HC900 Process Controller

Specifications
51-52-03-31, October 2015

Overview

The Honeywell HC900 Process Controller is an advanced

loop and logic controller offering a modular design sized to
satisfy the control and data management needs of a wide
range of process equipment. When combined with the
optional 900 Control Station operator Interface that is highly
integrated with the controller’s database, configuration and
setup time is minimized. This powerful combination together
with Honeywell’s performance proven control technology
provides users an ideal solution for process control. Open Applications
Ethernet connectivity with Modbus TCP Protocol also allows
Pump stations Furnaces
network access using a variety of HMI/SCADA software.
Boilers Kilns
Program execution environment is protected using an
Water treatment Autoclaves
independent watchdog timer.
Pilot operations Extruders
Fermenters Reactors
Easy-to-use Windows-based Designer software, operable
Utility DAQ Retorts
over Ethernet, an RS485 port (isolated) or modem
Sterilizers Crystal Growing
connection, simplifies controller configuration. It provides
Dryers
advanced monitoring functions for debug, allows run-mode
process configuration changes while maintaining process
Features Summary
control, uploads the complete, annotated graphic controller
configuration, plus supplies an array of reports for • Non-redundant and Redundant Architectures
enhanced documentation. The HC900 Controller provides • PID Control with advanced Accutune III auto-
superior PID loop control and more robust analog tuning
processing than most logic controllers without
• External watchdog timer with independent clocks
compromising logic performance. A separate, fast scan
that detect spurious CPU lockups.
cycle executes a rich assortment of logic and calculation
function blocks. Logic blocks may also execute in the same • Adjustable recipe pool memory lets you allocate

scan with analog function blocks for time critical events. memory for recipes, SP Profiles, sequences and

These function blocks may be fully integrated into a schedules to meet your needs.
combined analog and logic control strategy for • Up to 1920 points with remote I/O
uncompromising control performance. • Boolean Logic programming. Robust assortment of
For more information see specification sheets: over 100 algorithms
• Advanced Floating Point Math Functions.
• HC900 Process Controller Modules 51-52-03-41
• Extensive alarm and event monitoring
• Designer Software 51-52-03-43
• Up to 960 galvanically Isolated, Analog Inputs
2 HC900 Process Controller

• New I/O voting and output validation function • Sequencers with 16 Outputs each
blocks. • Modbus read/write parameters assignable to either
• Remote I/O Racks with wire for extended fixed or custom addresses for access by HMI or
distance. supervisory software.

• Scanner and I/O Insert/Remove under power • Modbus TCP Initiator

• LED on/off indicators on digital I/O • Gas flow function blocks per American Gas
• Graphic Function Block Configuration – 400, 2000 Association specs. (non Safety configurations

or 5000 blocks only).

• Fast updates – 10 ms logic, 0.5 sec analog • Calendar block for triggering events
0.1 second capable for v6.006 • Non-interfering process/safety worksheets capable
• Open 10MB or 10/100MB Ethernet interface using of handling process and safety configurations.
Modbus/TCP. Peer-to-peer communications via • Built in Version Control
Ethernet Fast updates - 10 ms logic, 100ms analog capable
• E-mail alarm/event messaging on priority using C75S, C70S, S50S, S75S version 6.006 and

• Ramp/Soak Setpoint Programmers qualified hardware configuration. Note: Low Level

AI updates @ 0.5 sec. (See qualified configuration).
• Setpoint Schedulers with multiple outputs

Non-redundant Architectures

Figure 1 - SINGLE PROCESS/SINGLE RACK- PROCESS

HC900 Process Controller 3

Figure 2 - SINGLE PROCESS/SINGLE RACK- SAFETY

Figure 3 - SINGLE PROCESS/MULTIPLE REMOTE RACKS- SAFETY

4 HC900 Process Controller

Figure 4 - MULTIPLE PROCESS/MULTIPLE RACKS – PROCESS

Figure 5 - MULTIPLE PROCESS/MULTIPLE RACKS – RED NETWORKS

HC900 Process Controller 5

HC900 Controller I/O Scanners

• The rack based HC900 Controller is available in 3 HC900 Remote I/O is processed and communicated to the
rack sizes with 4, 8 or 12 I/O slots each to support a main CPU module through a remote I/O Scanner module.
wide range of requirements. Two I/O scanner modules are available: a single port model
for non-redundant CPU systems and a dual port model for
• Redundant C75 controllers use a separate controller
redundant CPU systems. Scanner addressing in multi-rack
rack for CPUs without local I/O. Two power supplies
systems is selectable via DIP switch setting.
provide separate CPU power.
A redundant controller switch module provides status All HC900 I/O Scanner modules are based on the e300 32
and performs mode changes. Bit RISC based PowerPC Architecture. The operating
system and configuration files are stored in 16,777,216 by
CPU Modules
16 bit words. The scanners operate out of DDR2 memory
• The CPU options available for the HC900 Controller
organized as 8 Mb x 16 x 4 banks. DDR2 memory on all
include:
modules is supported with ECC circuitry to enhance

C30 and C50 for non-redundant applications. reliability and error detection.

C70 for dual networking. Program execution environment is protected using an

C75 for redundant CPU applications and dual independent watchdog timer.
networking. Inputs and Outputs - A variety of I/O modules are

All HC900 CPU modules are based on the e300 available for selection in creating a custom control
32 Bit RISC based PowerPC Architecture. The solution. These include:
operating system and configuration files are
• 8 point universal analog input modules: Inputs may be
stored in 16,777,216 by 16 bit words. The
mixed on a module and may include multiple
controller operates out of a battery-backed DDR2
thermocouple types, RTDs, ohms, voltage, current or
memory organized as 8 Mb x 16 x 4 banks for
millivoltage types – all easily assigned using the
C30,and C50 modules, and 8 Mb, x 32 x 4 banks
Designer configuration tool. High point-to-point isolation
for C70, C75 modules. DDR2 memory on all
simplifies installation and saves the expense of external
modules is supported with ECC circuitry to
isolation hardware.
enhance reliability and error detection.
• 16 point high level analog input module: each point is
Program execution environment is protected using
configurable for V or mA. Point-to-point isolation.
an independent watchdog timer.
• 4 point galvanically isolated analog output module:
• All HC900 CPU modules offer open Ethernet
Supports from 0 to 20mA each.
communications for access by a variety of HMI and
• 8 point analog output module. Galvanically isolated in
SCADA software applications and peer to peer
two groups of 4. Supports 0 to 20mA.
communications for control data exchanges between
controllers. The C70 and C75 provide dual Ethernet • 16 point digital galvanically isolated AC/DC input
ports for high network availability installations. module
• 16 point analog output module. Galvanically isolated in
• HC900 CPU modules use a dual scan method to
four groups of 4. Supports 0 to 20mA.
handle fast digital scanning and normal analog input
scanning in the same integrated control • 16 point digital galvanically isolated input modules:
environment. Both scans support a wide range of Contact closure type, DC voltage and AC voltage types.
computational function block algorithms and a user • 32 point galvanically isolated digital input (sink) module:
adjustable execution sequence order. DC voltage

• HC900 CPUs use Flash memory for permanent • 8 point AC or 16 point galvanically isolated DC digital
user configuration program storage and battery- output (sink) modules
backed memory for dynamic data storage allowing • 32 point galvanically isolated digital output (source): DC
for graceful recovery following a power interruption voltage
or other discontinuous operations. Using proven • 8 point galvanically isolated high voltage
TL5903 primary batteries to support up to 24 days • 8 point galvanically isolated relay output module: four
of continuous power outages form C type and four forms A type relays.
• 4 channel Pulse/ Frequency/Quadrature I/O module
6 HC900 Process Controller

See Module Specifucation sheet 51-52-03-41 for Remote Terminal Panels - Optional DIN rail mounted
details. Remote Terminal Panels (RTPs) are available for use with
pre-wired cables to reduce installation time and labor
Insert & removal of I/O under power - For ease of expense. RTP types available: analog input, relay output,
maintenance, the HC900 controller supports removing discrete input, discrete output, analog output.
and inserting modules from the card rack without Three cable lengths are also available to match
removing power from the controller. Each card is hardware to installation variations. See Module
sensed for validity by the controller and auto- Specification sheet 51-52-03-41 for more details.
configured on insertion. Hardware can be replaced
without shutting down operations for replacement of Redundant Power - A second (backup) power module may
CPU or Scanner modules thus reducing downtime and be added to each HC900 controller rack. An extended rack
total cost of ownership. is available that expands the standard 8 and 12 I/O rack to
accommodate a second (redundant) power supply and
I/O Terminal Blocks – 20-screw Terminal Blocks power status module.
are available with either barrier style or Euro style
screw connections. A module label area is provided for
field wiring identification. An available 36-screw
Euro Terminal block is required for certain high
capacity modules.

Remote I/O - I/O racks may be remotely mounted

from the controller via a dedicated Ethernet
10/100Base-T connection at up to 300 meters (984
feet) between the controller and the most remote rack
using two Ethernet switches. Use of fiber optic cable
extends distance to 1500 meters.

Table 1 CPU Capacities

Function Point per Module Max. for C30 CPU Max. for C50 CPU Max. for C70/C75
CPU
Analog In Universal: 8 Universal: 96 Universal: 480 Universal: 480
High level: 16 High level: 192 High level: 960 High level: 960
Analog Out 4, 8, 16 40 200 200
Analog Out 8, 16 192 960 960
(External power)
Digital In 8, 16 or 32 384 1920 1920
Digital Out 8 AC or 16 DC, 32 DC 384 1920 1920
Function Blocks n/a 400 2000 5000
HC900 Process Controller 7

Redundant Architectures

Multiple Systems / Multiple Racks

Safety and Non-Safety in Separate Systems

8 HC900 Process Controller

Redundant Architectures Operator Interface – The 900 Control Station operator

Redundant Controller Interfaces is supported with the C75 CPU. An Ethernet

Two redundant C75 CPUs operate in a separately connection is made to a switch connected to the Ethernet

mounted controller rack, each with an independent port of each CPU. The operator interface communication to

900PS2 model power supply. A Redundant Switch the controller follows the Lead controller assignment.

Module (RSM) is located in the rack between the two

Status/Diagnostics - An output parameter of the system
C75 CPUs. A key switch on the RSM allows the user
monitor function block of C75 CPUs provides a digital status
to change the operating mode of the Lead CPU. There
of the Reserve controller to allow integration of this
is no I/O in the controller rack; the CPUs communicate
information into the control strategy. C75 CPUs also provide
with up to 5 racks of I/O over a 100 base-T Ethernet
diagnostic status on redundancy operation that may be
physical communication link or fiber optics with an
observed using Designer configuration software. A
external media converter for greater distance. When
Redundancy status function block is also available to
more than one I/O rack is used in the system, Ethernet
monitor redundant controller operation.
switches are required, one port for each Scanner
connection. In operation, all control functions and host Function Blocks
communication exchanges are handled by the Lead
controller, including configuration and operator A large assortment of analog and digital function blocks are

changes. The Lead controller updates the Reserve available to solve the most demanding control requirements.
controller every scan cycle with all the information Function blocks are grouped by scan rate, fast or normal,
needed to assume control in the event of a fault and by function, Principal or Standard.
condition.
Function Block Execution - All function blocks operate
After power-up of the C75 CPUs, the first available synchronously with I/O processing. Inputs are measured at
CPU assumes the Lead function. The Lead may be the start of every scan and outputs are updated at the end of
transferred to the Reserve controller by: every scan. Function blocks such as Time Proportioning
Outputs (TPO) and Position Proportioning outputs (PPO)
• Failure of the Lead controller, require higher output resolution and are updated when the
• Manually changing a keyed switch located on function blocks are executing. Micro-controllers on digital I/O
the Redundant Switch Module, modules can maintain TPO duty cycle operation during
failsafe conditions. Micro-controllers on all I/O modules allow
• Input pin on Redundancy Status function
outputs to be configured to assume a default state in the
block, or
event of a fault condition.
• Instruction from host communication.
Normal Scan: Function blocks that execute during the
Dual Networks for Host communications are provided
Normal Scan are synchronized to the analog input
on the C75 CPU. Both network ports are continuously
measurements. The fastest update rate is 500ms.
active on the Lead controller. Matrikon OPC server is
100ms analog capable using C70S, C75S, S50S, S75S
available from Honeywell Matrikon to support dual
version v6.006 and qualified hardware configuration.
Ethernet communications and automatically transfer
Note: Low Level AI updates @ 0.5 sec (See qualified
communications.
configuration).
The C75 network ports may otherwise be used in non- Fast Scan: The fastest update rate for fast scan function
redundant mode where only one of the communication blocks in a single controller rack is 10ms. The update rate
ports is used. starts at 25ms when remote racks are used and for
redundant systems.
Remote I/O - To extend the distance between the
CPU rack and the most distant I/O rack to 300m (984
ft.) up to two Ethernet switches may be used in each
I/O connection. Distances up to1500m (4920 ft.) are
possible with fiber optic cable and two switches.
HC900 Process Controller 9

Principal Function Blocks – These function blocks DO-V - The DO-V block is similar to the DO block but it
are supported by dedicated Widget objects in Station provides additional functionality which allows users to
validate the status of the output using a feedback input
Designer software for configuring 900 Control Station
channel. The primary function of this block is to validate the
operator interfaces. They have Tag names and other feedback signal and provides indication when input fails to
attributes to support on-line user interaction. Principal match the output due to possible reasons such as field
function blocks can be used any number of times in a power failure, cable failure, fuse etc…. The function block
configuration. will also check the feedback input signal for input module
Typical Principal function blocks include PID, Set Point error, failed input channel and loss of feedback module
communications.
Programming, Sequencers, Alternators, Stage, etc.

Alarms/Events
Standard Function Blocks – The number of standard
function blocks that may be used in a configuration is Alarms and events represent changes in digital status that
virtually unlimited. Typical Standard blocks include require user notification. The HC900 controller supports an
totalizer, free-form math, average, mass flow, function internal alarm annunciation system that may be setup to
generator, periodic timers based on real-time, carbon operate via e-mail to a remote computer (see
potential, RH, Dew Point, signal selection, comparison, Communications, E-mail Alarming). Up to 360 alarm points
gas flow, real time clock, and many others. These per controller may be grouped in 30 groups of 12.
blocks may be configured to create control schemes Events are digital status changes that cause messages to
that precisely address the needs of your process. be presented on the 900 Control Station operator interface.
Digital status outputs are also provided on many of the Controller events may prompt e-mail messages,
analog function blocks to facilitate intelligent signal do not require acknowledgement, and are reported and
alarming and default operation strategies. logged in a separate group. Up to 64 event points are
Typical logic function blocks include AND, OR, supported in a controller.
XOR, NOT, Latch, Flip-flop, On/Off Delay and Alarms and events are time stamped in the controller to a
Resettable timers, Counters, Free-form Boolean logic one second resolution.
and more. The execution of analog and digital
functions is seamlessly integrated into a single Configuration
control strategy in the controller.
Controller configuration is performed using Designer
AI-V – The new AI-V function blocks will allow 1oo2 Configuration software on a PC operating with a Microsoft
and 2oo3 voting for inputs and compares its values ®
Windows 7 operating system. Configuration files are built
with one another and reports any deviation if validation independently on the PC and downloaded to the controller in
between one another fails. Output value is calculated a separate operation.
by comparing all inputs channels and selecting best of Validation of proper physical I/O to support the configuration
three. is provided along with appropriate warnings.
DI-V - The new DI-V function blocks will allow 1oo2 Configuration Back-build - In the event a PC configuration
and 2oo3 voting for inputs voting for inputs and file is lost or misplaced, it can be easily reconstructed using
compares its values with one another and reports any the upload function of the Designer configuration software.
deviation if validation between one another fails. Simply read the configuration from the controller to exactly
Output value is calculated by comparing all inputs duplicate the original configuration, including all text
channels and selecting best of three. descriptions.
AO-V – The AO-V block is similar to the AO block but it Configuration edit - In the event edits to a controller’s
provides additional functionality which allows users to configuration are required after the unit is in operation, an
validate the status of the output using a feedback input uploaded file may monitored during process operation,
channel. The primary function of this block is to edited, and downloaded with the on-line download function
validate the feedback signal and provides indication of the Designer. The software allows configuration changes
when input fails to match the output due to possible while in the Run mode, limiting process disturbances.
reasons such as field power failure, cable failure, fuse Note: Forcing and downloads cannot be made on Safety
etc…. The function block will also check the feedback controllers unless they are switched to the RUN/PROGRAM
input signal for input module error, failed input channel mode.
and loss of feedback module communications.
10 HC900 Process Controller

Recipes Recipes may also include Variables, which are dynamic

Recipes are groups of data defined by the user that analog and digital values used as inputs to standard and

are used to make multiple value changes in the principal function blocks. Recipes may be loaded through

controller through a single action. Function block types the 900 Control Station operator interface by name or
that accept recipe data and the quantity of recipes number, or via a dedicated recipe load function block and
stored in the controller are listed in Table 2. user configured logic.

Table 2 Recipe capacities

Function Description Content Recipe size # of recipes stored

Setpoint Profiles Ramp/Soak values, times and 50 Segments Configurable
Programs event actions
Setpoint Schedules Ramp/Soak values, times and 50 Segments Configurable
Schedules event actions
Sequencer Sequences State sequence, analog values 64 steps Configurable
Variable Recipe Variables Analog and digital values 50 Variables Configurable

Operator Interfaces

A HC900 controller can support up to three 900 Ethernet Modbus/TCP Communications – HC900
Control Station operator interfaces via Ethernet or controllers communicate with their host PC interfaces over
Serial communications. The interface is configured an Ethernet 10/100Base-T communication network using
with Station Designer software using a database the Modbus/TCP protocol, an open protocol interface
import function to simplify setup. See specification available for most popular HMI software packages. The
sheet 51-52-03-46 for more information on this controllers Ethernet ports are MDIX and configured to auto
interface. negotiate and will default to half duplex if host fails to
negotiate. The C30 supports up to 5 host connections while
Communications
the C50/C70/C75 support up to 10 concurrent host
Remote I/O Rack Port (C50, C70, C75) – An Ethernet connections over an Ethernet network for control
port is dedicated to supporting remote I/O racks. This supervision and data acquisition. The Designer software can
10/100Base-T Connection on the C50 and C70 CPU also address any of the controllers concurrently over
supports a single direct connected remote rack or up Ethernet for configuration monitoring, diagnostic
to 4 remote racks when connected through an external interrogation, upload/ download, or on-line configuration
Ethernet switch. The C75 CPU supports a single direct changes. As a result, a HC900 network of controllers and
connected rack or up to 5 remote racks using external operator interfaces can be partitioned into process
switches. segments to assure proper control performance. Each of
these process segments, in turn, can be accessed via
User Interface Support – The 900 Control Station common HMI software within the plant environment using an
interface may be connected via Ethernet or serial Ethernet LAN.
communications. Up to three interfaces may be
connected to a controller for distances up to 328 feet Ethernet Peer to Peer Communications - Peer data
(100Meters) via Ethernet or 2000 feet (609 meters) communications between one HC900 controller and up to
between the controller and operator interface. 32 other HC900 controllers is supported over Ethernet via
UDP protocol for process interlocks or data sharing. Both
3rd party user Interface support is provided through an
digital and analog data exchange are supported using peer
isolated RS485 port connection using Modbus/RTU
data exchange function blocks, up to 2240 parameters
protocol, or Ethernet with Modbus/TCP protocol.
between peer controllers. No specialized software is
required. Peer data can be given signal tag references for
use in a control or data acquisition strategy. Peer to peer
HC900 Process Controller 11

data interchange does not consume one of the host

connections.
Profibus – The HC900 can access data from Profibus slave
Serial Modbus RTU Communications - Serial devices using a Modbus-to-Profibus gateway device
Modbus RTU communications is available on the attached to the serial port of the controller. The gateway
isolated RS485 (2 wire) ports of the HC900 Controller device is a Profibus Master on the fieldbus network and a
CPU assembly in a Master or Slave mode. The Modbus slave to the HC900. The Profibus data is connected
protocol of these ports is user selectable between ELN into the control strategy using Modbus function blocks. This
protocol for use with HC Designer software or Serial application has been validated with a ProLinx 5104-MCM-
Modbus to interface with other compatible devices. ®
PDPM gateway (from ProSoft Technology).

Modbus RTU Slave - Isolated RS485 ports E-mail Alarms/Events--HC900 alarms or events can be
may be configured for simultaneous operation as a individually configured to send an e-mail alarm (or event)
Modbus slave port to allow each to communicate with message to e-mail addresses with the
a single Modbus master. assigned alarm priority.
The Modbus protocol supports read and write access • Number of e-mail addresses: 3 based on alarm
to a default address map of certain function blocks and priority
parameters.
• From: Controller name (up to 16 characters)
In configurations 4.0 and later, a map of customized • Subject: text (up to 32 characters)
addresses, blocks and parameters can be created
• Content: date and time of alarm/event, alarm/event
either by editing the default map or from scratch.
tag name, alarm/event state
In the default map (fixed), a 4000 register array is
• Message: 48 character text (for alarms only)
available to allow the user to specify the address
locations of specific controller data to optimize • Priority Levels: 4 for alarms, 1 for events

controller communications.
Controller Configuration Access –Designer software
The data in the array may also be accessed in user supports communicating with HC900 controllers using an
specified formats (data types) such as analog data in Ethernet or serial connection using ELN protocol to support
Float 32, unsigned 16, signed 16, unsigned 32, signed direct PC connection for configuration upload, download,
32, and digital data in signed 16 or unsigned 16. debug and maintenance. Modbus RTU protocol is also
The data type selections in the 4000 register supported through the serial port interface. Once the HC900
array provide compatibility with devices controller has been configured using Designer Software, on-
such as 3rd party touch panels. In the custom line configuration changes
map, all data formats are adjustable. may be made while maintaining process control.
Configurations may also be loaded into the controller via the
Modbus RTU Master - Either of the ports may be Ethernet TCP/IP network from a host PC. On-line monitoring
configured as a Modbus RTU master, one per for program debug and on-line program edit functions are
controller. Up to 32 devices may be multi-dropped on also supported via the Ethernet port.
the isolated RS485 port. Function blocks are available
in the HC900 controller to allow the user to specify Modem Access – Communications to the HC900 controller
read and write operations to up to 32 external Modbus may be via an external modem connected to the controller’s
compatible slave devices and up to 1024 data points. using an RS485/RS232 converter. HC Designer software
supports configuration upload, download and on-line edits
Modbus TCP Initiator – The Ethernet ports may be via modem. When modem communication is selected,
configured as a Modbus TCP initiator. Function blocks Modbus RTU communication timeouts are extended.
are available in the HC900 controller to allow the user
to specify read and write operations to compatible
slave devices for up to 1024 data points.
12 HC900 Process Controller

Experion Supervisory Software – Honeywell’s

Windows 7 version is available when PC-based
supervisory control and data acquisition is required.
Ethernet network interface to an Experion server is via
the controller host Ethernet 100 Base-T port using All Models: Ports S1 & S2 user-
Modbus/TCP protocol. Client Stations over Ethernet selectable type. Operator
allow multiple user access to an HC900 network. Using Interface and/or Configuration
the large selection of standard operating display port for direct or external modem
templates in Experion saves development time. When connection.
further customization is needed, the full graphic display
development environment of Experion may be used to
fully animate your process supervisory displays. All Models: Ethernet
10/100Base-T for host and LAN
A batch reporting option is offered in Release 410 and
connection
430 which enables batch reports to be created using a
standard template. User-entered lot data is supported
C70/C75 only: Ethernet
and up to 50 parameters can be defined for batch
10/100Base-T for dual host and
logging. The file can be exported in .csv format using a
LAN connection.
lot number-encoded filename.

SpecView32 Supervisory Software – SpecView32 C50/C70/C75 only: Ethernet

software can be used as a supervisory interface for 100Base-T for I/O rack connection.
thermal-based applications, offering historical trending,
batch reporting, recipe development involving setpoint
programs and simplified graphics configuration.

HC900 parameters are simply selected from Figure 1 Communication ports

Capacity
categorized lists for placement on user-configured
displays or onto display objects. The capacity of the HC900 system is determined by the type
of CPU selected, the quantity of I/O racks, the quantity’s
Network connection is via the controller host Ethernet
type of I/O modules, the update rate (scan rate) required,
10/100Base-T port using Modbus/TCP protocol. A
and CPU memory. In most applications, the CPU memory
variety of Windows operating environments are
limit has a low probability of limiting capacity.
supported including Windows 7 (32 & 64 bit versions)
How many I/O channels?
OPC Server – Network communication access to
Number of I/O is limited only by physical space. Namely, the
HC900 controllers through third party PC interfaces is
number of racks, the number of modules per rack, and the
simplified with Honeywell’s Matrikon OPC server
number of channels in the modules.
software program. This software supports the
In general,
Modbus/TCP interface to either redundant or non-
Maximum I/O channels = (max. number of I/O racks) x
redundant HC900 controllers. In redundant
(max. number of modules in each rack) x
applications, Matrikon OPC Server software supports
(max. number of channels per module)
dual Ethernet connections to both C75 CPUs.
Examples
Communications to the controller is maintained during
Maximum C30 I/O =
a single network failure and/or following the transfer of
1 rack x 12 modules x 32 channels per module =
the Lead function from one CPU to another.
384 I/O channels
Compatible OPC client programs can use the Ethernet
Maximum C50, C70,C75 I/O =
connection to the HC900 via Honeywell’s OPC Server
5 racks x 12 modules per rack x 32 channels per module =
for remote supervision, data collection or other
1920 I/O channels.
supervisory functions.
HC900 Process Controller 13

How many function blocks (loops, programmers, How many recipes in my pool?
etc.)? Unlike with function blocks, there is no quantity limit to
Fixed limits are not imposed on function block types. recipes. The only limiting factor to recipe pool size is
Your configuration can probably contain as many of available memory. Whatever memory is unused by the rest
each function block as needed. The limit is reached of your configuration (that is, function blocks) can be
when either allocated for recipes. As long as memory is available,
a) Dynamic memory is full or allocate as many recipes as needed.

b) Maximum function block quantity is reached or The rule of thumb is

c) Configuration memory is full or Max. number of recipes = Recipe memory allocation ÷
memory per recipe
d) Over 65,535 block configuration parameters or
block inputs used (but not Block Outputs). Configuration memory allocation

These limits are explained below. The configuration memory comprises one allocation for the

a) Dynamic Memory function block configuration and one allocation for recipes.
In general,
The rule of thumb is
Total configuration memory =
Max. number of function blocks = Dynamic memory
Configuration + Recipe allocation
÷ memory per function block
The smaller the function block, the more of them can ft Whatever memory has not been allocated to recipes is
in your configuration. available for your configuration. By changing the size of the
b) Quantity recipe pool allocation you control the amount of memory
available for recipes and therefore configuration. Need a
Regardless of memory availability, the total number of
small configuration but many recipes? Allocate more recipe
all function blocks regardless of type is:
space. Need a large configuration but few recipes?
C30 ≤ 400 function blocks
Allocate less recipe space.
C50 ≤ 2000 function blocks
Where are usage/capacities presented?
C70/C75 ≤ 5000 function blocks
File Properties in Designer displays statistics on
Complex blocks such as PID, Programmer, Scheduler, usage/availability of:
Sequencer use more memory than simpler blocks like • configuration memory (recipes + function block
On/Off, Device Control, Auto/Manual Bias. For configuration),
example, several thousand Auto/Manual Bias blocks • dynamic memory (function block configuration only)
would fit in the C30’s memory if not for the quantity
• fast scan time,
limit of 400. Conversely, about 300 Scheduler blocks
• Normal scan time,
will consume all the C30’s memory despite the higher
quantity limit of 400. • Normal CPU% used,
• Fast CPU% used,
Scan Time Consideration
• Each component of a configuration (variables,
Another consideration when configuring function
constants, etc.).
blocks is scan time and the potential for CPU scan
time to become insufficient for the application. Controller Data Storage
The controller may log process data values in the available
The scan time of a controller increases in fixed
memory that is not used by the configuration. Up to 250
increments. As function blocks are added to a
signal values may be logged in a rotating buffer using three
configuration, the time needed to execute the total
different sample rates with oldest data being replaced with
configuration is recalculated. If additional time is
new data after the buffer is full.
needed, the scan time will be increased to the next
increment in sequence. (See Specification section for Data is extracted from the controller using HC Historian data
scan time increments) harvesting software via Ethernet or Serial connection.
14 HC900 Process Controller

Specifications
Features
C30 C50 C70 C75
Controller Design Modular design with metal rack enclosure, power supply, controller CPU and user selectable
I/O module types.
Rack Mounting and Surface mounting with 4 screws in back of rack.
Installation Installation Category II, Pollution Degree 2, IEC 664, UL840 Installation coordination
Controller I/O 4, 8, or 12 I/O slots per Rack None (requires
support remote I/O racks)
Remote I/O racks None 1 w/o switch, using Ethernet direct cable. Up to 4 with recommended
Honeywell switches (part no. 50008930-001, copper to copper)
1 w/o switch, using Ethernet direct cable. Up to 5 with recommended
Honeywell switches (EDS-308-MM-SC, copper to fiber).
Remote I/O interface None Separate Ethernet 100Base-T port on CPU, RJ-45 connection,
type dedicated communications link
Remote I/O Distance None 100 m (328 ft.) – Ethernet cable, controller to remote rack or
controller to switch. Up to two switches per connection, 300m (984
ft.), maximum distance.
750m (2460 ft.) – Fiber optic cable, controller to remote rack or
controller to switch. Up to two switches per connection, 1500m
(4920 ft) maximum distance.
Fiber Optics Equipment Recommendations
Ethernet Switch Moxa Unmanaged Ethernet Switch model
EDS-308-MM-SC with (6) 10/100 Ethernet
ports, (2) multi-mode fiber ports with SC
Connectors (require 24VDC power)
Converter Moxa Media Converter model IMC-101-M-
SC with (1) 10/100BaseT(X) to 100BaseFX
multi-mode fiber port with SC connectors
(require 24VDC power)
Fiber Cable Multi-mode, Duplex, 62.5/125 with SC
connectors on both ends
Copper Ethernet Cable Shielded Cat5 Ethernet
I/O Capacity
Combined Analog and 384 1920
Digital
Analog Inputs 192 960
Analog Outputs 40 200
48 with heat de-rating 240 with heat de-rating
192 with external 960 with external power source
power source
HC900 Process Controller 15

C30 C50 C70 C75

Rack Size
*
4 I/O slot chassis 5.4”(137mm) H” x 10.5”(266.7mm) W x 6.0” (151.7 mm) D (rear mounting plate extends
height to 6.9” (175.3mm)
*
8 I/O slot chassis 5.4”(137mm) H x 16.5”(419.1mm) W x 6.0” (151.7mm) D (rear mounting plate extends
height to 6.9” (175.3mm)
8 I/O slot chassis with
5.4”(137mm) H x 20.9”(530.9.1mm) W x 6.0” * (151.7mm) D (rear mounting plate extends
redundant power
height to 6.9” (175.3mm)
support
*
12 I/O slot chassis 5.4”(137mm) H x 22.5”(571.5mm) W x 6.0” (151.7mm) D (rear mounting plate extends
height to 6.9” (175.3mm)
*
12 I/O slot chassis 5.4”(137mm) H x 26.9”(683.3mm) W x 6.0” (151.7mm) D (rear mounting plate extends
with redundant power height to 6.9” (175.3mm)
support
Redundant CPU rack N/A 5.4”(137mm) H x
10.3”(261.6mm) W x
*
6.0,,” (151.7mm) D
(rear mounting plate
extends height to
* 6.4 (162.6) for 32 DI/DO and 16 AI Modules 6.9” (175.3mm)
I/O Wiring
Type Removable terminal blocks
Terminal Block Styles 20 screw: Barrier or Euro-style, tin-plated or gold-plated (for DC connections)
36 screw: Euro style gold plated (Required with certain higher capacity modules)
Gauge wires 20 screw:
Barrier style – #14 to 26 AWG, solid or stranded
Euro-style - #14 to 26 AWG, solid or stranded
36-screw:
Euro-style - #12 to 26 AWG, solid or stranded
Shield terminals Optional brackets mounted top/bottom of rack
Power (P01)
Voltage Universal power, 90 to 264VAC, 47 to 63 Hz
In Rush Current 40 Amps peak-to-peak for 120 mS at 240VAC
Input rating 130 VA
Output rating 60W
Fuse Internal non-replaceable fuse. User installed external fuse.
Power (P02)
Voltage Universal power, 90 to 264VAC, 47 to 63 Hz
In Rush Current 40 Amps peak-to-peak for 120 mS at 240VAC
Input rating 90 VA
Output rating 28W
Fuse Internal non-replaceable fuse. User installed external fuse.
16 HC900 Process Controller

C30 C50 C70 C75

Power (P24) Voltage 21 to 29VDC
In Rush Current 30A for 3ms @29VDC
Input rating 72.5W
Output rating 60W
Fuse Internal non-replaceable fuse. User installed external fuse.
Power Supply 20milliseconds @ 115VAC, 60HZ maximum Load
Hold up time
Normal Scan Time 500ms. Each analog input card has its own A/D converter providing parallel processing.
100 ms on qualified system configuration and v6.006 Controller/ Scanner firmware
(See qualified configuration).
Fast Scan Time 25ms for up to~250 10ms for up to ~250 10ms for up to ~330 25ms for up to~500
fast logic blocks fast logic blocks fast logic blocks fast logic blocks

35ms for up to ~315 25ms for up to~500 25ms for up to~660 35ms for up to ~780
fast logic blocks fast logic blocks fast logic blocks fast logic blocks

50ms for up to ~400 35ms for up to ~780 35ms for up to ~1040 50ms for up to ~1040
fast logic blocks fast logic blocks fast logic blocks fast logic blocks

50ms for up to ~1040 50ms for up to ~1380 60ms for up to ~1300

fast logic blocks fast logic blocks fast logic blocks

60ms for up to ~1300 60ms for up to ~1700 130ms for up to~2500

fast logic blocks fast logic blocks fast logic blocks

130ms for up to~3300

fast logic blocks
System latency - Typical 3x scan
terminal to terminal
Switchover 0-100ms
Bumpless Failover Internal parameters, variables and outputs are maintained during transition.
Run-Mode Edit 3 normal scan times (1.5 sec. typical) for all configuration edits not including I/O changes
Transfer Time
Operating Modes Run (No configuration download in this position). No writes/forces for safety critical
configurations.
Run/Program (Download allowed)
Program (Outputs Off, initialization on download).
Offline mode is available via software selection (for AI calibration).
Maximum user- 400 2000 5000
configurable
Function Blocks
Maximum Control Quantity based on available memory
Loops
System Blocks (Not 100 (not part of 400, 2000 or 5000), for Alarm Group blocks, System block, Rack Monitor
user configurable) blocks, Communications
Loop Outputs Current, time proportional, position proportional, 3-position step (motor positioning), dual
output [heat/cool])
HC900 Process Controller 17

C30 C50 C70 C75

Control Loop Types PID A, PID B, Duplex A, Duplex B, Ratio, Cascade, % Carbon, Dewpoint, Relative
Humidity, On-Off, Auto/Manual-Bias
Auto-tuning Accutune III, fuzzy logic overshoot suppression, applicable to all control loops

Setpoint Programmers Ramp Types: Ramp Rate or Ramp Time

Time Units: Hours or Minutes
Segment Time: 0-99,999.999 hours or minutes
Program Cycles: Up to 100 or infinite, configurable segment range
Programmer Events Assignable to DO or internal status

Setpoint Profiles 50 segments per profile. Number of stored profiles is user-configurable.

Setpoint Scheduler Ramp type: Ramp time

Time units: Hours or minutes
Segment time: 0.001 to 9999.999 hours or minutes
Cycles: Per segment to 999 or infinite
Auxiliary Scheduler Up to 8 setpoints, soak only
Setpoints
Schedule events Up to 16, assignable to DO or internal status

Setpoint Scheduler 50 segments per schedule. Number of stored schedules is configurable.

Schedules
Sequencers States: 50
State text: 12 characters
Steps: 64
Time Units: Minutes or Seconds
Digital Outputs: 16
Analog Output: 1, configurable value/step
Step Execution: On Time, Event 1, Event2, or via Advance
Next Step: Any step
Sequences Number of stored Sequences is user-configurable
Recipes (Variables) Number of stored Recipes (Variables) is user-configurable
Recipe Parameters Up to 50 analog or digital Variables — (may include profile numbers)
Signal Tags (Read only) Up to 65,535
Tag Identification 16-character tagname, 16-character descriptor,6-character units of measure (analog
only), 6 character on/off state (digital only). Non Safety Critical enable.
Variables (Read/Write) Up to 2048
Variable Identification 16-character tagname, 16-character descriptor,6-character units of measure (analog
only), 6 character on/off state (digital only)
Controller Data Storage • Data types: Signals, Alarms, Events
• Maximum signals tags: 250
• Maximum points per group: 50
• Selectable storage rates: 3
• Storage rate resolution, 10 sec. to 24hr
• Data Access - via HC Historian PC software, manual upload using Ethernet or
Serial communications.
18 HC900 Process Controller

Specifications
Communications
C30 C50 C70 C75
Network Communications
Ports
Number of Ethernet 1 1 2 2
10/100Base-T connections
Ethernet 10/100Base-T, Supports Modbus/TCP Protocol to PC Supports dual Modbus/TCP ports to PC
RJ-45 connection supervisory and data acquisition software supervisory and data acquisition software
packages, OPC server, Modbus/TCP packages, OPC server, Modbus/TCP
Initiator, Peer to Peer, and Designer Initiator (non-redundant), Peer to Peer,
configuration software and Designer configuration software
Max. number of concurrent Up to 5 (peer data Up to 10 shared between two ports (peer data exchange does
Ethernet host connections exchange does not not consume a host connection).
consume a host
connection)
USB-RS485 Converter 50089787 -501
RS-485 Ports
Ports per controller Two, isolated RS-485 (connector supplied), Honeywell or Modbus RTU protocol.
Cable type 2-wire plus shield, Belden 9271 or equivalent
Distance from controller 2000 ft. (600 m.)
Modbus Slave addresses 1 to 247
Parity (user selectable) Odd, even, none
Stop bits (user selectable) 1 or 2

Speed (user selectable) 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

Double Register Format for Selectable byte order

Modbus RTU Slave and
Master data (User
selectable)
C30 C50 C70 C75
RS-485 Modbus, Slave
Operation
Number of ports per Up to two
controller
Masters per port One
Principal Function Block User selectable starting address range for registers assigned to each principal block
Address Range type.
HC900 Process Controller 19

RS-485 Modbus Master

Operation
Number of ports per controller One (isolated RS485)
Function Block Types Slave – 4 read and 4 write data points
Read (Slave extension block ) up to 16 parameters
Write (Slave extension) up to 8 parameters
(No limit on the number of Read and Write extension blocks per Slave block up to
the maximum 1024 parameters per controller.)
Slave devices per controller Up to 32
Number of read/write Modbus Up to 1024 max. per controller
Parameters
Double Register Format Selectable per device
Speed 1 second fastest – load dependent
Modbus Master Advanced
Application Recommended for use with gateway devices
Speed As fast as 500ms
Ethernet Modbus/TCP Initiator
Operation
Number of ports per controller One (Models C30 and C50) - Two (Models C70 and C75) isolated RS485
Function Block Types Slave – 4 read and 4 write data points
Read (Slave extension block ) up to 16 parameters
Write (Slave extension) up to 8 parameters
(No limit on the number of Read and Write extension blocks per Slave block up to
the maximum 1024 parameters per controller.)
Slave devices per controller Up to 32
Number of read/write Modbus Up to 1024 max. per controller
Parameters
Double Register Format Selectable per device
Speed 1 second fastest – load dependent
Peer-to-peer
10/100Base-T via Network port Supports UDP protocol and Peer Data Exchange function blocks for peer data
exchange
No. of Peers/Controller 32
Update rate 500 ms to 5 sec., selectable
Peer Data Digital and Analog Signal Tags, Variables - up to 2240 parameters
Ethernet
Ethernet Network Connection 10/100 Base-T, RJ-45
Host Network Protocol Modbus/TCP
Qualified configuration 100ms normal scan is restricted to 900C70S-0360, 900C75S-0360, 900S50S-
0360 (optional), 900S75S-0360 models that runs in v6.006 firmware and 900A16-
0102 High level input modules. The following restrictions also apply- (2) IO racks
maximum, (4) analog modules per rack maximum, Ethernet SCADA
communications 400 points per sec, <= 400 IO channels, <= 1500 function blocks.
NOTE: The 900A01 low level analog module continues to be updated at 500mS
during the 100 ms scan time and counts against the 4 module limit per rack.
20 HC900 Process Controller

Maximum distances per Ethernet specifications

Controller rack to I/O Rack Ethernet CAT5 cable with RJ-45 connectors 100m /328 ft
Fiber Optic cable with switch 750m
Fiber Optic cable with switch and repeater 1500m
Controller to Ethernet Switch Ethernet CAT5 cable with RJ-45 connectors 100m /328 ft
Ethernet Switch to I/O Rack Ethernet CAT5 cable with RJ-45 connectors 100m /328 ft
Controller to Network Switch Ethernet CAT5 cable with RJ-45 connectors 100m /328 ft
Network Switch to PC Ethernet CAT5 cable with RJ-45 connectors 100m /328 ft
Controller to 1042 Operator Shielded, Twisted pair 610m /2000 ft
Interface

Approvals
CE Conformity This product is in conformity with the protection requirements of the following European Council
Directives: 2006/95/EC, the Low Voltage Directive, and 2004/108/EC, the EMC Directive.
Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed. EN61326:
Electrical Equipment For Measurement, Control and Laboratory use. EMC requirements.
ATEX The apparatus fulfills the requirements for Group II, Category 3 equipment in accordance with
Directive 94/9/EC.
TUV (SIL2) HC900 complies with the requirements of the relevant standards and can be used in applications
up to SIL2 according to IEC 61508, for low demand applications and high demand applications
where the demand rate does not exceed 10 times per year. HC900 is capable of being used in
safety applications including (but not limited to) Emergency shutdown (ESD), Burner
Management Systems (BMS), Critical process control etc.
ABS PDA Certificate of Design Assessment - No. 06-HS186538-4-PDA (June 2014.)
Approval Certificate of Manufacturing Assessment - No. 06-BA766694-X (York Location)
Certificate of Manufacturing Assessment - No. BY1100081X (Pune Location)
General Purpose Compliant with EN61010-1, UL, UL 61010C-1, CSA C22.2 No. 1010-1
Safety
Hazardous FM Class I, Div. 2, Groups A, B, C, D
(Classified) CSA Class I, Div. 2 Groups A, B, C, D
Location Safety Class 1, Zone 2, IIC
HC900 Process Controller 21

Module Module Type “T” Module Type “T”

Temperature Rating Rating
Classifications (1) (1)
Redundant CPU Rack T6 S75 Scanner 2 Port T4
(1) (1)
Redundant PS Ext. Rack T5 Analog Input (8 chan) T6
(1)
8 Slot Redundant PS Ext. Analog Input (16 chan) T6
(1) T6
Rack
(1)
12 Slot Redundant PS Ext. Analog Output (4 chan) T4
(1) T6
Rack
(1) (1)
4 I/O Slot Rack T6 Analog Output (8 chan) T4
(1)
Analog Output (16 chan) T3C
(1) (1)
8 I/O Slot Rack Digital Input, Contact type T5
T6
(16 chan)
(1) (1)
12 I/O Slot Rack T6 Digital Input, 24 Vdc (16 chan) T4
(1) (1)
Power Supply (P01) T4 Digital Input, 120/240 Vac (8 T3C @ Ta=60 °C
chan) (1)
T4 @ Ta=40 °C
(1)
Power Supply (P02) T4 Digital Input Vdc (32 chan) T3C@60 °C and
T4@40 °C
(1) (1)
Power Supply (P24) T4 Digital Output, Relay type (8 T5
chan)
(1)
Power Status Module T6 Digital Output, 24 Vdc, (16 chan) T4
(1)
(PSM)
(1) (1)
C30/C50/C70/C75 CPU T4 Digital Output, 120/240 Vac T4
(8 chan)
(1)
Redundancy Switch T6 Digital Output Vdc (32 chan) T6
(1)
Module (RSM)
(1)
S50 Scanner 1 Port T4 Pulse/Frequency/Quadrature (4 T5
chan)
(1)
Modules – included in IEC-61508 certification

Specifications

Environmental Conditions
Ambient Temperature Reference Rated Extreme Transportation &
Storage
°F 77+/-5 32 to 140 32 to 140 -40 to 158
°C 25+/-3 0 to 60 0 to 60 -40 to 70
Ambient Relative Humidity *45 % to 55 % RH *10% to 90 % RH *5 % to 90 % RH *5 % to 95 % RH
non-condensing non-condensing non- condensing non-condensing
Mechanical Acceleration 0g 1g 1g Not rated
Duration 0 ms 30 ms 30 ms
Vibration 0 Hz 0 Hz to 14 Hz—amplitude 2.5 mm (peak-to-
0g peak). 14 Hz to 250 Hz—acceleration 1 g

* Applies up to 40°C
22 HC900 Process Controller

Dimensions

10.5 16.5
266.7 419.1

5.4* 5.4*
137 137
4 Slots 8 Slots
6.0** 6.0**
152.4 152.4

22.5
571.5

5.4*
137
12 Slots
6.0**
152.4

10.3 Key:
261.6 In
mm
5.4* * 6.9 with mounting flanges
137
Redundant 175
CPU 6.0** **Total depth (rack + components)
152.4 6.4 (162.6) for 32 DI/DO and 16 AI Modules

20.9
530.9

5.4*
137
8 Slots
Redundant Power Supply 6.0**
152.4

26.9
684.0

5.4*
137
12 Slots
Redundant Power Supply 6.0**
152.4

Figure 2 HC900 Process Controller Dimensions

HC900 Process Controller 23

Sales and Service

For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor, contact one
of the offices below.

ASIA PACIFIC EMEA AMERICA’S

Honeywell Process Solutions, Honeywell Process Solutions, Honeywell Process Solutions,
(TAC) hfs-tac- Phone: + 80012026455 or Phone: (TAC) 1-800-423-9883 or
support@honeywell.com +44 (0)1344 656000 215/641-3610
(Sales) 1-800-343-0228
Australia Email: (Sales)
Honeywell Limited FP-Sales-Apps@Honeywell.com Email: (Sales)
Phone: +(61) 7-3846 1255
FAX: +(61) 7-3840 6481 or FP-Sales-Apps@Honeywell.com
Toll Free 1300-36-39-36 (TAC) hfs-tac-support@honeywell.com or
Toll Free Fax: (TAC) hfs-tac-support@honeywell.com
1300-36-04-70

China – PRC - Shanghai

Honeywell China Inc.
Phone: (86-21) 5257-4568
Fax: (86-21) 6237-2826

Singapore
Honeywell Pte Ltd.
Phone: +(65) 6580 3278
Fax: +(65) 6445-3033

South Korea
Honeywell Korea Co Ltd
Phone: +(822) 799 6114
Fax: +(822) 792 9015

Specifications are subject to change without notice.

 Warranty/Remedy

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local
sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell
will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all
other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose.
Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this
printing. However, we assume no responsibility for its use.

While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the
customer to determine the suitability of the product in the application.

For more information

To learn more about HC 900 Process Controller,
visit www.honeywellprocess.com
Or contact your Honeywell Account Manager

Process Solutions
Honeywell

1250 W Sam Houston Pkwy S

Houston, TX 77042

Honeywell Control Systems Ltd

Honeywell House, Skimped Hill Lane
Bracknell, England, RG12 1EB

Shanghai City Centre, 100 Jungi Road

Shanghai, China 20061
51-52-03-31
October 2015
www.honeywellprocess.com 2015 Honeywell International Inc.