Honeywell ControlEdge 900 platform Hardware Planning And Installation Manual

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ControlEdge 900 Platform

Hardware Planning and Installation

Guide

HWDOC-X430-en-J

November 2018

ControlEdge PLC

ControlEdge UOC

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DISCLAIMER

This document contains Honeywell proprietary information. Information contained herein is to be used solely for the purpose submitted, and no part of this document or its contents shall be reproduced, published, or disclosed to a third party without the express permission of Honeywell International Sàrl.

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a purpose and makes no express warranties except as may be stated in its written agreement with and for its customer.

In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The information and specifications in this document are subject to change without notice.

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Contents 3

Chapter 1 - About this guide 7

Chapter 2 - Overview 13

Chapter 3 - ControlEdge PLC 15

PLC I/O Network Topology 15

Hardware Configuration of CPM 22

Hardware Configuration of EPM 27

Hardware Configuration of IO 27

Device Replacement 27

Chapter 4 - ControlEdge UOC 33

Contents

UOC I/O Expansion Network Topology 34

HSR Ring to 900 I/O 34

Non-Redundant or Redundant Star to 900 I/O 36

DLR Direct Connection to 900 I/O and EIP devices 38

DLR ETAP Connection to 900 I/O and EIP Devices 39

Non-Redundant Star to 900 I/O and EIP Devices 41

Hardware configuration of UOC-CPM 43

Hardware Configuration of UOC EPM 46

Hardware configuration of I/O 46

Device Replacement 47

Chapter 5 - ControlEdge 900 Common Reference Information 53

Installation 53

Rack options 53

Rack Types 55

Rack installation 64

Power Supply 77

Environmental considerations 81

Power Status Module 82

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Contents

Expansion Processor Module 82

Serial Communication Module 84

ControlEdge 900 I/O 87

Terminal block styles 100

Terminal Block-to-Field (Signal) Wiring 106

Chapter 6 - Wiring and cabling planning 149

Electrical considerations 149

Wiring and cabling distance guidelines 153

Chapter 7 - Maintenance 155

Safety considerations - PLAN AHEAD! 155

Periodic checks 157

Removal and Insertion Under Power (RIUP) 157

Replacing the power supply 158

Replacing an EPM 160

Replacing an I/O module 161

Spare parts and model numbers 164

Chapter 8 - Diagnostics and Troubleshooting 169

EPM Indicators 169

Serial Communication Module Indicators 171

I/O Indicators 172

UIO Indicators 176

Chapter 9 - Special Condition of Use and Approved Standards 179

Approval Rating 179

Special Condition of Use for Division 2/Zone 2 Hazardous Location Installation 179

For the United States 179

For Canada 180

For ATEX 180

Approved Standards for Division 2/Zone 2 Hazardous Location 181

US Approval Standards 181

Canadian Standards 181

European Standards (Zone 2) 182

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Contents

CE LVD and EMC Compliance Standards 182

UL Compliance Standards 184

Appendix A - Installing RTP 185

Overview of RTPs 186

RTP Dimension 187

Using the RTP to field wire the IOMs 188

Using an RTP to field wire the UIO 189

Using an RTP to field wiring the UAI 191

Using Dual RTPs to field wiring the 16 Point AI 196

Using an RTP to field wiring the 16 Point AC DI 199

Using an RTP to field wiring the 16 Point DC DI 202

Using Dual RTPs to field wiring the 32 Point DC DI 204

Using an RTP to field wiring the 8 Point AC DO 207

Using Dual RTPs to field wiring the 32 Point DC DO 210

Using an RTP to field wiring 4 Channel Analog Output 212

Using an RTP to field wiring the 8 Channel Analog Output 214

Using an RTP to field wiring Relay Output 217

RTP Cable wire positions, colors, and internal schematic 219

Securing the RTP to the DIN rail 228

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Contents

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CHAPTER

ABOUT THIS GUIDE

Scope

This guide describes how to set up the ControlEdge 900 platform and install UOC or PLC.

Revision history

Revision Date Description

A September

2016

B November

2016

C April 2017 Update for the PLC R140 Release including:

D June 2017 Update for PLC. Adding the following items:

Initial release of document

Update for PLC R130.2 Release including:

l Delete the Self-powered 3–wire transmitter for UIO AI,

and updated Self-powered 4-wire transmitter for UIO AI.

l Add 900RTP-H1xx RTP Cable

l Add MOXA Unmanaged Ethernet Switch EDS-308 and

EDS-316-MM-SC.

l Five new I/O modules

l Add new RTP and RTP Cables

l New Terminal Blocks

l New accessory parts

l Add UIO wiring limitation and hardware version

comparison

l Add RTP dimension for installing

E September

2017

F November Update for UOC network topologies

Added UOC information (for Experion R505 release)

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Chapter 1 - About this guide

Revision Date Description

2017

G December

Update for ControlEdge PLC R150 Release including:

2017

l Five new I/O modules

l Add new relay RTP

I July 2018 Update DLR topologies for UOC

J November

Update for UOCOne Slot Rack added

2018

Update for ControlEdge PLC R151 Release including:

l 8 channel Analog Output

l 16 Channel DC/AC Digital Input

l Quadrature Input and Pulse Output

l Serial Communication Module

l EtherNet/IP

Intended audience

This guide is primarily intended for Honeywell field personnel who do hardware planning, installation, operation, and maintenance for the Honeywell ControlEdge™ 900 Controller.

PLC I/O Network Topology

The ControlEdge PLC is configured with a non-redundant Control Processor Module (CPM) or a redundant CPM. This section provides details of each configuration.

ControlEdge PLC includes provisions for communication via Ethernet with host systems such as the Honeywell Experion Human Machine Interface (HMI) and other HMI software that support Modbus/TCP or OPC UA protocols. The communication structure of the ControlEdge PLC enables remote placement of input/output components, allowing economies in cabling and wiring.

The Ethernet ports provide a layer of protection against cyber-attacks. Multiple layers of protection are always considered good cybersecurity practice so using a firewall device configured to prevent uncontrolled messages into the CPM is advised. The figures in this manual assume the firewall is installed properly above the CPM's Ethernet port(s) ETH1 and ETH2.

While the CPM has an embedded firewall, it is still recommended to apply network firewall(s) to the control system as the application requires.

Close all Ethernet ports into PLC-CPM except:

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n Modbus TCP Slave

n OPC UA Server

n HART IP

n ControlEdge Builder Controller Configuration protocol

n Privacy protocol

n SNTP (if NTP server is enabled)

n Destination DHCP for uplink

n Modbus Master and OPC UA Client that configured in the relative

function blocks

n CDA Responder

The port number can be configured in ControlEdge Builder, and see the following table for the default port numbers.

Table 3-1: Default port numbers

Port number Port number type Description

41103 Fixed destination port Builder protocol

24558 Fixed destination port Discovery protocol

9050 Fixed source port Discovery protocol

123 Fixed source port SNTP protocol

123 Fixed destination port SNTP protocol

68 Fixed destination port DHCP Client for uplink

500 Fixed destination/source port IPSec for uplink (IKE ports)

4500 Fixed source port IPSec for uplink(IKE ports)

55601 Fixed destination port IPSec for uplink(CertMngr cleartext)

55602 Fixed destination port IPSec for uplink(CertMngr encryption)

80 Fixed source port IPSec for uplink (SCEP)

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I/O Network

In the I/O network used to connect the PLC-CPM to expansion I/O racks via the EPM, two network topologies are supported in the network: Ring and Star.

n Up to 144 I/O modules can be configured. Rationale: 12 racks x

12 modules per rack.

n Up to 4608, channels can be configured. Rationale: 12 racks x 12

modules per rack x 32 channels per module (applicable for certain I/O module types only)

Figure 3-1: System architecture with non redundant PLC-CPM

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Figure 3-2: System architecture with redundant PLC-CPM

Physical cabling/connection of the nodes forming the ring, applicable to the purple HSR/Ring topology on the right side of the above illustration, must be connected as follows:

n CPM port 3 (ETH3) must be connected to CPM port 4 (ETH4) or

EPM port 2 (ETH2).

n CPM port 4 (ETH4) must be connected to CPM port 3 (ETH3) or

EPM port 1 (ETH1).

n EPM port 1 (ETH1) must be connected to EPM port 2 (ETH2) or

CPM port 4 (EHT4).

n EPM port 2 (ETH2) must be connected to EPM port 1 (ETH1) or

CPM port 3 (EHT3).

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Table 3-2: System component list for ControlEdge 900 PLC Hardware

Item

Component Name

Description Source

1 I/O Rack System may consist of 5 different types of

I/O racks:

l 4-slot w/1 power supply

l 8-slot w/1 power supply

l 12-slot w/1 power supply

l 8-slot w/redundant power supplies

l 12-slot w/ redundant power upplies

Local I/O Rack

l 1 I/O Rack

l 1 CPM (for controller racks) or 1 EPM

(for I/O racks)

l Up to 4, 8 or 12 I/O modules

l 1 or 2 Power Supplies

Optional second Power Supply and Power Status Module (PSM) on 8and 12-slot I/O rack.

A Power Status Module (PSM) is required with redundant power supplies.

2 Redundant CPM

Rack

3 Expansion I/O

Rack (Optional)

l 1 Redundant Controller Rack

l 2 Power Supplies

l 2 CPMs: Redundancy is provided by

two CPMs operating in a Redundant Controller Rack; this rack has no I/O modules.

l 1 Filler block cover

Includes:

l 1 rack

l 1 Power Supply

l Optional second Power Supply and

Honeywell

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Item

Component Name

Description Source

Power Status Module (PSM) on 8and 12- slot I/O rack.

l 1 Expansion Processor Module

(EPM)

l Up to 4, 8 or 12 I/O modules

l A Power Status Module (PSM) is

required with redundant power supplies.

System may consist of 5 different types of I/O rack:

l 4-slot w/1 power supply

l 8-slot w/1 power supply

l 12-slot w/1 power supply

l 8-slot w/redundant power supplies

4 Human-Machine

Interface (HMI) (Optional)

5 Configuration

Station

6 Un-managed

Ethernet 100Base-T Switch

7 Ethernet

100Base-T

l 12-slot w/ redundant power upplies

PC links to Ethernet network, which includes other HMIs, other ControlEdge 900 Controllers, and other networks (including Internet). Typically includes HMI operating software which includes configuration tool from Honeywell.

HMI software is available from Honeywell or from thirdparty supplier.

Connects from ETH1/ETH2 of the certain CPM or network switch linking CPMs.

Configuration software is from Honeywell.

(Only for Star topology) Enables connection of the private Ethernet 100Base-T port on a CPM to the EPMs on Expansion I/O rack. (The switch is not required if there is no expansion I/O or only one expansion I/O rack in the system.)

Third-party suppliers or Qualified third party devices available from Honeywell

Enables inter-connection of several Third-party

suppliers.

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Item

Component Name

Description Source

Switch or Router/Firewall

8 Ethernet CAT5

shielded cable

Fiber Optics Cable

9 Communications

cable

100Base-T Ethernet devices in an Ethernet network. Devices include other ControlEdge 900 Controller, HMIs, and includes routers, servers, and other devices in wider networks. Use of a properly configured firewall provides a more robust network limiting exposure to uncontrolled network traffic.

Connects I/O expansion racks to CPMs and/or to 100Base-T Ethernet switches. The maximum length of the Ethernet cable is 100m.

The maximum length of multi-mode fiber optic cable depends on the specification of network device, typically 5 Km with a MOXA EDS-308-MM-SC. A qualified Fiber Optic Convertor is required.

Ethernet able or Fiber Optic Cable connects devices icn Ethernet Open Connectivity network to SCADA applications.

Third-party suppliers

Following sections provide information about installing racks, EPM, power supply and so on.

Table 3-3: Reference about installing racks, EPM, power supply and so on

Components Reference section

Racks For information about options and types of racks, see the sections

Rack Options and Rack Types. For information about installing

Racks, see the section Rack Installation.

EPM For information about installing EPM, see the section Expansion

Processor Module.

Power Supply For information about connecting to AC or DC power supply, see

the section Power Supply.

Configuration For information about configuration, refer to the Software

Configuration Guide.

Environmental For information about environmental consideration to be taken

care, see the section Environmental Considerations.

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Hardware Configuration of CPM

Control Processor Module

A Redundant Controller Rack contains two CPMs. Either CPM can be primary.

The CPM is shown in the following figure:

Figure 3-3: Control Processor Module

Table 3-4: CPM Components

Item Description

1 Status LED indicator for the CPM. For more information, see CPM Indicators

section.

2 Role LED indicator for the CPM. For more information, see CPM Indicators

section

3 SD card slot: supports 32GB Class 6 / Class 10 industry standard, not hot-

swappable, maximum weight 3g (0.0066 lb, 0.1058 oz).

4 Mode switch. For more information, see CPM mode switch section.

As indicated in this figure, CPM includes:

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Item Description

5 ETH1 and ETH2 host ports to PC applications and/or other CPMs, or other

devices.

6 ETH3 and ETH4 ports connect to the Ethernet ports of EPM, switch (for star

topology), or CPM.

7 Ethernet LED status indicators for communications functions. For more

information, see CPM Indicators section.

CAUTION: Do not remove or insert the Ethernet connection when the CPM is powered unless the area is known to be nonhazardous.

PLC-CPM mode switch

There are four mode switch positions on CPM: STOP, RUN, and two REMOTE positions which are identical.

Figure 3-4: Mode switch on CPM

The switch can be rotated in a clockwise or counter-clockwise fashion in order to engage the four switch positions. When the mode switch is

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in REMOTE position, the operating modes can be configured in the Configuration tool.

For more information for the operating modes, see “Selecting operating modes” in ControlEdge Builder User’s Guide.

ATTENTION: For redundant controller system, the position of mode switch in primary PLC-CPM in this box determines the system operating mode. If the mode switches on the primary and secondary CPMs are in different positions, the system will drop sync. Do not rotate the Mode switch when the CPM is powered unless the area is known to be non-hazardous.

PLC-CPM Rotary Switch

PLC CPM system does not utilize the Rotary switches. They are set to zero as indicated in the picture.

Figure 3-5: Control Processor Module

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PLC-CPM Indicators

The following diagram displays the location of the LED indicators on the CPM. The following table explains the meaning of each LED state.

Figure 3-6: LED Indicators on PLC-CPM

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Table 3-5: LED Indications on PLC-CPM

Item LED

LED State/Color

Description

1 Status OFF No Power is applied to CPM.

On/Green The controller is working normally.

On/Red The controller is stopped.

On/Orange The controller is in power-up process.

Blinking Red

The controller is running with error.

@ 1HZ

Blinking Red @ 0.5HZ

The controller is accessible via online communication, but no application is loaded.

Blinking Red

IP address is in conflict.

@ 5HZ

Blink @ 1HZ /

The controller is upgrading firmware. Green & Orange

2 Role OFF It is a non-redundant system or;

3, 5, 7, 9

Ethernet Port Speed ( Upper LED)

On/Green The controller is in primary role and the

system is synchronized, or;

On/Orange The controller is in secondary role and

the system is synchronized.

Blinking Green @ 1HZ

Blinking Orange @

The controller is in primary role and the

system is synchronizing.

The controller is in secondary role and

the system is synchronizing. 1HZ

Blinking Green @

The controller is in primary role and the

system is unsynchronized.

0.5HZ

Blink Red @

0.5HZ

The controller is in secondary role and

the system is unsynchronized.

Yellow On/Off OFF for 10Base-T; ON for 100Base-TX.

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Item LED

LED State/Color

Description

4, 6, 8, 10

Ethernet Port Link/ Active ( Lower LED)

Green On/Off/ Blinking

On for connection; Off for no

connection; and blinking for activity

Hardware Configuration of EPM

Refer to the common EPM section.

Hardware Configuration of IO

Refer to the I/O module type section.

Device Replacement

ATTENTION: If Secure Communication is enabled in the system, the relative information of the new CPM should be updated in the IPsec configuration of the PC installed the ControlEdge Builder and IPsec should be configured and enabled on the new CPM. For more information, see "Chapter 9 " in the ControlEdge PLC and ControlEdge RTU Network and Security Planning Guide.

Replacing a non-redundant or unsynchronized

primary PLC-CPM

ATTENTION: This procedure can only be performed while offprocess. We recommend that you proceed with extreme caution whenever replacing any component in a control system. Be sure the system is offline or in a safe operating mode. Component replacements may also require downloading appropriate configuration data to the replaced component through ControlEdge Builder. Wear an ESD wrist strap and observe static precautions.

Before replacing a non-redundant or unsynchronized primary PLCCPM:

n It is recommended to upload and SAVE a copy of the

configuration, or ensure that a previously saved copy of the

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current configuration is available.

n It is recommended to bring the process to a safe and orderly

shutdown.

You will need a #2 Phillips screwdriver.

To replace a non-redundant or unsynchronized primary PLC-CPM

1. If a process is currently in operation, bring it to the safe mode, and orderly shutdown if it is required.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power.

3. Observe where communications cables are plugged into the CPM, and if necessary, tag them to identify their functions. Unplug all communications cables.

4. At the top and bottom of the module, loosen the captured screws that secure the module in the rack, and remove the CPM from the rack. (Note that an up/down rocking motion helps with removal of the module.)

5. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

6. Re-install communications cables.

7. Set the new CPM’s mode switch position to STOP (to prevent an old/stale configuration from running and to enable firmware update and configuration load).

8. Using the (user-supplied) switch, re-connect power supply in the rack (associated with the new CPM) the source main power to the rack.

9. Optional-for IPsec enable system, if Secure Communication is enabled in the system, disable the IPsec in the PC installed the ControlEdge Builder. See "Disable IPsec policy on PCs" in

ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.

10. Use the ControlEdge Builder to load firmware to the new CPM to match the version that was running in the removed CPM.

11. Use the ControlEdge Builder to download the configuration to the new CPM.

12. Set the new CPM’s mode switch position to the desired operation state.

13. Optional-for IPsec enable system, setup certificates and IPsec policy in the CPM. See "Setup certificates and IPsec policy in

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PLC/RTU" in ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.

14. Optional-for IPsec enable system, enable the IPsec in the PC installed the ControlEdge Builder. See "Enable IPsec policy on PCs" in ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.

Replacing a secondary PLC-CPM

ATTENTION: Replacing a secondary CPM can be performed while on-process or off-process. We recommend that you proceed with extreme caution whenever replacing any component in a control system. Be sure the system is offline or in a safe operating mode. Component replacements may also require firmware update. Wear an ESD wrist strap and observe static precautions

You will need a #2 Phillips screwdriver.

To replace a secondary PLC-CPM

1. [Optional] It is recommended to disable and prevent synchronization first by issuing the redundancy disable synchronization command from ControlEdge Builder.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power.

3. Observe where communications cables are plugged into the CPM to be replaced, and if necessary, tag them to identify their functions. Unplug all communications cables.

4. At the top and bottom of the module to be replaced, loosen the captured screws that secure the module in the rack, and remove the CPM from the rack. (Note that an up/down rocking motion helps with removal of the module).

5. At the top and bottom of the module, loosen the captured screws that secure the module in the rack, and remove the CPM from the rack.

6. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

7. Re-install communications cables.

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8. Set the new CPM’s mode switch position to STOP (to enable firmware update).

9. Using an external (user-supplied) switch, re-connect the power supply in the rack (associated with the new CPM) to the source main power.

10. Optional-for IPsec enable system, setup certificates and IPsec policy in the CPM. See "Setup certificates and IPsec policy in PLC/RTU" in ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.

11. Use the ControlEdge Builder to load firmware to the new CPM to match the version that is running in the primary redundant partner CPM.

12. Check the redundancy synchronization state by monitoring the role LED of the primary or secondary CPM.

13. Switch the new secondary CPM’s mode switch position to match the primary redundant partner CPM.

Replacing a primary PLC-CPM

ATTENTION: Replacing a synchronized primary CPM can be performed while on-process or off-process. Replacing an unsynchronized primary CPM can only be performed off-process. We recommend that you proceed with extreme caution whenever replacing any component in a control system. Be sure the system is offline or in a safe operating mode. Component replacements may also require firmware update and/or downloading appropriate configuration data to the replaced component through ControlEdge Builder. Wear an ESD wrist strap and observe static precautions.

You will need a #2 Phillips screwdriver.

Replacing an unsynchronized primary PLC-CPM

n It is recommended to first establish redundancy synchronization

between the redundant controllers (when possible) and follow the procedure to replace a synchronized primary PLC-CPM below.

n When primary CPM on-process replacement is either not required

or not possible due to inability to synchronize the redundant controllers, follow the off-process procedures in Replacing a non-

redundant PLC-CPM section.

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Replacing a synchronized primary PLC-CPM

1. [Optional] It is recommended to first transition the synchronized primary CPM into the secondary role by issuing the redundancy switchover command from ControlEdge Builder. This step {1} transitions the synchronized secondary (redundant partner) CPM into the primary role and {2} the CPM to be replaced restarts into the secondary role.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power. If the optional switchover command was not issued, this step transitions the synchronized secondary (redundant partner) CPM into the primary role. and {2} the CPM to be replaced restarts into the secondary role.

3. Observe where communications cables are plugged into the CPM to be replaced, and if necessary, tag them to identify their functions. Unplug all communications cables.

5. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

6. Re-install communications cables.

7. Set the new CPM’s mode switch position to STOP (to enable firmware update).

8. Using an external (user-supplied) switch, reconnect the power supply in the rack (associated with the new CPM) to the source main power.

9. Optional-for IPsec enable system, setup certificates and IPsec policy in the CPM. See "Setup certificates and IPsec policy in PLC/RTU" in the ControlEdge PLC and ControlEdge RTU Network and Security Guide for more information.

10. Use the ControlEdge Builder to load firmware to the new secondary CPM to match the version that is running in the primary redundant partner CPM.

11. Switch the new secondary CPM’s mode switch position to match the primary redundant partner CPM.

12. Check the redundancy synchronization state by monitoring the role LED of the secondary CPM.

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Following section provides information about replacing EPM, I/O Module and Spare parts that are common to both PLC and UOC.

Table 3-6: Component Replacement Reference

Component replacement

Reference

EPM For information about replacing EPM, see the section EPM

device replacement.

I/O Module For information about replacing I/O Module, see the section I/O

module replacement.

Spare parts For information about replacing spare parts, see the section

Spare parts.

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CHAPTER

CONTROLEDGE UOC

ControlEdge UOC is DCS controller available with Experion. UOC provides control for process units through level 0 I/O devices and provides communication data access from level 1 and level 2 FTE networks. Like other Experion DCS controllers, ControlEdge UOC uses the Experion Control Execution Environment (CEE) as the control engine and is configured with Experion Control Builder.

ControlEdge UOC uses many of the ControlEdge 900 platform components. These include the following:

n CPM

n EPM (Firmware version 140 or later)

n ControlEdge 900 UIO Module

n Redundant Controller Rack

n I/O Controller Rack

n Power System

n RTP Kit

n Barrier Terminal Blocks

n Accessories (switches, jumpers, resistors)

Points to note specific to the use of the CPM as a UOC in Experion:

n SD card slot on CPM is currently not utilized and is reserved for

use in future.

n The CPM Mode switch is not utilized by UOC firmware. Honeywell

recommends that it be covered using (HW part number, if available) after conversion of the PLC CPM into a UOC CPM. However, the switch movement has no effect. For further information on conversion, see UOC User’s Guide.

n Currently, of the ControlEdge 900 I/O modules described in this

document, the UOC supports only the UIOM. Support for additional I/O card types will be extended in future releases.

This section provides information about following:

n UOC I/O Expansion Network Topology

n Hardware Configuration of UOC-CPM

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n Hardware configuration of EPM

n Hardware configuration of I/O module type

n Device Replacement

UOC I/O Expansion Network Topology

UOC has four Ethernet ports. Port 3 and 4 are used to connect to I/O network, used for I/O. Table below shows UOC supported these network topologies.

Topology Type Description Switch Types

Topology 1 HSR ring to 900 I/O. None

Topology 2 Non-redundant star to 900 I/O Generic

Topology 3 Redundant star (via PRP) to 900 I/O Generic

Topology 4 DLR direct connection to 900 I/O and

EIP devices

Topology 5 DLR ETAP connections 900 I/O and

EIP devices.

Topology 6 Non-redundant star to 900 I/O and

EIP devices

Uplink and downlink subnets must be unique. The Downlink subnet mask must be limited to the number of addresses expected in that subnet.

For example, if a max of 64 addresses is expected, you could use a mask of 255.255.255.192.

HSR Ring to 900 I/O

When connecting to ControlEdge 900 I/O only, a redundant ring topology may be used. The ring type is HSR (High Availability Seamless Redundancy). In this topology no third party redundancy boxes are required. The UOC CPM connects directly, using its two downlink Ethernet ports. Similarly, EPM modules connect directly using their two Ethernet ports. When a UOC downlink is constructed in this fashion, it is not possible to connect third party I/O, Devices or PLCs. Only 900 I/O racks may be connected.

None

ETAPs for EPMs or nonDLR devices

Generic and stratix

When connecting CPMs and EPMs into an I/O network ring, the numbered ports must be connected so that odd numbered ports always connect to even numbered ports. This is shown in the

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following diagram for the case of a redundant UOC rack with two UOC CPMs connecting to two, 4-I/O slot, non-redundant racks, each with its own EPM. Also shown are the CPM’s connection of ETH1 to the A, Yellow FTE network tree and ETH2 to the B, Green FTE network tree.

Downlink I/O Network

Considerations for components that connect to a UOC’s downlink HSR ring network are summarized in the following table.

Component Type

ControlEdge UOC CPM

Comments

The UOC CPM must be connected to the downlink I/O ring such that even numbered ports always connect to odd numbered ports. Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder. This includes configuration of the UOC DHCP server for assigning EPM IP addresses. It also includes setting the Downlink Network Configuration to Ring-HSR.

ControlEdge 900 I/O Racks with

An EPM must be connected to the downlink I/O ring such that even numbered ports always connect to odd numbered ports. Before it is inserted into its slot, the 100X rotary switch on the EPM board must

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Component Type

EPMs be set to indicate I/O network connectivity. This is done by setting it to

Comments

position 3. The IP address of the EPM is assigned by the UOC CPM based on the module number set on the 10X and 1X rotary switches. Ensure that the values within the range of 1-12 are used, as these are the valid values. This too must be set before the EPM is inserted into its slot.

Non-Redundant or Redundant Star to 900 I/O

When connecting to ControlEdge 900 I/O only, either a nonredundant or redundant star topology may be used. The network redundancy type is PRP (Parallel Redundancy Protocol). In this topology no third party redundancy boxes are required. The UOC CPM connects directly, using its two downlink Ethernet ports. Similarly, EPM modules connect directly using their two Ethernet ports. When a UOC downlink is constructed in this fashion, it is not possible to connect third party I/O, Devices or PLCs. Only 900 I/O racks may be connected.

An example of a UOC and two 900 I/O racks on a downlink, redundant, star network is shown in the following diagram. Also shown are the CPM’s connection of ETH1 to the A, Yellow FTE network tree and ETH2 to the B, Green FTE network tree.

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Redundant Star Network

The UOC does not support star topologies which mix redundant and non-redundant connectivity. Downlink star networks must be set up as exclusively redundant or exclusively non-redundant.

Considerations for components that connect to a UOC’s downlink non-redundant or redundant star network are summarized in the following table.

Component Type

ControlEdge UOC CPM

ControlEdge 900 I/O Racks with EPMs

Comments

Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder. This includes configuration of the UOC DHCP server for assigning EPM IP addresses. It also includes setting the Downlink Network Configuration to “Non-redundant” in the case of a non-redundant star network or “Star-PRP” in the case of a redundant star network.

Before it is inserted into its slot, the 100X rotary switch on an EPM board must be set to indicate I/O network connectivity. For a nonredundant or redundant star network, this is done by setting it to position 4. The IP address of the EPM is assigned by the UOC CPM based on the module number set on the 10X and 1X rotary switches. Ensure that the values within the range of 1-12 are used, as these are the valid values. This too must be set before the EPM is inserted into

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Component Type

Comments

its slot.

Unmanaged Switches

900 I/O racks with EPM gateways have been qualified to communicate with UOC through unmanaged switches. Managed switches may not be used. For information on qualified switches see the ControlEdge 900 Hardware and Installation Guide.

DLR Direct Connection to 900 I/O and EIP devices

DLR is layer 2 data link layer protocol that provides media redundancy, faster network fault detection, and network fault resolution in a ring topology. On network with only DLR devices, one device act as an active ring supervisor and other devices form ring nodes. DLR network contain a maximum 50 IP address nodes(This is Honeywell specification).

DLR network should have at least one node configured as ring supervisor. If there are multiple nodes configured as supervisor, then the node with highest supervisor precedence value becomes active supervisor, others will be backup Supervisors. Ring supervisor connects to CPM through a third party devices.

The active ring supervisor cyclically sends out Beacon Frames and Announce Frames on both ports. They are received on one port of a ring node, processed and passed on to the next ring node via the other port. By default the Beacon Frames are sent every 400 microseconds and the Announce Frames are sent every second.

An example of a DLR Ring network is shown in the following diagram

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Downlink DLR Network

DLR ETAP Connection to 900 I/O and EIP Devices

As an alternative to an HSR ring network with only ControlEdge 900 I/O, UOC can optionally be connected to an EtherNet/IP-based I/O, device and PLC ring network through its ETH3 downlink port. Under that configuration a UOC can communicate simultaneously with ControlEdge 900 I/O and third party devices attached to the same EtherNet/IP network.

One supported EtherNet/IP network topology is that of a DLR ring which provides redundancy protection against a single network ring fault. Installation and maintenance of a downlink EtherNet/IP network must be done in accordance with the best practices of Ethernet networking in general and EtherNet/IP in particular. In Experion R510, UOCs will be directly connected to DLR network, and EPMs must be connected to a DLR ring using redundancy boxes called ETAPs (EtherNet/IP Taps). This requirement will be removed in a future release.

In this topology, UOC connects directly to the ring through downlink ports ETH3 and ETH4. EPMs connect through their ETH1 port with ETH2 port disconnected

An example is shown in the diagram below.

DLR ETAP Connection to 900 I/O and EIP Devices

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Installation and maintenance practices for the UOC’s downlink EtherNet/IP network generally follow those described in (EtherNet IP User's Guide) for topology 2, “C300 Through EIM To EtherNet/IP”. Additional considerations for components that connect to the EtherNet/IP network are summarized in the following table.

Component Type

ControlEdge UOC CPM

ControlEdge 900 I/O Racks with EPMs

EtherNet/IP TAPs (ETAPs)

Comments

The UOC CPM connects to a downlink EtherNet/IP network through its ETH3 and ETH4 ports. Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder. This includes configuration of the UOC DHCP server for assigning EPM IP addresses. It also includes Downlink Network Configuration to Non-redundant.

When 900 I/O is used, the EPM in the I/O rack serves the role of communication gateway into the I/O rack. When an EPM is connected to an EtherNet/IP network, its ETH1 port is connected to the ETAP while its ETH2 port is left disconnected. Before it is inserted into its slot, the 100x rotary switch on the EPM board must be set to indicate the type of network connectivity in use. This is done by setting it to position 4. The IP address of the EPM is assigned by the UOC CPM based on the module number set on the 10X and 1x rotary switches. These switches must also be set before the EPM is inserted into its slot.

UOC systems use redundancy boxes called ETAPs for connectivity to downlink DLR rings. For further information on the use of ETAPs, see EtherNet IP User's Guide_EPDOC-X399-en-510A.pdf.

ControlLogix PLC

EtherNet/IP I/O and Devices

UOC can communicate with Rockwell Allen Bradley ControlLogix PLCs by passing instances of User Defined Types (UDTs). References to ControLogix data are created in Experion Control Builder with the aid of tag names provided by the Matrikon Allen Bradley OPC server or by export of ControlLogix tag names from the Rockwell Allen Bradley Studio 5000 designer tool. ControlLogix PLCs on a UOC’s downlink EtherNet/IP network must always use static IP address assignments. For information on the configuration of ControlLogix communications, see EtherNet IP User's Guide_EPDOC-X399-en- 510A.pdf.

UOC supports a set of EtherNet/IP devices with pre-populated CEE block types in Experion Control Builder (CB). In addition, CB provides the Parameter Definition Editor (PDE) tool which allows for the integration of new EtherNet/IP I/O and devices independent of Experion release. Although some third party EtherNet/IP devices support IP address assignment from a network resident DHCP server, this feature cannot be used when the EtherNet/IP network

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Component Type

Comments

connects to UOC. All device IP addresses must be statically assigned. For further information, see EtherNet IP User's Guide_EPDOC-X399- en-510A.pdf.

Allen Bradley OPC Server from MatrikonOPC

Studio 5000 Logix Designer Software

The Rockwell Allen Bradley OPC Server from MatrikonOPC can be installed on the Experion Server in systems which incorporate UOC. The Matrikon OPC Server enables one of two methods whereby ControlLogix tag names can be used to make UDT references in a UOC strategy. For further information, see EtherNet IP User's Guide_ EPDOC-X399-en-510A.pdf.

Studio 5000 Logix Designer Software from Rockwell Allen Bradley is used in conjunction with UOC configurations to configure IP addresses of Rockwell Allen Bradley EtherNet/IP devices. It can also be used to export a file which defines ControlLogix tag names so that they can be used in Control Builder to construct UDT data references from UOC. For further information, see EtherNet IP User's Guide_ EPDOC-X399-en-510A.pdf.

While using DLR (Device Level Ring) on Stratix 5700 Switch, DO NOT CONNECT a DLR network to a Non-DLR port on the Switch. DLR should be connected only to the DLR ports on the switch. Doing this will result in the entire down link network going down. The recovery is to only remove the DLR connection from the switch.

Non-Redundant Star to 900 I/O and EIP Devices

In addition to the DLR ring topology, the UOC can also connect to a non-redundant star EtherNet/IP network through its ETH3 downlink port. This allows it to communicate simultaneously with ControlEdge 900 I/O as well as EtherNet/IP-capable I/O, devices and PLCs.

Installation and maintenance of a downlink EtherNet/IP network must be done in accordance with the best practices of Ethernet networking in general and EtherNet/IP in particular.

In this topology, CPMs connect through their ETH3 downlink port with ETH4 port disconnected. EPMs connect through their ETH1 port with ETH2 port disconnected. An example is shown in the diagram below.

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UOC CPM to 900 I/O and EIP Devices

Installation and maintenance practices for the UOC’s downlink EtherNet/IP network generally follow those described in EtherNet IP

User's Guide_EPDOC-X399-en-510A.pdf for topology 2, “C300 Through EIM To EtherNet/IP”. Additional considerations for

components that connect to the EtherNet/IP network are summarized in the following table. ControlLogix PLCs and EtherNet/IP I/O and Devices are equivalent to those for DLR ring networks.

Component Type

ControlEdge UOC CPM

ControlEdge 900 I/O Racks with

Comments

The UOC CPM connects to a downlink EtherNet/IP network through its ETH3 and ETH4port. Important properties of UOC CPM communications on the downlink network are configured on the UOC Platform Block in Control Builder. This includes configuration of the UOC DHCP server for assigning EPM IP addresses. It also includes Downlink Network Configuration to Non-redundant.

When 900 I/O is used, the EPM in the I/O rack serves the role of communication gateway into the I/O rack. When an EPM is connected to an EtherNet/IP network, its ETH1 port is connected to the switch

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Component Type

EPMs while its ETH2 port is left disconnected. Before it is inserted into its

Comments

slot, the 100x rotary switch on the EPM board must be set to indicate the type of network connectivity in use. This is done by setting it to position 4. The IP address of the EPM is assigned by the UOC CPM based on the module number set on the 10X and 1x rotary switches. These switches must also be set before the EPM is inserted into its slot.

Unmanaged Switches

Stratix Switches

Table 4-1: Reference for installing racks, EPM, power supply and so on

Components Reference section

Racks For information about options and types of racks, see the sections

EPM For information about installing EPM, see the section Expansion

Power Supply For information about connecting to AC or DC power supply, see

900 I/O racks with EPM gateways have been qualified to communicate with UOC through unmanaged switches. EPMs may not be connected through managed switches.

EIP I/O, devices and PLCs may be connected to UOC through qualified, Stratix managed switches. For further information on how to deploy and configure Stratix switches, see EtherNet IP User's Guide_ EPDOC-X399-en-510A.pdf.

Following section provides information about installing racks, EPM, power supply and so on.

Rack Options and Rack Types. For information about installing

Racks, see the section Rack Installation.

Processor Module.

the section Power Supply.

Configuration For information about configuration, refer to the Software

Configuration Guide.

Environmental For information about environmental consideration to be taken

care, see the section Environmental Considerations.

Hardware configuration of UOC-CPM

For more information refer to the UOC User’s Guide (PLC to UOC conversion).

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Control Processor Module

A Redundant Controller Rack contains two CPMs. Either CPM can be primary.

The CPM is shown in the following figure.

Figure 4-1: Control Processor Module

As indicated in this figure, CPM includes:

Table 4-2: Control Processor Module Components

Item Description

1 Status LED indicator for the CPM.

2 Role LED indicator for the CPM.

3 SD card slot: Reserved for future use.

4 Mode switch

5 Ethernet port 1 (ETH1) and Ethernet port 2 (ETH2) for uplink connectivity to

an Experion FTE network. ETH1 should be connected to the FTE A (yellow) and ETH2 should be connected to FTE B (green) networks. For more information, see Experion documentation.

6 Ethernet port 3 (ETH3) and Ethernet port 4 (ETH4) for connectivity to the

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Item Description

downlink network for ControlEdge 900 Expansion I/O racks or third party I/O. Only ring network topologies are supported.

7 Ethernet LED status indicators for communications functions. Refer to UOC

User’s guide for detailed information.

CAUTION: Do not remove or insert the Ethernet connection when the CPM is powered unless the installation is in a hazardous area.

UOC-CPM mode switch

Although the Mode switch is used when the CPM is programmed as PLC, it is not used when programmed as UOC.

Figure 4-2: UOC-CPM Rotary Switch

The FTE Device Index uniquely identifies the controller on the FTE Network. The FTE Device Index is configured in two places. First, the CPM rotary switches are used to set the FTE device index of the UOC. Second, Experion PKS Control Builder is used to configure the FTE Device Index in the UOC Platform Function Block.

Control Builder enforces the following:

n The primary controller (of a redundant controller pair) always

configured with an odd numbered Device Index.

n A non-redundant controller is only configured with an odd

numbered Device Index.

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n The secondary controller of a redundant controller pair is

configured with the even Device Index that is consecutive with its primary partner’s Device Index (i.e. primary controller Device Index plus 1)

Set the Device Index (FTE DEVICE INDEX) by turning the three rotary decimal switches (range 001 to 509). The leftmost switch on top is used for setting the hundreds digit, the right switch on top is used for setting the tens digit, and the bottom switch sets the ones digit.

Example: For a redundant pair, the primary and secondary indexes respectively could be 001, 002; 111, 112; 507, 508 and so on. In a non-redundant setup, the index could be: 001 or 111 or 507 and so on.

Failure to replicate the UOC Device Control Index according to their Control Builder configured Device Indexes will lead to failure in establishing Control Builder - controller communication thereby preventing configuration load.

For in-rack redundancy, the left controller is recommended to be configured as the odd device index and the right controller as the event device index (of the consecutive device index pair).

Redundancy communication between a pair of redundant UOC is not possible if their device indices are not set to a consecutive odd/even pair.

UOC-CPM Indicators

For detailed information on UOC CPM firmware, on how to convert a PLC CPM into a UOC CPM and on the behaviors of UOC CPM LEDs, refer to the UOC User’s Guide.

Hardware Configuration of UOC EPM

Refer to the common EPM section.

Hardware configuration of I/O

Installation and Wiring

Currently, only the ControlEdge 900 UIO is supported. Refer to the I/O Installation & Wiring section.

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Modules Types

Currently, only the ControlEdge 900 UIOM is supported. Refer to the I/O module type section.

Device Replacement

CAUTION: Explosion hazard. Removal and Insertion Under Power is not supported in Division 2/ Zone 2. CPM and/or EPM removal under power is not supported. The up/down rocking motion required to remove the module causes intermittent communications to other modules resident in the same rack. It is recommended that before removing an active CPM or EPM, the user first disconnects the power supply in the rack (associated with the CPM or EPM to be removed) from the source main power.

Replacing a non-redundant or unsynchronized

primary UOC-CPM

ATTENTION: This procedure can only be performed while offprocess. We recommend that you proceed with extreme caution whenever replacing any component in a control system. Be sure the system is offline or in a safe operating mode. Component replacements may also require downloading appropriate configuration data to the replaced component through Control Builder. Wear an ESD wrist strap and observe static precautions.

Before replacing a non-redundant or unsynchronized primary UOCCPM:

n Make sure all UOC configuration data and operator commands

are up to date within saved checkpoints or uploaded Control Builder data. If not, save checkpoint, upload to Control Builder or both.

n It is recommended to bring the process to a safe and orderly

shutdown.

You will need a #2 Phillips screwdriver.

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To replace a non-redundant or unsynchronized primary CPM:

1. If a process is currently in operation, bring it to the safe mode, and orderly shutdown if it is required.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack from the source main power.

3. Observe where communications cables are plugged into the CPM to be replaced, and if necessary, tag them to identify their functions. Unplug all communications cables.

4. At the top and bottom of the module to be replaced, loosen the captured screws that secure the module in the rack (associated with the CPM to be replaced), and remove the CPM from the rack. (Note that an up/down rocking motion helps with removal of the module).

5. Configure the new UOC/CPM rotary device index switches to match the old UOC/CPM rotary device index switches on the removed module.

6. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

7. Re-install communications cables.

8. Using an external (user-supplied) switch, re-connect the power supply in the rack (associated with the new CPM) to the source main power.

9. Use the Firmware Manager to load firmware to the new CPM to match the version that was running in the removed module.

10. Use the Control Builder to load the configuration to the new CPM.

Replacing a secondary UOC-CPM

You will need a #2 Phillips screwdriver.

To replace a secondary UOC-CPM:

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1. [Optional] It is recommended to disable and prevent synchronization first by issuing the redundancy disable synchronization command from Control Builder.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power.

3. Observe where communications cables are plugged into the CPM to be replaced, and if necessary, tag them to identify their functions. Unplug all communications cables.

5. Configure the new CPM rotary device index switches to match the rotary device index switches on the removed module.

6. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

7. Re-install communications cables.

8. Using an external (user-supplied) switch, re-connect the power supply in the rack (associated with the new CPM) to the source main power.

9. Use the Firmware Manager to load firmware to the new CPM to match the version that is running in the primary redundant partner CPM.

10. Check the redundancy synchronization state by monitoring the role LED of the primary or secondary CPM.

Replacing a primary UOC-CPM

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replaced component through Control Builder. Wear an ESD wrist strap and observe static precautions.

You will need a #2 Phillips screwdriver.

To replace an unsynchronized primary UOC-CPM:

n It is recommended to first establish redundancy synchronization

between the redundant controllers (when possible) and follow the procedure to replace a synchronized primary UOC-CPM below.

n When primary CPM on-process replacement is either not required

or not possible due to inability to synchronize the redundant controllers, follow the off-process procedures in Replacing a nonredundant UOC-CPM section.

To replace a synchronized primary UOC-CPM:

1. [Optional] It is recommended to first transition the synchronized primary CPM into the secondary role by issuing the redundancy switchover command from Control Builder. This step {1} transitions the synchronized secondary (redundant partner) CPM into the primary role and {2} the CPM to be replaced restarts into the secondary role.

2. Using an external (user-supplied) switch, disconnect the power supply in the rack (associated with the CPM to be replaced) from the source main power. If the optional switchover command was not issued, this step {1} transitions the synchronized secondary (redundant partner) CPM into the primary role and {2} the CPM to be replaced restarts into the secondary role.

3. Observe where communications cables are plugged into the CPM to be replaced, and if necessary, tag them to identify their functions. Unplug all communications cables.

5. Configure the new CPM rotary device index switches to match the old CPM rotary device index switches

6. Ensure that the new CPM is properly aligned with the slot guides, insert the new CPM in the rack, and secure it in place with the captured screws at top and bottom of the module.

7. Re-install communcation cables.

8. Using an external (user-supplied) switch, reconnect the power supply in the rack (associated with the new CPM) to the source main power.

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9. Use the Firmware Manager to laod firmware to the new CPM to match the version that is running in the primary redundant partner CPM.

10. Check the redundancy synchronization state by monitoring the role LED of the primary or secondary CPM.

To replace an unsynchronized primary CPM,:

Refer to Replacing a non-redundant UOC-CPM section for this information.

Following section provides information about replacing EPM, I/O Module and Spare parts that are common to both PLC and UOC.

Table 4-3: Reference for replacing EPM, I/O Module and Spare parts that are common to both PLC and UOC

Component replacement

Reference

EPM For information about replacing EPM, see the section EPM

device replacement.

I/O Module For information about replacing I/O Module, see the section I/O

module replacement.

Spare parts For information about replacing spare parts, see the section

Spare parts.

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Page 53

CHAPTER

CONTROLEDGE 900 COMMON REFERENCE

INFORMATION

This section is applicable to both UOC and PLC systems and provides the following information:

n Installation

n Wiring and cabling planning

n Maintenance

n Diagnostics and Troubleshooting

n Special Condition of Use and Approved Standards

Installation

The topics covered in this chapter are:

n See "Rack options" below for more information.

n See "Rack Types" on page55 for more information.

n See "Rack installation" on page64 for more information.

n See "Power Supply" on page77 for more information.

n See "Environmental considerations" on page81 for more

n See "ControlEdge 900 I/O " on page87 for more information.

n See "Terminal block styles" on page100 for more information.

n See "Terminal Block-to-Field (Signal) Wiring" on page106 for

information.

more information.

Rack options

I/O racks are available in 4-slot, 8-slot, and 12-slot versions and can be utilized to house either a controller and I/O or as an I/O expansion rack containing EPM and I/O.

Both 8-slot I/O rack and 12-slot I/O rack have two types of racks:

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n 8-slot or 12-slot I/O rack with non-redundant power supply

n 8-slot or 12-slot I/O rack with redundant power supply

A Power Status Module is required if the I/O rack with redundant power supply is used.

Figure 5-1: Rack Options

Additionally, to eliminate single point of failure, you can also use the dual rack redundancy solution.

As part of this solution you have two single slot racks deployed separately in different areas. The distance between the two racks can be 100 meters if you use a Cat6 shielded cable. Each one slot rack hosts a power supply, a controller module, and a redundancy module (Redundancy +Module (RM) is being introduced as part of the dual rack redundancy solution). Another one slot rack with the same modules is deployed at a different location. The connection between the two racks is established using a specific Ethernet LAN cable. Ethernet ports are present in both the Redundancy Modules (RM).

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You can also use two Fiber Optics modules between the Redundancy Modules to extend the distance to 500m (Multi-mode Transmission Distance) or 10Km (Single-mode Transmission Distance).

Rack Types

ControlEdge 900 Controller supports the following types of racks:

n Redundant Controller Rack

n Non- redundant Rack, containing 4, 8 or 12 I/O slots (Containing

n Single Controller Rack - Currently this option is supported only for

I/O slot numbers are assigned from left to right from 1 to n, where n represents the maximum number of slots:

1 CPM or EPM and 4, 8, or, 12 I/O slots) – There are 3 types of I/O racks.

UOC for Experion R510 release.

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Figure 5-2: Rack Types

Installation Category II, Pollution Degree 2, IEC 60664-1, UL840 Installation coordination.

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One Slot Rack, 1 CPM/1 EPM, 1 P/S, 1 RM

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Redundant Controller Rack

Redundant Controller Rack is shown in the following figure.

Figure 5-3: Redundant Controller Rack Components

As indicated in Redundant Controller Rack Components section, the Redundant Controller Rack includes:

Item Description

1 Redundant Controller Rack

2 Redundant Switchover Module Slot Filler

3 Two CPMs (Redundant Primary and Secondary)

4 Two Power Supplies

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One Slot Rack

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I/O rack

I/O rack can include a topology with; either a non-redundant power supply or with redundant power supplies, accommodate a CPM or an EPM, and additional input/output modules. The I/O rack inserted with an EPM enables I/O modules to be located close to the field devices and remote from the CPM.

Figure 5-4: I/O rack with non-redundant power supply

Figure 5-5: I/O rack with redundant power supplies

As indicated in I/O rack with non-redundant power supply section and

I/O rack with redundant power supplies section, the I/O rack includes:

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Table 5-1: I/O Rack Componets

Item Description

1 Rack, available in 4-, 8- or 12-slot versions

2 Power Supply

3 CPM or EPM with Security Cover

4 Grounding bars (for I/O wiring; optional; required for safety applications)

5 Input/Output modules

6 I/O Terminal Blocks

7 Power Status Module (PSM) (required if using redundant power supply)

Rack orientation and mounting

Racks must be mounted horizontally and must never be mounted with the backplane flat on a horizontal panel or tabletop. This allows airflow and ventilation through the racks. The Environmental specifications provided in this guide apply only when using the recommended mounting configuration.

Rack dimensions, including overall dimensions and patterns for drilling holes for mounting, are provided in Rack dimensions section and Rack orientation and mounting section.

Figure 5-6: Rack dimensions

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Figure 5-7: Rack dimensions with redundant power supply

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Table 5-2: Rack size

I/O Slot Option Height Width Depth Comments

4-slot 5.4" 10.5" 6.0" Rear mounting plate extends

height to 6.9” (175mm)

8-slot 5.4" 16.5" 6.0"

8-slot with redundant

5.4" 20.9" 6.0"

power supply

12-slot 5.4" 22.5" 6.0"

12-slot with redundant

5.4" 26.9" 6.0"

power supply

Redundant Controller

5.4" 10.3" 6.0"

Rack

1-slot 5.4" 5.9" 6.0"

Recommended vertical spacing of racks, which is required for rack ventilation and for routing wires, is shown in Vertical spacing of racks

(all models).

Figure 5-8: Vertical spacing of racks (all models)

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Rack installation

This section contains procedures for installing the racks. It is recommended that the information in this section be reviewed before beginning the installation to help to prevent errors and promote efficiency.

Pre-requisites

Before the installation of the racks and modules, check that the required tools and equipment’s are prepared. The dimension and spacing details in the Rack orientation and mounting section should also be checked.

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Table 5-3: Installation tools

Types Item Description

Common tools

Screwdrivers Small flat-tip For Euro-style Terminal Blocks

Other Electric drill, with drill bits for

Wire strippers For Power Supply and for I/O

Wiring

Crimper For Terminal Lugs on Power

Supply wiring and on I/O wiring shields

Small/medium flat-tip or #2 Phillips or 3/16 inch slotted screwdriver

Large (long blade) For use as I/O Module extractor

#10 or M4 screws, and with drillbit extender

Vacuum cleaner, brush For use during and after drilling

Pen, ball-point or felt-tip, for entering data on labels for I/O modules)

For Barrier style Terminal blocks; also for captured screws in Terminal Blocks

For rack mounting

operations

For entering data on labels for I/O modules

Multi-Meter (Volt/Ohms/Amps) For safety checks and for

equipment test

Soldering pencil or gun (for attaching filter capacitors to I/O wiring shields)

For attaching filter capacitors on I/O wiring shields

Preparing the installation site

Table 5-4: Site and equipment preparation

Step Procedure

1 Racks (4-, 8- and 12-slot) Mount racks section.

2 Install (or verify correct installation of) enclosures for

CPM and ancillary equipment:

For more information, see

Mount racks section

Installing I/O

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Step Procedure

For more information, see

Install (or verify correct installation of):

l External disconnect switches

l Fuses at the power source associated with input

sensor or output devices for I/O modules

4 Arrange and organize items to be installed at or near

enclosures.

Mount racks

ATTENTION: Never mount racks vertically, or with the backplane horizontal, or upside down.

Figure 5-9: Incorrect rack mounting direction

Installing I/O modules section

CAUTION: Mark hole locations then either remove or cover any equipment below to ensure metal chips generated from drilling / tapping do not migrate causing electrical hazard or damage.

1. Mount the Rack in the enclosure by completing these steps:

a. Using the diagrams below as a guide, mark the locations for the

top holes in the rack.

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Dimensions and drill patterns are shown here:

b. Drill and tap for # 10 (or M4) screws.

c. Start the mounting screws (supplied by the user) in the drilled

holes.

d. Hang the Rack on the screws at the top.

e. Mark the locations for the bottom screws.

f. Drill and tap for # 10 (or M4) screws.

g. Remove the rack from the enclosure.

2. Aluminum grounding bars for the I/O module wiring are optional. They can be mounted at the top, at the bottom, or at the top and bottom of the rack, as indicated below. If grounding bars are

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included, attach them with two M3 screws (supplied with grounding bars in plastic bag), as shown below.

ATTENTION: The plastic bag also includes four M4 screws for attaching the grounding wire lugs, which are attached later. Attach the M4 screws loosely to the grounding bars for safe keeping.

3. Hang the rack in the enclosure on the top screws, as shown below. Install the mounting screws in the bottom of the rack, then tighten all screws.

CAUTION: Postpone this step until all components have been installed in the rack.

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4. Repeat for each rack in the system.

Module Insertion

When inserting a module, carefully align the card with the rack. Press the module to ensure that the backplane connector is fully inserted. Secure the module to the rack using the top and bottom screws. Ensure that the screws are properly secured.

Assembling the Redundant Controller Rack

To assemble the Redundant Controller Rack assembly:

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1. Carefully place the Power Supplies in the slots in the Rack.

2. Make sure that the connector at the back seats properly. Insert a flat blade in the slots at the top and bottom of the power supply cover while pulling backward to open the cover.

3. Fasten the screws (located in the face of the power supply) into the tabs at the top and bottom of the rack. Set the Torque to 0.4 -

0.5 N.m (3.5 - 4.4 Lb-In). See the following figure for power supply mounting details.

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ATTENTION: It is recommended each power supply should be powered from a separate power source and a power switch should be installed to allow for servicing of each Processor/Supply separately.

4. Ensure that wiring to the Power Supply is disconnected from the site source, and then connect the AC or DC wiring to the power supply as shown below.

CAUTION: Hazardous Voltage Ensure that wiring to the Power Supply is disconnected from the site AC source before installing wiring. Do not remove Yellow/Green wire from grounding stud on the power supply. Do not connect PE Ground (Green) Wire directly to terminal on Power Supply. Failure to comply with these instructions could result in death or serious injury.

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ATTENTION: The Yellow/Green wire is supplied with the power supply. The nuts (w/star washers) for the grounding stud are on the stud. For AC power supply use 3.0A, slowblow for 115V AC operation for each line; 2.5A, slow-blow for 230V AC operation. For DC power supply use 7.0A slowblow. Do not apply AC voltages of any kind to DC power supply to avoid the DC power supply being destroyed and vise-versa.

Apply power. For AC power supply only, test voltages at the test points provided on the face of the Power Supply.

ATTENTION: Test-points are electrically connected to the backplane of the rack, and voltage is measured at the backplane. Therefore, if the power supply is not properly seated in the backplane connectors, no voltage will be measured at the test points.

5. Carefully place the CPMs in the rack, adjacent to the Power Supplies. Fasten them in place with captured screws at top and bottom. Torque to 0.4 - 0.5 N.m (3.5 - 4.4 Lb- In).

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CAUTION: Ensure that AC power to the rack is disconnected. Insert the Filler plate in the middle slot and attach with screws at top and bottom.

6. Insert the Filler block cover in the middle slot and attach with screws at top and bottom.

Assembling I/O rack

To assemble the I/O rack assembly:

1. Insert the power supply into left-most slot of the main I/O rack as shown in the figure below. See Assembling the Redundant

Controller Rack section.

If the redundant power is used, the I/O rack will contain a second smaller compartment, as shown in item 1 in the following figure. Insert the first power supply in the larger compartment as shown, to the immediate right of the plate dividing the two compartments.

2. If the redundant power is used, the I/O rack will contain a second smaller compartment, this is where the secondary redundant power supply is housed, as shown as item 1.

3. Insert the PSM between the two power supplies. Fasten it in place with screws at top and bottom.

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4. Install EPM or CPM as required.

l Install EPM:

a. Set the EPM address and network topology for the I/O rack

using the rotary switches, as shown below.

TIP: Set the 10x and 1x switches to the two digit address ranging from 01 to 99. The lower switch (10x) is used to set the tens digit and the upper switch (1x) sets the ones digit. A small slotted screwdriver works well; avoid pencils. Set the network topology using the 100x switch. 3 is for Ring network topology and 4 is for Star network topology.

b. Insert EPM to the right of the power supply, and secure it in

place with the two captured screws in the faceplate, as shown below.

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c. Insert the Ethernet cables, and mount the security cover for

the EMP.

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d. Optional, mount a wire security seal. The user should get a

wire security seal themselves.

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l Install CPM: insert CPM to the right of the power supply, and

secure it in place with the two captured screws in the faceplate. Set the mode switch, insert the SD card and the Ethernet cables, and mount the security cover for the EMP. Optional, mount a diameter 0.6 mm wire security seal. Themselves.

5. Repeat steps 1 through 4 for each I/O rack.

I/O modules are ready to be installed. See Installing I/O modules section.

ATTENTION: Install a serial communication module in any I/O slot and secure it in place with the two captured screws in the faceplate. Up to six serial communication modules can be added under one CPM.

Power Supply

Both AC power supply and DC power supply can be used in Redundant Controller Rack, I/O rack and Expansion I/O rack.

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Figure 5-10: AC Power Supply

Figure 5-11: DC Power Supply

As indicated in the figures, the power supplies include:

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Table 5-5: Power Supply Components

Item Description

1 Voltage test points

2 AC/DC Input terminal block

3 Wiring label

4 Grounding lug (Reference; lug is not part of power supply; it is mounted to

bottom of rack.)

Table 5-6: Specification of power supplies

Item AC power supply DC power supply

Input voltage 100-240 V AC 24 V DC

Input voltage range 90 to 264 V AC 21 to 29 V DC

Output voltage 5 V DC and 24 V DC 5 V DC and 24 V DC

Input rating 130 VA 72.5 Watt

Output rating 58 Watt 58 Watt

Each power supply includes a non-field-replaceable internal fuse to protect the supply under certain conditions. (External circuit breaker must be added on both phases of L-N or L-L by the user for Division 2 and Zone 2, the circuit breaker is used for controlling power ON/OFF.)

Power consumption calculation for rack power supply

The following table outlines how to calculate power consumption for a rack power supply. The wattage rating is 60W.

Table 5-7: Power consumption calculation for rack power supply

Module

CPM ( ) 750mA 0mA ( ) ( 0 )

A: Enter Quantity

B: Max Current @ 5V

C: Max Current @ 24V

D: Calculate 5V current (D = A * B)

E: Calculate 24V current (E = A * C)

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E: Calculate 24V current (E = A * C)

Module

A: Enter Quantity

B: Max Current @ 5V

C: Max Current @ 24V

D: Calculate 5V current (D = A * B)

EPM ( ) 500mA 0mA ( ) ( 0 )

PSM ( ) 22 mA 0 mA ( ) ( 0 )

UIO ( ) 380

0 mA* ( ) ( 0 )

UAI ( ) 40 mA 25 mA ( ) ( )

DIM, 120/240 VAC, 16 Channel

DIM, AC/DC, 16 Channel ( ) 130

( ) 130

0 mA ( ) ( 0 )

DIM, 24 VDC, 32 Channel ( ) 130

0 mA ( ) ( 0 )

DOM, 120/240 VAC, 8 Channel

DOM, 24 VDC, 32 Channel ( ) 235

( ) 220

0 mA ( ) ( 0 )

Relay Output, 8 Channel ( ) 110

AOM, 4 Channel

( ) 40 mA 200

100 mA

( ) ( )

AOM, 8 Channel ( ) 225

350 mA

( ) ( )

HLAI, 16 Channel ( ) 75 mA 50 mA ( ) ( )

DIM, Contact type, 16 Channel

Pulse/Frequency/Quadrature ( ) 110

Serial Comm Module ( ) 400

( ) 130

40 mA ( ) ( )

250

( ) ( )

0 mA ( ) (0)

Redundancy Module ( ) 1 mA 0 mA ( ) (0)

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Module

A: Enter Quantity

B: Max Current @ 5V

C: Max Current @ 24V

D: Calculate 5V current (D = A * B)

E: Calculate 24V current (E = A * C)

Total mA @ 5V - ( )

* The field device is powered by external 24 V power supply. For more information, see Universal Input/Output Module on section.

Total mA @ 24V - ( )

Environmental considerations

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

Consideration should be given to the installation so that the potential for the build-up of static electricity is minimized or eliminated.

Table 5-8: Environmental specifications

Item Description

Operating temperature 0 to 60 °C

Storage and transportation temperature

Ambient Relative Humidity 5% to 95% relative humidity (non-condensing)

Vibration (Operative) IEC 60068-2-6 Sinusoidal (5 to 8.4 Hz) 3.5mm /

Shock (Operative) Half-sine, 15g peak / 11 ms duration, 6 directions

Protection against corrosive atmospheres (for offshore installations)

Altitude 2000 meters

-40 to 85 °C

(8.4 to 150 Hz) 1.0 g; 1 octave/min, 10 cycles per axis, 3 axes.

ANSI/ISA S71.04 Class G3

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Power Status Module

The Power Status Module (PSM), shown in the following figure, sits between redundant power supplies on the I/O rack. It is a status module for both power supplies and indicates which are powered, PS1 (left) or PS-2 (right) or both (typical).

When the status indicator for either or both of the power supplies is lit, it is reporting that the status of the associated power supply is good and that the outputs are within specified limits. When the status is off, either the power supply is off or the voltages are out of tolerance.

Figure 5-12: Power Status Module

Expansion Processor Module

EPM is shown in the following figure.

Figure 5-13: Expansion Processor Module

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It is installed in the expansion I/O rack and provides the link between the CPM and remote I/O modules. Features at the front of the module include:

Table 5-9: Expansion Processor Module Components

Item Description

1 Status LED indicator for EPM functions. For more information, see EPM

Indicators section.

2 Role LED indicator for EPM functions. For more information, see EPM

Indicators section.

3 Ethernet 10/100 Base-T Ports; connect to the ports on other EPMs, CPM, or a

switch that connects to the CPM (for star topology).

4 Ethernet LED status indicators for communications functions. For more

information, see EPM Indicators section.

CAUTION: Do not remove or insert the Ethernet connection when the EPM is powered unless the area is known to be nonhazardous.

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Serial Communication Module

The rack-slot based serial communication module is used to communicate to serial based controllers. The module can be used to communicate to Modbus RTU Slave, Modbus RTU Master, Modbus ASCII Slave, Modbus ASCII Master and user defined protocol type devices. It contains one Multi-SPI at 4MBps of maximum communication code rate. Also it supports short circuit protection and over voltage protection. The galvanic isolation is 2000 VDC.

There are two DB9 connectors for RS232 and a dual-row terminal connector for RS485 shown in the following figure.

As indicated in this figure, Serial Communication Module includes:

Table 5-10: Serial Communication Module Components

Item Description

1 Module Status LED indicator for the Serial Communication Module. See

"Serial Communication Module Indicators" on page1 for more information.

2 RS232 LED indicator for the Serial Communication Module. See "Serial

Communication Module Indicators" on page171 for more information.

3 RS232 Ports (two)

4 RS485 LED indicators for the Serial Communication Module. See "Serial

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Item Description

Communication Module Indicators" on page1 for more information.

5 RS485 Ports (two)

CAUTION: Do not remove or insert the serial communication connection when the Serial Communication Module is powered

unless the area is known to be non-hazardous.

Table 5-11: RS485 Pin definition

Pin Type Description

T- Output RS485 terminal resister

T+ Output RS485 terminal resister

A Input/output RS485 A line (+)

B Input/output RS485 B line (-)

Typically, short T+ and T-, and a 120-ohm resistor is activated between A and B to revent signal reflections potentially interfering with communications.

Table 5-12: RS232 Pin definition

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Figure Pin Definition Type Description

1 DCD Input Date carrier detect

2 RX Input Receive data

3 TX Output Transimit data

4 DTR Input Data terminal ready

5 GND_ISO1 Input Isolated ground

6 DSR Input Data set ready

7 RTS Output Request to send

8 CTS Input Clear to send

Male DB9

9 RI Input Ring Input

Application cable:

n RS232 port connect to Male DB9 connector:

As below figure shows, cable require Female-Female cross connection:

n RS232 port connect to Female DB9 connector:

As below figure shows, cable require Female-Male direct connection:

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The application cables are not supplied by Honeywell, and you could prepare them by yourself.

ControlEdge 900 I/O

The configuration and operation of the I/O expansion network is automatic, it is entirely under control of built-in private software that resides in the CPM and in each EPM included in the ControlEdge 900 Controller system. The controller examines the control strategy stored in its memory, verifies that the physical configuration (Rack Numbers and I/O Module type- by Module Number) matches the stored control strategy, and establishes communication with each of the I/O modules in each of the I/O rack.

CAUTION: The ControlEdge 900 Controller I/O expansion network is a private network and the switch used for the interconnection of the CPM and EPMs must not be connected to any other LAN or WAN. Likewise, no devices other than the ControlEdge 900 Controller components should be connected to the switch. Failure to comply will cause communication failures on the I/O expansion network causing I/O modules to go in and out of their failsafe settings.

Placing I/O modules in the racks

Each I/O module is placed in an I/O slot in a rack.

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Each slot in a rack includes a set of guides that locate the circuit board in the rack, and a pin socket in the backplane that receives the associated pin plug at the back of the I/O module.

At the front of each I/O module, a pin plug receives the associated socket on the back of a terminal block. When the I/O module is inserted into the rack and the terminal block is placed on the circuit board, two captured screws in the terminal block are fastened to metal tabs on the rack.

Figure 5-14: I/O module installation

CAUTION:

l Do not use an input/output terminal block if the terminal block

is damaged, if the door is missing, or if one or both mounting screws are missing.

l Always tighten both terminal block screws to proper torque

settings before applying field power to the module. Torque to

0.4 - 0.5 Nm (3.5 - 4.4 Lb-In).

l Do not apply energized (“live”) field wiring to an input/output

module that is not installed in one of the racks in the system.

l Do not operate the module without a Protective Earth

connection on the rack.

Failure to comply with these instructions could result in death or serious injury.

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I/O Module Specification

ControlEdge PLC supports various input/output modules. This section provides technical information to configure ControlEdge PLC IO Modules. The following IO modules are included:

n Universal Input/output module, 16 channel

n Universal AI – RTD,TC,V 8 Channel

n Analog Input High Level, 16 Channel

n Analog Output, 4 Channel

n Analog Output, 8 Channel

n Digital Input 120/240 VAC, 16 Channel

n Digital Input 24 VDC, 32 Channel

n Digital Input Contact, 16 Channel

n Digital Input 120/240 VAC, 125 VDC (16 Channel Isolated)

n Digital Output 120/240 VAC, 16 Channel

n Digital Output 24 VDC, 32 Channel

n Digital Relay Output, 8 Channel

n Pulse/Frequency/Quadrature, 4 Channel

See ControlEdge PLC Specification for details.

Universal Input/Output Module

The maximum current of the Universal Input/Output Module (UIO) field side is 4.2 A.

One UIO module provides a 20-terminal block with 16 channels, and it can be connected with two external 24 V DC power supplies. At least one power supply must be connected.

See UIO module wiring section.

UIO module supports:

n 16 Channel, each channel can be configured for AI, AO, DI & DO

l Analog Input (AI), 0-20 mA

l Analog Input (AI) with open wire detection, 4-20 mA

l Analog Output (AO), 4-20 mA, See Field wiring for Analog

Output section for channel restrictions on the same UIO

module.

l Digital Input (DI) with line monitoring

l Digital Output (DO) with short circuit protection

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l Reverse polarity protection is limited to max of Field Supply

Voltage.

l Module I/O configuration and maximum power delivery by

I/Os, depends on number of channels, configuration Type and the environment.

n 20 pin EURO style terminal block

n 20 position Barrier style terminal block

n HART Support (AI and AO)

n RTP support. See "Installing RTP" on page185 for more

information.

Figure 5-15: UIO module terminal block

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Universal Analog Input Module (UAI)

One UAI module provides a 20-terminal block with 8 channels, it supports inputs mixed on a module. Each channel can be configured as

n mV, V, mA

n T/C

n RTD

n Ohms

n Input impedance: 10 megohm for T/C and mV inputs; >1 megohm

for volts and 250 ohms for mA inputs;

n Isolation: 400 V DC for Channel to channel isolation and 1000 V

DC for channel to rack isolation;

n Noise Rejection

n Series Mode >60 dB

n Common Mode >130 dB at 120 V AC;

n A/D resolution: 15 Bits

n Update rate: 500 ms (Analog to Digital Converter per module)

n Power Supply Loading: 5 V: 40 mA maximum and 24 V: 25 mA

maximum

n 20 pin EURO style terminal block

n RTP support, but TC signal not support RTP solution. For more

information, see Using an RTP to field wiring the UAI section.

Digital Input Module (16 channels) - AC Voltage Type

The DI AC Voltage type module is a sinking type module and provides a 20-terminal block with 16 channels. Its input voltage range is from 80V AC to 264 V AC.

DI AC Voltage type module supports:

n Isolation: Galvanic ally isolated in 2 groups of 8 channel to chassis

n ON Voltage Level: 75 V AC

n OFF Voltage Level: 20 V AC

n Input Impedance: 48 K ohms nominal

n Input Current: 1 mA nominal 120V AC, 60 Hz and 2 mA nominal

230 V AC, 50 Hz

n Minimum ON Current: 0.3 mA

n Maximum OFF Current: 0.2 mA

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n OFF to ON Response Time: 4 ms maximum with 1.5 lines cycle

maximum

n ON to OFF Response Time: 4 ms maximum with 2 lines cycle

maximum

n Power Supply Loading: 5 V: 130 mA max and 24 V: 0 mA

n RTP support. For more information, see Using an RTP to field

wiring the 16 Point AC DI section.

Digital Input Module (32 channels) - DC Voltage Type

The Digital Input Module-DC Voltage Type is sinking type module with below features:

n Channel Density: 32 Channels with two groups of input, each with

a pair of terminals of connection to common

n Input voltage range: 10 V DC to 32 V DC.

n Isolation: Galvanic ally isolated in 2 groups of 16 points to rack (30

V DC maximum)

n ON Voltage Level: 9.5 V DC minimum

n OFF Voltage Level: 3.5 V DC maximum

n Minimum ON Current: 1.0 mA

n Maximum OFF Current: 0.7 mA

n OFF to ON Response Time: 5 ms maximum

n ON to OFF Response Time: 5 ms maximum

n Power Supply Loading: 5 V: 215 mA maximum and 24 V: 0 mA

n 20 pin EURO style terminal block

n RTP support, 2 RTP are needed for each module. For more

information, see Using Dual RTPs to field wiring the 32 Point DC DI section.

Relay Output Module (8 Channels)

8 channel electromechanical relay output supports:

n Channel 1, Channel 2, Channel 7 and Channel 8 are form C type,

provide both NO and NC contact

n Channel 3 ~ Channel 6 are form A type, provide NO contact.

n Input Voltage: 120/240 V AC or 30 VDC

n Output Device: Electromechanical relay; Specified relay life:

1000000 cycles

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n Current Rating:

l 4 A at 240 VAC or 30 VDC resistive load;

l 0.5 A at 240 VAC or 30 VDC incandescent lamp load

n OFF to ON response time: 11 ms Max

n ON to OFF response time: 8 ms Max

n Maximum Leakage Current: 1 mA @ 350 VDC

n Power Supply Loading: 5V- 110mA maximum; 24V-100mA

maximum

n Galvanic Isolation:

l Relay output contact to relay output contact

l Relay output contact to logic

Pulse Input/Frequency Input Module (4 Channels)

The 4 Channel Pulse/Frequency/Quadrature Module provides four different functionalities in the form of Pulse Input, Frequency measurement, Quadrature encoder input and Pulse Output. Each of the 4 channels can be configured for any one of these four functionalities; with the exception that quadrature encoder input (A and B pulses) can be applied to only Channels 1 and 2 respectively. When configured for quadrature, Channels 3 and 4 will still be available for use.

The Pulse Output functionality uses the digital output available on the module for outputting pulses. 4 Digital Outputs, Open collector, 5 to 24 V DC, 30 mA max used for fast signaling.

Pulse Input Type supports:

n Input Voltage: 0 V DC to 24 V DC

n ON Voltage Level: 3.0 V DC minimum

n OFF Voltage Level: 1.0 V DC maximum

n Input Impedance: 25K ohm

n Frequency: 10 KHz maximum

n Minimum Pulse Width: 3 μsec

n Pulse Counter: 32 bits

n Digital Output:

l If preset action ON, output turns ON for 1 second.

l If preset action OFF, output latches ON, and remains ON until

counter reset command.

Pulse Output supports:

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n Channel Used: Any one of the channels can be used for Pulse

Output. However, the use of a particular channel for outputting pulses will render the particular input channel unusable for either of pulse, frequency or quadrature input.

n Digital Output Type: Open Collector, 5 to 24V, 30 mA max

n Frequency Range: 25 Hz – 10 KHz

n Duty cycle: Always 50%

n Pulse Output Duration: Selectable CONTINUOUS or NUMBERED

PULSES.

Frequency Input supports:

n Input Voltage: 0 V DC to 24V DC

n ON Voltage Level: 3.0 V DC minimum

n OFF Voltage Level: 1.0 V DC maximum

n Input Impedance: 25K ohm

n Frequency: 10 Hz to 100 KHz

n Minimum Pulse Width: 500 μsec (10 Hz to 500 Hz) ; 50 μsec (10 Hz

to 5 KHz) ; 2.5 μsec (10 Hz to 100 KHz)

l The input signal will be rejected if it is below a selected pulse

width.

l The input signal whose pulse width is above the selected pulse

width must be within the frequency range specified, otherwise a invalid value (NAN) will be shown and a fail-to-convert error occurs.

n Digital Output ON if input frequency out of range, else OFF

Quadrature Input Supports:

n Channel Used: Only channel 1 and 2 can be used for quadrature

pulses A and B respectively. Index pulse is provided in addition.

n Input Voltage Range: Differential: -6 VDC to +6 VDC; Single-ended:

0 VDC to 24 VDC

n ON Voltage Level: Differential: 0.2 VDC minimum; Single-ended:

3.0 VDC minimum

n OFF Voltage Level: Differential: -0.2 VDC maximum; Single-ended:

1 VDC maximum

n Common Mode Voltage: +/- 12VDC

n Input Sensitivity: +/- 200mV

n Hysteresis: +/- 50mV

n Module powered encoder: 5V DC, 0.50A

n Frequency: 200 KHz maximum

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n Minimum Pulse Width: 2.25 μsec

n Quadrature Counter: 32 bits signed

n Quadrature Modes: For variable resolution there are three count

modes for the Pulse/Quadrature input: X1: rising edges of signal A are counted (increment); falling edges of signal A (decrement) X2: rising and falling edges of signal A are counted X4: rising and falling edges of signals A and B are counted

n Quadrature LEDs: Two LEDs indicate UP and DOWN direction of

counting.

Analog Output Module (4 Channels)

n 4 channel 0-21.8 mA, range selectable analog output

n Load resistance: 750 ohms maximum

n Accuracy: 0.1% full scale

n D/A resolution: 12 Bitsat reference conditions

n Modules per rack: 10 max, up to 12 with product ambient

temperature de-rating. See the figure below:

Figure 5-16: De-rating of AO modules

n Update rate: 500 ms

n Minimum current sensing: >3.5 mA per output

n Isolation:

l 500V DC channel to channel

l 600V DC isolation from logic

n Output Verification: Readback to controller that indicates output

current flowing.

n D/A resolution: 12 bits

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n Configurable failsafe behavior between failsafe value and hold last

value.

n Failsafe Value: A user-configurable failsafe value to allow

predictable in the event of communication between the module and the controller is interrupted or controller exception stop.

n Hold Last value: AO channel hold last value when module is in

failsafe state.

n Minimum settable failsafe value is EU Ex Low.

n AO channel of a module be in failsafe will output 0mA when the

failsafe value is set as EU Ex Low, and open wire or EU Ex Low error will not be triggered in this case.

Analog Output Module (8 Channels)

The Analog Output module provides eight 0 to 21.0 mA outputs . Outputs are isolated in groups of four with no isolation between outputs in a group. All points are isolated from controller logic.

A green blinking status LED on the module indicates when the module is being scanned. A red status LED when module or channel diagnostics exist. A user specified failsafe value is supported to allow predictable operation in the event communication between the module and the controller is interrupted. Outputs are updated synchronous with control execution.

n Outputs per module: 8, isolated in 2 groups of 4 outputs (1-4, 5-8)

n Current: 0 to 21.0 mA, selectable options: 0-20 mA and 4-20 mA

n Load resistance: 750 ohms max

n Galvanic Isolation: 500VDC group to group. Groups 1-4, 5-8

n Galvanic Isolation from logic: 500 VDC

n Accuracy: 0.1% full scale at reference conditions

n Modules per rack: 4 max when powered from internal 24V

backplane power

n Minimum current sensing: >0.5mA per output

n Output Verification: Feedback to controller to indicate output

current is flowing.

n D/A Resolution: 13+ bits (1 part in 13332)

n Power Supply Loading: 5V; 225 mA max 24V; 350 mA max

n Terminal Block: 36 Position – Euro style, (Model 900TCK-0001)

A DIP switch on the module selects the use of 24V from Rack PS (internal) power or external loop power via a separate 24V DC power source. The as-shipped (default) switch setting is external power.

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ATTENTION: When the DIP switch is set to be off , while the external power is down, the open wire detection is not available.

n External Power Source requirement: Vin:18 to 36 VDC

n Current: 350 mA per module

Digital Input Module-AC DC Voltage type

The AC/DC Input Module provides 16 individually isolated, inputs that are powered externally. Two terminals are provided for each circuit. AC or DC power applied between the input terminals cause the inputs to turn On.

There is a green LED state indicator for each channel on the module to indicate when a digital input is ON. A green blinking status LED on the module indicates when the module is being scanned. A red status LED when module diagnostics exist. Logic in the controller allows the state to be inverted when necessary. Requires Euro style 36-terminal terminal block.

*Nominal times excluding controllers scan time and excluding transmission time from module to rack. DC application must include controller line filter setting of 50/60 Hz.

Figure 5-17: Active input De-rating table for AC/DC DI

High Level Analog Input Module (16 Channels)

16 user-configurable channel, each channel can be configured as below type: 0-20 mA；4-20 mA；0-1 V；0-2 V；0-5 V；0-10 V；-1-1 V；-2-2 V；-5-5 V； -10-10 V

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n Input Impedance : >1 megohm for volts and 250 ohms for mA

inputs

n Galvanic Input Isolation:

l 400 VDC point to point, solid state switching;

l 1K VDC to logic.

n Noise Rejection:

l Series Mode >31dB

l Common Mode >90dB at 120VAC

n Over-range limit: +/- 10% for linear ranges

n Accuracy:

Factory configured accuracy = ± 0.1 % of range with below Reference condition:

Temperature = 25 °C ± 3 °C (77 °F ± 5 °F)

Humidity = 45 % to 55 % RH non-condensing

Line voltage = Nominal ± 1 %

Source resistance = 0 ohm

Series mode and common mode = 0 V

Frequency = Nominal ± 1 %

n Temp. Effect on Accuracy: ±0.01% of full scale per degree Celsius

maximum

n A/D Converter: One per module

n A/D resolution: ±15Bits

n Update rate: 100ms (Analog to Digital Converter per module)

n Long term Stability: 0.1% per year

n Channel Configuration Data : Stored in non-volatile memory.

n Power supply loading: 5V ; 75mA max 24V ; 50mA max

Digital Input Module-Contact Type (16 Channel)

16 channel Contact Type:

n Inputs per module: 16 (single-ended)

n Voltage supplied: 15 V DC nominal

n Maximum Contact Resistance: 1000 ohms

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n Update Rate: 6 ms Maximum

n Switching current: 2.6mA norminal

n Galvanic Isolation: Between Field wiring (input or output) and

Module

n Power supply Loading:

l 5 V; 130 mA maximum

l 24v; 40 mA maximum

Digital Output Module (8 Channels) - AC Voltage Type

DO AC Voltage type module supports:

l Channel Density: 8 Channels

l Output Type: Triac (Zero switching voltage)

l Input voltage range: 85 V AC to 240 V AC.

l Isolation: Galvanic ally isolated per Channel to channel and

channel to rack.

l Transient Overload Voltage Protection

l Maximum Load Current: 2 A per channel and 8 A max. per module

(Resistive load)

l OFF to ON Response Time*: 3 ms + 0.5 line cycle max

l ON to OFF Response Time*: 3 ms + 0.5 line cycle max

l Power Supply Loading: 5 V: 220 mA max and 24V: 0 mA

l Per channel Field-replaceable fuse support

l 20 pin EURO style terminal block

l RTP support. For more information, see Using an RTP to field

wiring the 8 Point AC DO section.

TIP: *Excluding controllers scan time and excluding transmission time from module to rack.

Digital Output Module (32 Channels) - DC Voltage Type

The Digital Output Module – DC Voltage Type is current sourcing type module.

DO DC Voltage type module supports:

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l Channel Density: 32 Channels

l Input voltage range: 10.5 V DC to 32V DC.

l Isolation: Galvanic ally isolated in 2 groups of 16 channel to rack

l Overload Current Protection: Active Current Limiting is integrated

into the output driver as 4 groups of 8 channels each. Power cycling is not required to reset the module after a fault condition.

l Short Circuit: Whole group of 8 output channels will be switched

off if short circuit happens in any channel of the group. Power cycling is not required to reset the module.

l Maximum Load Current:

0.5 A per channel;

6 A maximum per channel group ;

12 A maximum per module;

Resistive load 0.25 A per point incandescent lamp load (5 mH maximum)

OFF to ON Response Time*: 6 ms

ON to OFF Response Time*: 6 ms

Power Supply Loading: 5 V: 235 mA max and 24V: 0 mA

20 pin EURO style terminal block

RTP support, 2 RTP are needed for each module. For more information, see Using Dual RTPs to field wiring the 32 Point DC DO section.

TIP: *Excluding controllers scan time and excluding transmission time from module to rack.

Terminal block styles

The terminal block is available in the barrier style, shown below at left below, and the Euro style, shown at right. Not shown: a Euro style with 36 connections is also available for certain high capacity modules.

Figure 5-18: Terminal block Euro styles

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Honeywell ControlEdge 900 platform Hardware Planning And Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

PLC I/O Network Topology

Hardware Configuration of CPM

Hardware Configuration of EPM

Hardware Configuration of IO

Device Replacement

UOC I/O Expansion Network Topology

HSR Ring to 900 I/O

Non-Redundant or Redundant Star to 900 I/O

DLR Direct Connection to 900 I/O and EIP devices

DLR ETAP Connection to 900 I/O and EIP Devices

Non-Redundant Star to 900 I/O and EIP Devices

Hardware configuration of UOC-CPM

Hardware Configuration of UOC EPM

Hardware configuration of I/O

Device Replacement

Installation

Rack options

Rack Types

Rack installation

Power Supply

Environmental considerations

Power Status Module

Expansion Processor Module

Serial Communication Module

ControlEdge 900 I/O

Terminal block styles