User Action
Contact AC DC Relay AC DC
register failed.
√ √ √ √ √ √
Replace module
Bad channel details
Below is a list of conditions that can cause a BAD CHANNEL I/O module diagnostic.
Table 24 Bad Channel details
I/O Summary Error Status Description What to do
Bad Channel If the channel is an Analog Output: There is no
physical output device connected to this
channel, or the output device is showing an
open connection.
If the channel is a Pulse Output: The channel is
failing to output the correct value.
A BAD CHANNEL I/O module diagnostic is
posted.
Burnout Fail The sensor – T/C, RTD, or mV source -- is
failing burnout checks. A BAD CHANNEL I/O
module diagnostic is posted.
Check terminal block
connections.
Replace module.
Check terminal block connections
Replace source element
Replace module.
Convert Fail When attempting to take a reading, the analog-
to-digital (ADC) fails. This can occur if the
incoming signal is either too large or too small.
It also could result if the ADC circuit is failing. If
the problem is the ADC circuit, most likely other
channels will have the same failure. A BAD
CHANNEL I/O module diagnostic is posted.
No Channel There is no hardware on the I/O module to
support this channel. For example, the
customer configured Channel #15 for a given
module, but there is an 8-channel module
installed in the rack. A BAD CHANNEL I/O
module diagnostic is posted.
Over Current A Digital Output module detected an excessive
amount of current on its output terminals. Note
that this message will only appear for the 32channel DO module. A BAD CHANNEL module
diagnostic is posted.
Check the signal level being
applied to the terminals.
Replace module.
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Main Menu
Diagnostics Communication Diagnostics
Communication Diagnostics
This links to the main Communications menu. See page 20.
Redundant Overview
This display summarizes the status of all of the major components of a redundant system.
Table 25 Redundant Overview
Item Status Possible Cause Controller Action What to do
RESERVE
STATUS
REDUNDANCY
STATUS
RESERVE
AVAILABLE
RESERVE NOT
AVAILABLE
GOOD
NO RSM MODULE
DETECTED
RSM SWITCH IS
BAD
Normal operation N/A N/A
1. Reserve not
installed in rack.
2. Power not applied
to reserve CPU
3. Neither lead nor
reserve CPU has a
valid configuration
database
4. Firmware
mismatch (lead
and reserve CPUs
have different
firmware revisions
5. Database not
synchronized with
the lead
Normal operation N/A N/A
Switch on RSM is set
between two positions.
RSM Module is not
inserted
RSM Module has failed
Switch is indicating an
invalid position
The lead controller
will continue to
control the process,
but failover is not
possible.
The controller will
continue to operate
with a missing RSM.
Automatic failover is
still possible if
required.
The controller will
continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.
Install RSM module
Install reserve CPU
Apply power to reserve CPU
Download a configuration and
cold start the controller
Perform a firmware upgrade so
both CPUs have the same
version
Replace the reserve CPU. If
this doesn’t help, replace the
lead CPU. If this doesn’t help,
replace the backplane.
Make sure switch is in desired
position
Replace RSM
Replace RSM
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Main Menu
Redundant Overview Diagnostics
Item Status Possible Cause Controller Action What to do
I/O COMM ERROR
ON RESERVE
Reserve CPU is unable
to communicate with
one or more of the I/O
racks.
The lead controller
will continue to
control the process.
Failover to the
reserve is still
possible if a
subsequent failure
renders the current
lead less capable
than the reserve.
Verify all cabling between the
reserve CPU and the scanners.
Replace any Ethernet switches
between the reserve CPU and
the I/O rack(s).
Replace the reserve CPU
Replace the scanner CPU
Contact Honeywell service
DATABASE NOT
SYNCHRONIZED
INVALID CONFIG.
Hardware failure on the
reserve CPU
Hardware failure on the
lead CPU
Hardware failure on the
CPU rack backplane
Neither CPU has a valid
configuration database
The lead controller
will continue to
control the process,
but failover is not
possible.
An empty database
is created.
Replace the reserve CPU
Replace the lead CPU
Replace the CPU rack backplane
Contact Honeywell service
Download the desired
configuration file and perform a
cold start.
FIRMWARE
VERSION
MISMATCH
The reserve controller
does not have the same
version of controller
firmware installed
The lead controller
will continue to
control the process,
but failover is not
Upgrade the CPU firmware so
both the lead and reserve have
the same version.
possible.
CONTROLLER
STATUS
GOOD N/A N/A N/A
FORCED OUTPUT
A block has an output
None Remove force on block output..
that is forced.
INVALID CONFIG.
A configuration that
exceeds the loop
An empty database
is created.
Download a valid configuration.
capacity of the controller
was downloaded or an
invalid configuration
exists.
SWITCH FAULT
RMS switch is indicating
an invalid position
The controller will
continue to operate
Replace RSM
with a bad RSM.
Automatic failover is
still possible if
required.
NO MASTER
PORT
The controller
configuration contains at
least on Modbus slave
block, but Serial Port S1
The controller is not
scanning the
Modbus slave
devices.
Select Modbus Master or
Modbus Master Advanced
protocol for either the RS-232 or
RS-485 port.
is not set up as a
Modbus Master port.
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Main Menu
Diagnostics Redundant Overview
Item Status Possible Cause Controller Action What to do
RSM SWITCH
MISMATCH
NO RSM MODULE
DETECTED
BAD RSM SWITCH
(LEAD)
BAD RSM SWITCH
(RESERVE)
Item Status Possible Cause
CPU STATUS GOOD
MEMORY STATUS
RTC STATUS
I/O RACK COMM PORT
STATUS
RACK I/O MODULE
STATUS
COMM PORTS
E1/E2/S1/S2 STATUS
ERROR IN RACK 1
ERROR IN RACK 2
ERROR IN RACK 3
ERROR IN RACK 4
ERROR IN RACK 5
ERROR IN LEAD CPU
ERROR IN RESERVE CPU
ERROR ON SERIAL PORT S1
ERROR ON SERIAL PORT S2
ERROR ON E1 NETWORK PORT
ERROR ON E2 NETWORK PORT
ERROR ON SCANNER I/O LINK
The lead and reserve
controller are both
reading the switch on
the RSM, but are getting
different values.
Switch on RSM is set
between two positions.
RSM Module is not
inserted
RSM Module has failed
Switch is indicating an
invalid position
Switch is indicating an
invalid position
The controller will
continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.
The controller will
continue to operate
with a missing RSM.
Automatic failover is
still possible if
required.
The controller will
continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.
The controller will
continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.
REFER TO Table 26 (page 51)
REFER TO Table 26 (page 51)
REFER TO Table 26 (page 51)
REFER TO Table 26 (page 51)
REFER TO Table 26 (page 51)
REFER TO Table 27 (page 57)
REFER TO Table 27 (page 57)
REFER TO Table 7 (page 24)
REFER TO Table 7 (page 24)
REFER TO Table 11 (page 28)
REFER TO Table 11 (page 28)
REFER TO Table 26 (page 51)
Replace the RSM
Replace the reserve CPU
Force a failover and replace the
new reserve CPU
Contact Honeywell service
Make sure switch is in desired
position
Install RSM module
Replace RSM
Replace RSM
Force a failover and replace the
CPU (formerly the lead, now the
reserve)
Replace RSM
Replace the reserve CPU
50 900 Control Station User Guide Revision 9
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Main Menu
Redundant Overview Diagnostics
Table 26 Details of Rack diagnostics error status messages
Item Status Possible Cause Controller Action Fix
CPU GOOD N/A N/A N/A
ADDRESS ERROR
PREFETCH ERROR
DATA ABORT
ERROR
S/W INTERRUPT
ERR
UNDEFINED INSTR
ERROR
WATCHDOG
ERROR
VECTOR ERROR
MEMORY GOOD N/A N/A N/A
5 DAY BATTERY
WARNING
LOW BATTERY Battery voltage is low.
The reserved
exception occurred for
an unknown reason.
CPU failed when
attempting to fetch an
instruction from the
prefetch register.
CPU failed when
attempting to access
data.
Software Interrupt
occurred which is not
supported by the
software.
Bad Instruction
Detected
Watchdog reset
resulting from software
failure
Corrupted interrupt
vectors in RAM.
Estimated battery life is
less than 5 days.
See PREFETCH
ERROR.
1. Controller
2. Associated rack
3. SYSTEM
performs a restart
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
See PREFETCH
ERROR.
See PREFETCH
ERROR.
See PREFETCH
ERROR
1. Associated rack
2. SYSTEM
Interrupt vectors
were restored.
1. Associated rack
2. SYSTEM
1. Associated rack
2. SYSTEM
3. SYSTEM
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s LOW
BATTERY pin is
turned on.
MONITOR
block’s HW OK
pin is turned off.
See PREFETCH ERROR.
1. Force a cold start.
2. Isolate system from noise and
force a cold start.
3. Replace CPU board.
See PREFETCH ERROR.
See PREFETCH ERROR.
See PREFETCH ERROR.
1. Force a cold start.
2. Upgrade controller module
software.
3. Replace CPU board.
4. Contact Honeywell Service.
See WATCHDOG ERROR.
Replace battery.
Replace battery.
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Main Menu
Diagnostics Redundant Overview
Item Status Possible Cause Controller Action Fix
FLASH ERROR Flash failed to burn
1. Associated rack
monitor block’s
RACK OK pin is
1. Force a cold start.
2. Replace CPU board.
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
POWER
SUPPLY DIAG
POWER
SUPPLY
STATUS
GOOD N/A N/A N/A
POWER SUPPLY
PS-1 FAILED
POWER SUPPLY
PS-2 FAILED
UNKNOWN
A scanner has
redundant power
supplies installed and
the one identified as
PS-1 is not working
Failed Power Supply
Failed Redundant
Power Backplane
detection circuit
Failed Rack backplane
status signal
Failed Scanner2 status
input
A scanner has
redundant power
supplies installed and
the one identified as
PS-2 is not working
Failed Power Supply
Failed Redundant
Power Backplane
detection circuit
Failed Rack backplane
status signal
Failed Scanner2 status
input
No Rack
communication
I/O rack continues to
function normally
using the remaining
power supply
I/O rack continues to
function normally
using the remaining
power supply
If under power, I/O
will switch to failsafe
values
Loss of Comms
If not powered (unpowered outputs)
Loss of AC mains
Bad Power Supply
Failed Scanner2
Verify that the power supply is
connected to a power source
Replace power supply
Requires unit shutdown – replace
redundant power backplane
Requires unit shutdown – replace
rack backplane.
Requires unit shutdown – replace
Scanner2.
Contact Honeywell Service.
Verify that the power supply is
connected to a power source
Replace power supply
Requires unit shutdown – replace
redundant power backplane
Requires unit shutdown – replace
rack backplane.
Requires unit shutdown – replace
Scanner2.
Contact Honeywell Service.
Determine and correct cause of
communication failure.
Determine and correct cause of
communication failure.
Restore rack operation
Restore AC mains power, reset
breaker
Replace Power Supply
Replace Scanner2
52 900 Control Station User Guide Revision 9
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Main Menu
No action required if single
Redundant Overview Diagnostics
Item Status Possible Cause Controller Action Fix
REDUNDANT P/S IS
NOT PRESENT
Single Power Supply
configuration
Redundant Power
Backplane not
detected
Rack continues to
function properly
power supply rack
If dual power supply is
installed:
Replace Redundant
Power Backplane
Replace rack backplane
Replace Scanner2
LEAD CPU
POSITION
POWER SUPPLY
PS-1 FAILED
POWER SUPPLY
PS-2 FAILED
BOTH POWER
SUPPLIES ARE
GOOD
CPU-A
CPU-B
CPU IS MISSING
A scanner has
redundant power
supplies installed and
the one identified as
PS-1 is not working
Failed Power Supply
Failed Redundant
Power Backplane
detection circuit
Failed Rack backplane
status signal
Failed Scanner2 status
input
A scanner has
redundant power
supplies installed and
the one identified as
PS-2 is not working
Failed Power Supply
Failed Redundant
Power Backplane
detection circuit
Failed Rack backplane
status signal
Failed Scanner2 status
input
N/A None None
CPU-A is currently the
lead
CPU-B is currently the
lead
Reserve CPU is not
installed or not
powered.
CPU rack backplane
failure
I/O rack continues to
function normally
using the remaining
power supply
I/O rack continues to
function normally
using the remaining
power supply
N/A N/A
N/A N/A
The lead controller
will continue to
control the process,
but failover is not
possible.
Verify that the power supply
is connected to a power
source
Replace power supply
Requires unit shutdown –
replace Redundant Power
Backplane
Requires unit shutdown –
replace rack backplane.
Requires unit shutdown – replace
Scanner2.
Contact Honeywell Service.
Verify that the power supply
is connected to a power
source
Replace power supply
Requires unit shutdown –
replace redundant power
backplane
Requires unit shutdown –
replace rack backplane.
Requires unit shutdown –
replace Scanner2.
Contact Honeywell Service.
Install reserve CPU
Apply power to reserve CPU
Replace CPU rack backplane
Contact Honeywell Service.
Revision 9 900 Control Station User Guide 53
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Main Menu
•
Diagnostics Redundant Overview
Item Status Possible Cause Controller Action Fix
LEAD I/O
COMM DIAG
GOOD Normal operation N/A
DATA LINK
FAILURE
Scanner2 address
switches are not in
the correct position
•
An I/O cable is
Controller continues
to run but is not able
to access the I/O on
the associated rack
unplugged.
•
Cables are defective
or are not properly
shielded
•
If a hub is used, it
may be powered
down.
•
The Scanner2 is
powered down.
•
The Scanner2 is
defective
1. Verify that the address
switches on the scanner 2 are
set correctly.
2. If a hub is used, check that all
cables are properly connected
to the hub, proper crossover
cables are used, that the hub
is powered, and it supports
100 Base-T.
3. Check cable shielding for
proper grounding and noise
immunity.
4. Make sure the cables have the
correct pin out.
5. Cycle power to the Scanner 2.
6. Cycle power to the hub.
7. Cycle power to the C70R.
8. Replace the expansion rack’s
scanner module.
9. Replace the expansion rack’s
power supply.
10. Replace the expansion rack.
11. Replace the main CPU.
HARDWARE
FAILURE
PORT A/B CABLE
MISMATCH
The I/O interface has a
hardware failure.
The I/O cables from
CPUA and CPUB are
connected to the
wrong ports on the I/O
Controller continues
to run but is not able
to access any I/O.
Controller continues
to run but is not able
to access the I/O on
the associated rack
Replace the CPU.
Swap the cables so that I/O A is
connected to I/O on CPUA and
I/O B is connected to I/O on
CPUB
scanner CPU
PROTOCOL
MISMATCH
The firmware version
in the controller CPU is
not compatible with the
firmware version in the
Controller continues
to run but is not able
to access the I/O on
the associated rack
Upgrade the firmware in the CPU
and/or scanner to be compatible
versions
I/O scanner
LEAD I/O
COMM
STATUS
NO
COMMUNICATIONS
MARGINAL: PORT
I/O A
Possible causes are
defined by the LEAD
I/O COMM DIAG that
is being reported.
Rack communication
with CPU-A is
experiencing a high
error rate
Controller continues
to run but is not able
to access the I/O on
the associated rack
Controller continues
to run but is
marginally
accessing the I/O
on the associated
rack
See the fix defined for the LEAD
I/O COMM DIAG that is being
reported.
1. Check cable shielding for
proper grounding and noise
immunity.
2. Check connectors of all
cables.
3. If a hub/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables.
54 900 Control Station User Guide Revision 9
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Page 67
Main Menu
•
Redundant Overview Diagnostics
Item Status Possible Cause Controller Action Fix
MARGINAL: PORT
I/O B
Rack communication
with CPU-B is
experiencing a high
error rate
Controller continues
to run but is
marginally
accessing the I/O
on the associated
rack
1. Check cable shielding for
proper grounding and noise
immunity.
2. Check connectors of all
cables.
3. If a hub/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables
GOOD: PORT I/O A Normal operation N/A N/A
GOOD: PORT I/O B Normal operation N/A N/A
NOT USED IN THIS
CONFIGURATION
None of the I/O
modules contained in
N/A N/A
this rack are being
used to execute the
control configuration
that is currently running
in the controller.
RESERVE I/O
COMM DIAG
GOOD N/A N/A N/A
DATA LINK
FAILURE
Scanner2 address
switches are not in
the correct position
•
An I/O cable is
unplugged.
•
Cables are defective
Controller continues
to run but is not able
to access the I/O on
the associated rack
1. If LEAD I/O COMM DIAG is
2. If a hub is used, check that all
or are not properly
shielded
•
If a hub is used, it
may be powered
down.
•
The Scanner2 is
powered down.
•
The Scanner2 is
3. Check cable shielding for
4. Make sure the cables have the
defective
5. Cycle power to the hub.
also “DATA LINK FAILURE”,
follow the Fix defined for that
diagnostic.
cables are properly connected
to the hub, proper crossover
cables are used, that the hub
is powered, and it supports
100 Base-T.
proper grounding and noise
immunity.
correct pin out.
6. Cycle power to the C70R.
7. Replace the main CPU.
8. Cycle power to the Scanner 2.
9. Replace the expansion rack’s
scanner module.
10. Replace the expansion rack’s
power supply.
11.Replace the expansion
rack.
HARDWARE
FAILURE
The I/O interface has a
hardware failure.
Controller continues
to run but is not able
Replace the CPU.
to access any I/O.
PORT A/B CABLE
MISMATCH
The I/O cables from
CPUA and CPUB are
connected to the wrong
ports on the I/O
Controller continues
to run but is not able
to access the I/O on
the associated rack
Swap the cables so that I/O A is
connected to I/O on CPUA and
I/O B is connected to I/O on
CPUB
scanner CPU
Revision 9 900 Control Station User Guide 55
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Main Menu
marginally accessing
Diagnostics Lead/Reserve CPU Diagnostics
Item Status Possible Cause Controller Action Fix
RESERVE I/O
COMM
STATUS
I/O MODULE
DIAGNOSTICS
PROTOCOL
MISMATCH
NO
COMMUNICATIONS
MARGINAL: PORT
I/O A
MARGINAL: PORT
I/O B
GOOD: PORT I/O A Normal operation N/A N/A
GOOD: PORT I/O B Normal operation N/A N/A
NOT USED IN THIS
CONFIGURATION
GOOD
MODULE ERROR
MODULE HI CJ
TEMP
FAILURE
NO COMM
BAD VERSION
The firmware version in
the controller CPU is
not compatible with the
firmware version in the
I/O scanner
Possible causes are
defined by the
RESERVE I/O COMM
DIAG that is being
reported.
Rack communication
with CPU-A is
experiencing a high
error rate
Rack communication
with CPU-B is
experiencing a high
error rate
None of the I/O
modules contained in
this rack are being
used to execute the
control configuration
that is currently running
in the controller.
The detailed information for the I/O MODULE DIAGNOSTICS entry in
the table above is also shown in Table 19 in the main part of the manual,
under the “I/O” Class.
Controller continues
to run but is not able
to access the I/O on
the associated rack
Controller continues
to run but is not able
to access the I/O on
the associated rack
Controller continues
to run but is
marginally
accessing the I/O
on the associated
rack
Controller continues
to run but is
the I/O on the
associated rack
N/A N/A
Upgrade the firmware in the CPU
and/or scanner to be compatible
versions
See the fix defined for the
RESERVE I/O COMM DIAG that
is being reported.
1. Check cable shielding for
2. Check connectors of all
3. If a hub/switch is being used,
4. Replace cables.
1. Check cable shielding for
2. Check connectors of all
3. If a HUB/switch is being used,
4. Replace cables.
proper grounding and noise
immunity.
cables.
verify that it is one that is
recommended by Honeywell
proper grounding and noise
immunity.
cables.
verify that it is one that is
recommended by Honeywell
Lead/Reserve CPU Diagnostics
These displays show the status of the Lead and Reserve CPU modules in the redundant system. The same
categories of status information are shown for Lead or Reserve. The CPU Position parameter on each
display identifies which physical CPU module is currently acting as the Lead or Reserve.
Refer to Table 27 through for a description of the information contained on these displays.
56 900 Control Station User Guide Revision 9
May 2014
Page 69
Main Menu
Lead/Reserve CPU Diagnostics Diagnostics
Table 27 Details of Lead or Reserve CPU diagnostics error status messages
Class Status Possible Cause Controller Action Fix
RESERVE
STATUS
RESERVE
AVAILABLE
RESERVE NOT
AVAILABLE
Normal operation N/A N/A
1. Reserve not installed
in rack.
2. Power not applied to
reserve CPU
3. Neither lead nor
reserve CPU has a
valid configuration
database
4. Firmware mismatch
(lead and reserve
CPUs have different
firmware revisions
5. Database not
synchronized with
the lead
The lead controller
will continue to
control the process,
but failover is not
possible.
Install reserve CPU
Apply power to reserve CPU
Download a configuration and cold
start the controller
Perform a firmware upgrade so
both CPUs have the same version
Replace the reserve CPU. If this
doesn’t help, replace the lead
CPU. If this doesn’t help, replace
the backplane.
Revision 9 900 Control Station User Guide 57
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Main Menu
Diagnostics Lead/Reserve CPU Diagnostics
Class Status Possible Cause Controller Action Fix
CPU POSITION CPU-A N/A Normal operation
CPU-B N/A Normal operation
CPU IS MISSING
CPU GOOD N/A N/A N/A
ADDRESS
ERROR
PREFETCH
ERROR
DATA ABORT
ERROR
S/W
INTERRUPT
ERR
UNDEFINED
INSTR ERROR
WATCHDOG
ERROR
VECTOR
ERROR
MEMORY GOOD N/A N/A N/A
5 DAY BATTERY
WARNING
Reserve CPU is not
installed or not powered.
CPU rack backplane
failure
The reserved exception
occurred for an unknown
reason.
CPU failed when
attempting to fetch an
instruction from the
prefetch register.
CPU failed when
attempting to access
data.
Software Interrupt that is
not supported by the
software occurred.
Bad Instruction Detected
Watchdog reset resulting
from software failure
Corrupted interrupt
vectors in RAM.
Estimated battery life is
less than 5 days.
The lead controller
will continue to
control the process,
but failover is not
possible.
See PREFETCH
ERROR.
1. Controller
2. Associated rack
3. SYSTEM
performs a restart
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
See PREFETCH
ERROR.
See PREFETCH
ERROR.
See PREFETCH
ERROR
1. Associated rack
2. SYSTEM
Interrupt vectors
were restored.
1. Associated rack
2. SYSTEM
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
monitor block’s
RACK OK pin is
turned off.
MONITOR
block’s HW OK
pin is turned off.
Install reserve CPU
Apply power to reserve CPU
Replace CPU rack backplane
Call Honeywell service
See PREFETCH ERROR.
1. Force a cold start.
2. Isolate system from noise and
force a cold start.
3. Replace CPU board.
See PREFETCH ERROR.
See PREFETCH ERROR.
See PREFETCH ERROR.
1. Force a cold start.
2. Upgrade controller module
software.
3. Replace CPU board.
4. Contact Honeywell Personnel.
See WATCHDOG ERROR.
Replace battery.
58 900 Control Station User Guide Revision 9
May 2014
Page 71
Main Menu
Lead/Reserve CPU Diagnostics Diagnostics
Class Status Possible Cause Controller Action Fix
LOW BATTERY Battery voltage is low.
1. Associated rack
Replace battery.
monitor block’s
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s LOW
BATTERY pin is
turned on.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
FLASH ERROR Flash failed to burn
1. Associated rack
monitor block’s
RACK OK pin is
1. Force a cold start.
2. Replace CPU board.
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
RTC GOOD N/A N/A N/A
NOT
PROGRAMMED
RTC not programmed
1. Time and date is
set to 00:00:00,
Program RTC.
January 1, 1970.
2. Associated rack
monitor block’s
RACK OK pin is
turned off.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
BAD DATA Bad date and time
See NOT
PROGRAMMED.
1. Program RTC.
2. Cycle power.
3. Replace CPU.
4. Replace boards in rack.
5. Replace rack.
PROGRAMMIN
RTC failed to program
G FAILURE
READ FAILURE Unable to read RTC
See NOT
PROGRAMMED.
See NOT
PROGRAMMED.
See BAD DATA.
See BAD DATA.
Revision 9 900 Control Station User Guide 59
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Page 72
Main Menu
•
Diagnostics Lead/Reserve CPU Diagnostics
Class Status Possible Cause Controller Action Fix
I/O RACK
COMM PORT
GOOD Normal operation N/A
DATA LINK
FAILURE
Scanner2 address
switches are not in the
correct position
•
An I/O cable is
Controller continues
to run but is not able
to access the I/O on
the associated rack
unplugged.
•
Cables are defective or
are not properly
shielded
•
If a hub is used, it may
be powered down.
•
The Scanner2 is
powered down.
•
The Scanner2 is
defective
1. Verify that the address
switches on the scanner 2 are
set correctly.
2. If a hub is used, check that all
cables are properly connected
to the hub, proper crossover
cables are used, that the hub
is powered, and it supports
100 Base-T.
3. Check cable shielding for
proper grounding and noise
immunity.
4. Make sure the cables have the
correct pin out.
5. Cycle power to the Scanner 2.
6. Cycle power to the hub.
7. Cycle power to the C70R.
8. Replace the expansion rack’s
scanner module.
9. Replace the expansion rack’s
power supply.
10. Replace the expansion rack.
11.Replace the main CPU.
HARDWARE
FAILURE
The I/O interface has a
hardware failure.
Controller continues
to run but is not able
Replace the CPU.
to access any I/O.
PORT A/B
CABLE
MISMATCH
The I/O cables from
CPUA and CPUB are
connected to the wrong
ports on the I/O scanner
Controller continues
to run but is not able
to access the I/O on
the associated rack
Swap the cables so that I/O A is
connected to I/O on CPUA and I/O
B is connected to I/O on CPUB
CPU
PROTOCOL
MISMATCH
The firmware version in
the controller CPU is not
compatible with the
firmware version in the I/O
Controller continues
to run but is not able
to access the I/O on
the associated rack
Upgrade the firmware in the CPU
and/or scanner to be compatible
versions
scanner
NETWORK
REFER TO Table 11 Ethernet Port E1/E2: Port Diagnostic status page 28
PORT E1
NETWORK
REFER TO Table 11 Ethernet Port E1/E2: Port Diagnostic status page 28
PORT E2
SERIAL PORT
REFER TO Table 7 Serial Port S1/S2: Port Diagnostic status page 24
S1
SERIAL PORT
REFER TO Table 7 Serial Port S1/S2: Port Diagnostic status page 24
S2
60 900 Control Station User Guide Revision 9
May 2014
Page 73
Main Menu
View Data Station Settings
Station Settings
View Data
Lets you view data on the CompactFlash card. Touch the + and – buttons to scroll through the folder and
file names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.
Delete Data
Lets you delete data on the CompactFlash card. Touch the + and – buttons to scroll through the folder and
file names. Touch Delete button to delete a file or folder. Touch Delete All to delete all data on
CompactFlash card.
Export Data to USB
Note. USB 3.0 support is only available on the 900CS10.
Lets you export data from the CompactFlash to USB. Insert USB memory device into Port A. (Export does
not function without USB device inserted.)
Total Memory and Free Memory are displayed for CompactFlash and USB memory device. Touch the Get
CF Status or Get USB Status buttons to update status.
Touch Export All Data button to export CompactFlash data to the USB device. USB device must have
enough free memory.
Export Selected Data button shows CompactFlash data and USB memory device data. Press >> and << to
transfer data between the two devices.
Note:
1. File/ folders can’t be copied from USB memory device to CompactFlash’s LOG folder.
2. There may be a delayed response in actions involving the USB memory device since it is an external
device.
Revision 9 900 Control Station User Guide 61
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Main Menu
Station Settings Format Memory Device
Format Memory Device
Lets you format CompactFlash or USB device.
Note that the Control Station uses the FAT16 file system. You may achieve better performance if the
memory device is formatted on the Control Station as opposed to your computer.
Station Setup
Lets you:
• Change languages
• Adjust display brightness
• Calibrate the touch screen
• Test the touch screen
• Test the soft membrane keys left of the display
• Clean the screen – this disables the touch screen. Use when cleaning the screen or when replacing the
optional protective film that covers the screen.
Station Status
Shows the status of the Control Station.
• Versions of boot loader, firmware, application
• Path and name of HC900 configuration file being monitored by the Control Station
• Time and cause of last several Control Station restarts
Station Comm Ports
Shows status of the Control Station’s communication ports (Ethernet, RS232 program, RS232 Comm,
RS485).
Change Passwords
Lets you change user passwords.
Language Menu Selection
Lets you change the language on the Control Station UI. Use one of the following methods to change the
language.
• Go to Station Setup Menu > Languages.
or
• Click the flag icon present on the screen.
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Language Menu Selection Log On
Select the required language.
Log On
Enter name and password. Once logged on, your level of access to displays and functions depends on the
security credentials you were configured for.
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Main Menu
Alarms and Events Alarm Access
Alarms and Events
Alarm Access
Use the Alarms icon to access all the alarms present in Control Station.
Alarm Definition
• 900 Control Station shows both the HC900 Controller alarms and Station alarms on the same alarm
console.
• Station alarms can be configured for a .cde file tag present in the .sds configuration. An alarm can be
defined in the desired tag properties.
• In Controller configuration, a desired tagged point present in the controller can be designated as an alarm
point.
Alarm Indicator
• When there are no alarms present, alarm icon and text on status indicator are grayed out.
• When an alarm is active, the text is displayed in white color and the background turns red.
• Status indicator flashes when an alarm is active and not acknowledged. Acknowledge the alarm to stop
the flashing.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the indicator will
turn yellow and continue to flash until acknowledged.
Display Details
• Alarm Console - 900 Control Station shows both the HC900 Controller alarms and Station alarms on the
same alarm console.
• Alarms programmed to automatically acknowledge when the alarm clears may also be manually
acknowledged while the alarm is active, halting the flashing indications on the alarm displays.
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Alarm Groups Alarms and Events
Alarm Groups
The Alarm Groups screen shows the status of the alarm groups of the controller. Touch an Alarm Group
button to open its Alarm Group display. There is a button at the bottom of the Alarm Groups screen to
access Station alarms.
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Main Menu
Alarms and Events Alarm Group Indication
Alarm Group Indication
• When there are no active alarms present, the background is gray with black text indicating NORMAL.
• When any alarm within a group is active, the text is displayed in white color and the background turns
red.
• For active, non-acknowledged alarms the background turns red, text changes to Unacknowledged and
flashes.
• Once acknowledged, the alarm background remains red until the alarm condition goes away, the text
changes to Acknowledged and the background stops flashing.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the background
will turn yellow, the text will remain Unacknowledged and continue to flash until acknowledged.
Alarm Group Overview
The Alarm Group screen shows the status of each point present in the selected Alarm Group.
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Alarm Point Indication Alarms and Events
Alarm Point Indication
• When an alarm is not active, the background is white with black text indicating Normal and the alarm
indicator light is gray.
• When any alarm is active, the alarm indicator light turns red, flashes and the text changes to
Unacknowledged.
• Once acknowledged, the alarm indicator light stops flashing, remains red until the alarm condition goes
away and the text changes to Acknowledged.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the alarm
indicator light will turn yellow and continue to flash until acknowledged. The text will change to
Cleared.
Alarm Point Detail
Following details are displayed.
• Tag name
• Alarm details text
• Last time the selected point was in alarm state
• Last time the selected point went out of alarm state
• Number of occurrences
Alarm Acknowledgement
• When 900CS is connected to C30S, C50S, C70S and C75S Controllers then it will not be allowed to
Acknowledge Alarms in Safety portion of the configuration when controller is in RUN-LOCKED mode,
it is allowed when controller is RUN-program mode.
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Main Menu
Alarms and Events Event Access
Event Access
All the events are accessed through the Alarm and Event Summary indicator present on the bottom of all
pages.
Event Definition
• 900 Control Station shows both the HC900 Controller events and Station events on the same Alarm and
Event Summary console.
• Station events can be configured for a .cde file tag present in the .sds configuration. An event can be
defined in the Alarms tab of the desired tag properties.
• In Controller configuration, a desired tagged point present in the controller can be designated as an event
point.
Event Indication
• When an Event exists, the event text appears in black color and the background of Alarms and Event
Status indicator turns yellow.
• When no event exists, no text is present on status indicator and it is grayed out.
Display Details
• Alarm and Event Summary – It displays the time stamp and text of each alarm and event.
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View Alarm & Event Logs Data Logging
Data Logging
View Alarm & Event Logs
Lets you view the alarm and event logs. Touch the + and – buttons to scroll through the folder and file
names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.
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Data Logging View Data Logs
View Data Logs
Lets you view the data log files on CompactFlash. Touch the + and – buttons to scroll through the folder
and file names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.
View Audit Logs
Lets you view the audit log. The audit log is a record of actions performed by users. Touch the + and –
buttons to scroll through the folder and file names. Touch Open button to open a folder or file. Touch Back
to go back to the top level folder. Touch the Show Data Logs button to view the data logs and touch the
Show Batch Logs button to view the batch logs.
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Export Data Logs to USB Data Logging
Export Data Logs to USB
Lets you export data logs from the CompactFlash to USB. Insert USB memory device into Port A. (Export
does not function without USB device inserted.). Note: USB 3.0 support is only available on the 900CS10.
Total Memory and Free Memory are displayed for CompactFlash and USB memory device. Touch the Get
CF Status or Get USB Status buttons to update status. Touch Export All Data button to export
CompactFlash data to the USB device. USB device must have enough free memory.
Export Selected Data button shows CompactFlash data and USB memory device data. Press >> and << to
transfer data between the two devices.
File/ folders can’t be copied from USB memory device to CompactFlash’s LOG folder.
View Batch Groups & View Batch Status
(Concurrent Batch for Control Station)
The operator at the 900 Control Station can simply touch the LOGS button on the master slide to access the
Data Logging menu. (Alternately, you can touch the soft key Menu > Data Logging.) The Data Logging
menu has two buttons on it for concurrent batch. View Batch Groups and View Batch Status.
View Batch Groups Summary Display
The operator can touch the View Batch Groups button on the Data Logging menu to display the Batch
Groups display. This display shows a summary of which batch groups have a batch running in them. A
green arrow on a batch group button means a batch is running, while a red square means a batch is not
running:
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Data Logging View Batch Groups & View Batch Status
Touching a batch group button that has a batch running retrieves the details for that batch:
Touching a batch group button that does not have a batch running retrieves the batch header display so that
the identification details of the next batch can be entered. Note that in the picture which follows, the values
entered from the last batch were retained. This is Data Logger property Retain Header in Station Designer
under the Data Logger’s Groups tab, so the field values shown are not empty.
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View Batch Groups & View Batch Status Data Logging
NOTE: The batch names for the batches within a batch group (batch set) must be unique and must be
between 1 and 8 characters in length and must contain only characters that are valid in a folder name.
The other header field values can be of any length, although a maximum of 48 characters is recommended.
If you specify a very long value, note that it can overflow its data box. Just touch on a data box to the right
of a field name to specify its value. Touch the Confirm Header button when you are satisfied with your
entries:
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Main Menu
Data Logging Delete Data Logs
View Batch Groups Detail Display
The operator can touch the View Batch Status button on the Data Logging menu to display the Batch
Status display. This display shows detailed information for all of the batch groups. For each batch group,
it indicates whether a batch is running or not, when the batch starts, when the batch stops, and the duration
for each running and stopped batch. By touching one of the small blue batch group buttons on the left-hand
side of the display, you can view the batch header details for any batch group. Touch the Close button to
close the batch header details box:
Delete Data Logs
Lets you view one or all data log files on CompactFlash. Use the + and – buttons to navigate through the
folder and files.
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Main Menu
Download Configuration Files Downloading and Uploading Controller Configuration
Downloading and Uploading Controller Configuration
Lets you download the .cde configuration file directly from the Control Station onto the HC900 controller.
You can also upload the .cde configuration file from the HC900 controller to the Control Station.
Download Configuration Files
1. Go to Station Settings > Memory Device Utilities > Download Controller Configuration Display.
The Download Controller Configuration dialog box appears.
2. All the .cde files and folders present in the Compact Flash and USB Drive are listed. Select a drive to
view the files present in that drive. Press Open to open the file/folder and to show its contents. Press
Back to close the opened file/folder. Press Close to close the dialog box.
3. Select a file and press Download. The Download Controller Configuration dialog box appears.
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Downloading and Uploading Controller Configuration Download Configuration Files
4. Press Start Download to start the process. A progress bar indicates the percentage of completion.
5. Once the download is complete, the Controller Download Complete dialog box appears.
6. Select one of the following options as required and continue.
• Hot Start: Updated the configuration settings.
• Cold Start: To re-initialize the memory.
• Stay in Program Mode: Remains in program mode.
• Abort: To cancel the download operation.
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Upload Controller Configuration Downloading and Uploading Controller Configuration
In case you select Hot Start the following warning appears on the screen.
Press Yes to continue and complete the operation.
Upload Controller Configuration
1. Go to Station Settings > Memory Device Utilities > Upload Controller Configuration Display.
The Upload Controller Configuration dialog box appears.
2. All the .cde files and folders present in the Compact Flash and USB Drive are listed. Select a drive to
view the files present in that drive. Press Open to open a folder and to show its contents. Press Open
to select a file. Press Back to close the opened file/folder. Press Close to close the dialog box.
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Downloading and Uploading Controller Configuration Upload Controller Configuration
3. Select a file and press Upload. The Upload Controller Configuration dialog box appears.
4. Press Start Upload to start the process. A progress bar indicates the percentage of completion.
5. Once the upload is complete, the Controller Upload Complete dialog box appears.
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Main Menu
Upload Controller Configuration Uploading Database Image
Uploading Database Image
Lets you upload an image.sdi file from Control Station to an external device (compact flash or USB
memory device).
1. On the Memory Device Utilities menu, press Upload Database Image. Use this option to export an
image file to a memory device.
2. The Select Location for uploading database image dialog box is displayed. Select a location.
Depending on your device selection, image.sdi file is created on either compact flash or USB
memory device. On successful file upload, Successfully Uploaded Database Image message is
displayed. In case the upload fails, Error in uploading database image message is displayed.
3. When the Control Station is powered on, the image.sdi file is automatically detected from the compact
flash and starts uploading the file to the Control Station. Loading From CF message appears on the
screen.
To upload an image .sdi file from a memory stick appropriate settings must be enabled via Station
Designer, the PC configuration tool. (see manual 51-52-25-149).
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Main Menu
Uploading and Downloading Recipe Files Download Recipe Files
Uploading and Downloading Recipe Files
Using the 900 Control Station you can upload the recipe files from a controller to a USB memory device.
You can also download the recipe files present in the USB Memory device or Compact Flash card onto the
controller. You can upload and download the following recipe files.
• Variable Recipe (.rcp)
• Profile Recipe (.prf)
• Sequence Recipe (.seq)
• Schedule Recipe (.sch)
Download Recipe Files
1. Go to Main Menu > Station Settings > Memory Device Utilities > Download Recipe. The Select
Download Recipe Type dialog box appears.
2. Select a file to download. You can select Download Variable Recipe File, Download Profile Recipe
File, Download Sequence Recipe File, or Download Schedule Recipe File.
3. Browse to the file that you want to download. File can be present in C: or D: drive.
4. Click Download. The Download to Location dialog box appears. Please note that the below screen
appears only when you select Download Variable Recipe File in step 1.
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Upload Recipe Files Uploading and Downloading Recipe Files
5. Select a recipe location and press Start to proceed. Use the Previous and Next buttons to toggle
between the various recipe pages.
6. The Edit Variable Recipe page is displayed. Click Download to download the edited or selected
recipe file onto the controller.
7. Press Save to save the changes made in the recipe file. The changes are saved to the file in the
memory device.
On successful file download, File Downloaded Successfully message is displayed. In case the download
fails, an error message is displayed.
Similar method is used for downloading different types of recipe file.
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Main Menu
Uploading and Downloading Recipe Files Upload Recipe Files
Upload Recipe Files
1. Go to Main Menu > Station Settings > Memory Device Utilities > Upload Recipe. The Select Upload
Recipe Type dialog box appears.
2. Select a file to upload. You can select Upload Variable Recipe File, Upload Profile Recipe File,
Upload Sequence Recipe File, or Upload Schedule Recipe File.
3. Select a location to save the file. File can be saved in C: or D: drive. By default file is saved as
Upload1. However, you can overwrite the file name.
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Upload Recipe Files Uploading and Downloading Recipe Files
4. Click Upload. The Upload from Location dialog box appears. Please note that the below screen
appears only when you select Upload Variable Recipe File in step 1
5. Select a recipe location and press Start to proceed. Use the Previous and Next buttons to toggle
between the various recipe pages.
6. The Edit Variable Recipe page is displayed. Click Upload to upload the edited or selected recipe
file.
7. Press Save to save the changes made in the recipe file. The changes are saved to the file in the
memory device.
On successful file upload, File Uploaded Successfully message is displayed. In case the upload fails, an
error message is displayed.
Similar method is used for uploading different types of recipe file.
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Main Menu
Uploading and Downloading Security Settings Upload Security Displays and Functionality
Uploading and Downloading Security Settings
You can upload the security settings (password) from Control Station to memory Devices and download
them to the Control Station holding database with the same GUID.
Upload Security Displays and Functionality
1. Go to Main Menu > Station Settings > Memory Device Utilities > Upload Security. The Upload
Security Database dialog box appears.
2. Select a location and type a file name to save the security settings. The Upload button is enabled and
‘.dat’ extension is added to the file name.
3. Press Upload to upload the file to the database. The following message appears indicating the
successful upload of security file.
In case the upload fails, the following message is displayed.
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Upload Security Displays and Functionality Uploading and Downloading Security Settings
By default, Security is used as the file name. If you over write the file name, you are prompted with the
following message. Press Yes or No as required.
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Main Menu
Using Barcode Reader Download Security Displays and Functionality
Download Security Displays and Functionality
1. Go to Main Menu > Station Settings > Memory Device Utilities > Download Security. The
Download Security Database dialog box appears.
Note: A USB memory device or CompactFlash card must be connected to Control Station or else an error
message is displayed.
2. Browse and open the file that you want to download.
3. Press Download. The selected file gets downloaded from the selected location. A success message
appears on successful completion of file download.
In case the download fails, an error message is displayed.
Using Barcode Reader
1. Touch a data box on the Control Station. A keypad appears.
2. Scan a bar code. Data appears in the entry area of keypad pop-up.
If the bar code reader includes carriage return and line feed, the keypad pop-up goes away and the data
appears in the data box.
If carriage return and line feed are not included in the scan, the user touches the Enter button on the
keypad, the pop-up goes away, and the data appears in the data box.
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Overview
Access
Press the Home key to access an array of 16 buttons. See example below. Your actual buttons may vary.
Each button takes you to a display that was custom-configured for your HC900’s process.
Process Displays
Widget displays
Your Control Station’s process displays were configured using a variety of objects such as figures,
symbols, text boxes, and widgets. A widget is a graphical object designed to work with a specific function
block type in your HC900’s process configuration. For example, some widgets, like Digital Pushbutton,
perform a simple on/off function for monitoring and controlling a digital signal. Other widgets have many
functions. For example, a loop PID widget lets you not only view and adjust the loop’s SP and output, but
also lets you jump to detailed displays for the loop (such as loop setup, trending, tuning, alarm setpoints,
and output limiting).
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Process Displays
Overview Widget displays
The table below lists all the widgets that may appear on your displays. Your actual displays may vary.
Widget type See page
Pushbuttons, signals and variables 90
AGA8DL & AGA8GS 91
4-Selector Switch 97
Device Control 98
Hand/Off/Auto Switch 100
Stage 101
Ramp 103
Alternator 105
Calendar Event 109
Wireless transmitters 113
Setpoint Programmers 119
Setpoint Schedulers 133
Sequencers 141
Loops (A/M Bias, Carbon, On/Off, PID, 3 Position Step Control) 147
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