900 Control Station

For use with HC900 Hybrid Controller

User Guide
Doc. No.: 51-52-25-148
Revision: 7
Date: March 2013

Honeywell Process Solutions

 Notices and Trademarks

Copyright 2011 by Honeywell

Revision 7, March 2013

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

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

Honeywell Process Solutions

Honeywell
512 Virginia Drive
Fort Washington, PA 19034

HC900, 559 and 1042 are U.S. registered trademarks of Honeywell

Other brand or product names are trademarks of their respective owners.

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 Contents

About This Document

Abstract
This manual describes the installation and operation of the 900 Control Station Operator Interface.

References
The following list identifies all documents that may be sources of reference for material discussed in this
publication.

Document Title Doc ID

HC900 Control Station Installation 51-52-33-147

900 Control Station Specification 51-52-03-46

HC900 Controller Installation and User Guide 51-52-25-107

Station Designer User Guide 51-52-25-149

Hybrid Control Designer User Guide 51-52-25-110

Hybrid Control Designer Function Block Reference Guide 51-52-25-109

HC900 Hybrid Controller Communications User Guide 51-52-25-111

HC900 Controller Redundancy Overview & System Operation 51-52-25-133

Revision Information
Document Name Revision Number Publication Date
This manual … 51-52-25-148 900 Control Station
New Revision 1 April 2009
Languages added, IP address setup, model specific
Revision 2 October 2009
notes
Summary Dispalys added, Alarms & Events added,
batch Logging and Download and upload Revision 3 March 2010
configurations + others
Variable Recipes added, Alarm & Events section
Revision 4, 5 October 2010
updated, Compact Flash Min/Max added
CS 15” USB conflict note added Revision 6 September 2011
“USB 3.0 support is only available for 900CS10”
Revision 7 March 2013
note added

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Support and contact info

United States and Canada
Contact: Honeywell Process Solution
• Global Technical Support - Phone: 001-800-423-9883
• Customer Service (HFS) - Phone: 001-800-343-0228
• Outside United States - Phone: 001-215-641-3610
Calls are answered by dispatcher between 6:00 am and 4:00 pm Mountain Standard
Time. Emergency calls outside normal working hours are received by an answering
service and returned within one hour.
Email support: ask-ssc@honeywell.com
Mail: Honeywell Process Solutions
1860 West Rose Garden Lane,
Phoenix, AZ, 85027

For more contact details for Europe, Asia, North and South Americas, please see back page.

World Wide Web

Honeywell Solution Support Online:
www.honeywellprocess.com

Elsewhere
Call your nearest Honeywell office. See back page for details.

Training Classes
Honeywell Automation College:
http://www.automationcollege.com

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Symbol Definitions
The following table lists those symbols that may be used in this document to denote certain conditions.

Symbol Definition

This DANGER symbol indicates an imminently hazardous situation, which,

if not avoided, will result in death or serious injury.

This WARNING symbol indicates a potentially hazardous situation, which, if

not avoided, could result in death or serious injury.

This CAUTION symbol may be present on Control Product instrumentation

and literature. If present on a product, the user must consult the
appropriate part of the accompanying product literature for more
information.

This CAUTION symbol indicates a potentially hazardous situation, which, if

not avoided, may result in property damage.

WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,
42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these
instructions could result in death or serious injury.

ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for

handling electrostatic sensitive devices

Protective Earth (PE) terminal. Provided for connection of the protective earth
(green or green/yellow) supply system conductor.

Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.

Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.

Chassis Ground. Identifies a connection to the chassis or frame of the equipment

shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requirements.

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Contents
Support and contact info.............................................................................................. iv
Symbol Definitions ........................................................................................................ v

Introduction ............................................................................................. 1
Overview ....................................................................................................................... 1
What’s in this guide ................................................................................................................1
Typical readers of this guide ..................................................................................................2
What you can do with the Control Station ..............................................................................2
Specifications ...............................................................................................................2
CE Conformity (Europe) ............................................................................................... 2
Components ................................................................................................................. 3

Preparation and startup ........................................................................... 4

Site Preparation ............................................................................................................ 4
Control Station Mounting .............................................................................................. 4
Noise Protection ........................................................................................................... 4
How to configure your Control Station.......................................................................... 4
Startup .......................................................................................................................... 5

Features .................................................................................................. 7
Overview ....................................................................................................................... 7
Touch screen ................................................................................................................ 8
Navigation and data entry ......................................................................................................9
Status bar .............................................................................................................................10
Keys ............................................................................................................................ 11
CompactFlash ............................................................................................................ 11
Status LEDs ................................................................................................................ 12
Ports ........................................................................................................................... 13
900 Control Station 10 inch model .......................................................................................13
900 Control Station 15 inch model .......................................................................................13
USB Device ..........................................................................................................................14
USB Host .............................................................................................................................14
Ethernet................................................................................................................................14
RS485 ..................................................................................................................................14
RS232 ..................................................................................................................................14

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Main Menu ............................................................................................ 15

Overview .....................................................................................................................15
Access..................................................................................................................................15
Functions..............................................................................................................................15
Main menu tree ....................................................................................................................16
Controller ....................................................................................................................17
Controller Status ..................................................................................................................17
Controller Setup ...................................................................................................................19
Summary Displays...................................................................................................... 20
About Summary Displays .....................................................................................................20
Communications ......................................................................................................... 22
Menu Overview ....................................................................................................................22
Serial Port S1/S2 ..................................................................................................................22
Ethernet Port E1/E2 Status ..................................................................................................27
Expansion Rack Communications........................................................................................29
Modbus Slave Devices .........................................................................................................31
Host Connections .................................................................................................................32
Peer Connections .................................................................................................................33
Troubleshooting a Comm Quality problem ...........................................................................35
Troubleshooting Data Link Errors .........................................................................................35
Diagnostics ................................................................................................................. 36
Menu Overview ....................................................................................................................36
Controller Diagnostics ..........................................................................................................37
I/O Module Diagnostics and I/O Calibration .........................................................................42
Communication Diagnostics .................................................................................................48
Redundant Overview ............................................................................................................48
Lead/Reserve CPU Diagnostics ...........................................................................................56
Station Settings .......................................................................................................... 61
View Data .............................................................................................................................61
Delete Data ..........................................................................................................................61
Export Data to USB ..............................................................................................................61
Format Memory Device ........................................................................................................62
Station Setup........................................................................................................................62
Station Status .......................................................................................................................62
Station Comm Ports .............................................................................................................62
Change Passwords ..............................................................................................................62
Language Menu Selection....................................................................................................62
Log On ........................................................................................................................63
Alarms and Events ..................................................................................................... 64
Alarm Access .......................................................................................................................64
Alarm Definition ....................................................................................................................64
Alarm Indicator .....................................................................................................................64
Display Details .....................................................................................................................64
Alarm Groups .......................................................................................................................65
Alarm Group Indication ........................................................................................................66
Alarm Group Overview .........................................................................................................66
Alarm Point Indication ..........................................................................................................67
Alarm Point Detail ................................................................................................................67
Event Access .......................................................................................................................67
Event Definition ....................................................................................................................67
Event Indication....................................................................................................................68
Display Details .....................................................................................................................68

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Data Logging .............................................................................................................. 69

View Alarm & Event Logs .....................................................................................................69
View Data Logs ....................................................................................................................70
View Audit Logs ...................................................................................................................70
Export Data Logs to USB .....................................................................................................71
View Batch Groups & View Batch Status .............................................................................71
Delete Data Logs .................................................................................................................74
Downloading and Uploading Controller Configuration ............................................... 75
Download Configuration Files ..............................................................................................75
Upload Controller Configuration ...........................................................................................77
Uploading Database Image ........................................................................................ 79
Uploading and Downloading Recipe Files.................................................................. 80
Download Recipe Files ........................................................................................................80
Upload Recipe Files .............................................................................................................82
Uploading and Downloading Security Settings .......................................................... 84
Upload Security Displays and Functionality .........................................................................84
Download Security Displays and Functionality .....................................................................86
Using Barcode Reader ............................................................................................... 86

Process Displays ................................................................................... 87

Overview .....................................................................................................................87
Access..................................................................................................................................87
Widget displays ....................................................................................................................87
How to edit a parameter .......................................................................................................89
Pushbuttons, signals and variables ............................................................................ 90
AGA8DL & AGA8GS .................................................................................................. 91
AGA Detail Gas Components...............................................................................................95
AGA8 Gross Setup ...............................................................................................................96
4-Selector Switch........................................................................................................ 97
Device Control ............................................................................................................ 98
Device Control Setup ...........................................................................................................99
Hand/Off/Auto Switch ............................................................................................... 100
Stage ........................................................................................................................101
Stage setup display ............................................................................................................102
Ramp ........................................................................................................................ 103
Ramp setup display ............................................................................................................104
Alternator .................................................................................................................. 105
Alternator Setup display .....................................................................................................106
Alternator Edit Setup display ..............................................................................................106
Calendar Event ......................................................................................................... 109
Calendar Event Block Menu ...............................................................................................110
Edit Event Setpoints ...........................................................................................................111
Set Active Setpoint Group ..................................................................................................111
Edit Special Days ...............................................................................................................111
View Special Days Event Setup .........................................................................................112
Wireless transmitters ................................................................................................ 113
XYR5000 Base Radio ........................................................................................................113
XYR5000 Transmitter .........................................................................................................114
XYR6000 Transmitter .........................................................................................................115

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VARIABLE RECIPES .......................................................................... 117

Overview ................................................................................................................... 117
Description .........................................................................................................................117
Variable Recipe Load vs. Variable Recipe Upload/Download ............................................117

Setpoint Programmers ........................................................................ 119

Overview ................................................................................................................... 119
Description .........................................................................................................................119
Setpoint Programmer Overview widgets ............................................................................120
Setpoint programmer – Pre Plot Display .................................................................. 122
General Description ...........................................................................................................122
Setpoint Programmer Pre-Plot Graph attributes.................................................................123
Process Variable Trend Plot attributes ...............................................................................124
Special cases and actions ..................................................................................................124
Auxiliary SP and PV Pre-plot..............................................................................................125
Setpoint programmer Operate .................................................................................. 125
View/Edit profile ........................................................................................................ 129
View/Edit Profile Segments ...................................................................................... 131
Edit Type and Value ...........................................................................................................131
Edit Events .........................................................................................................................132

Setpoint Scheduler .............................................................................. 133

Overview ................................................................................................................... 133
Setpoint Scheduler Operate ..................................................................................... 134
View/Edit schedule ................................................................................................... 137
View/Edit Schedule Segments ................................................................................. 138
Edit Setpoints .....................................................................................................................138
Edit Auxiliary Setpoints ......................................................................................................138
Edit Time & Recycles .........................................................................................................139
Edit guarantee hold ............................................................................................................139
Edit segment events ...........................................................................................................139

Sequencers ......................................................................................... 141

Overview ................................................................................................................... 141
Sequencer Operate .................................................................................................. 142
View/Edit Sequence ................................................................................................. 144
View/Edit Sequence Steps ....................................................................................... 145
Edit Time/Events ................................................................................................................145
Edit Auxiliary ......................................................................................................................146
View Outputs 1-8/9-16 .......................................................................................................146

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Loops .................................................................................................. 147

Overview ................................................................................................................... 147
Loop widgets ......................................................................................................................147
Loop Setup ............................................................................................................... 148
Overview ............................................................................................................................148
Loop modes .......................................................................................................................149
Loop control setup ..............................................................................................................150
Loop Tuning .......................................................................................................................151
Tuning constants ................................................................................................................155
Alarm setpoints ..................................................................................................................156
High Output Limiting ...........................................................................................................157

I/O Calibration ..................................................................................... 159

Overview ................................................................................................................... 159
AI Calibration ............................................................................................................ 160
Overview ............................................................................................................................160
Calibration equipment ........................................................................................................160
Calibrate AI channel ...........................................................................................................161
Cancel Calibration ..............................................................................................................161
Restore AI factory calibration .............................................................................................161
CJ Calibration ........................................................................................................... 162
Cancel Calibration ..............................................................................................................162
Restore CJ factory calibration ............................................................................................162
AO Calibration .......................................................................................................... 163
Cancel Calibration ..............................................................................................................164
Restore AO factory calibration ...........................................................................................164
PPO Motor Calibration.............................................................................................. 165
Overview ............................................................................................................................165
Calibration Status Information ............................................................................................165
Cancel Calibration ..............................................................................................................166
Calibration Errors ...............................................................................................................166
Auto Calibration Procedure ................................................................................................167
Semi-Auto Calibration Procedure .......................................................................................168
Hand Calibration Procedure ...............................................................................................169
Motor Setup .............................................................................................................. 171

Maintenance ........................................................................................ 172

Troubleshooting ........................................................................................................ 172
What to do if the Control Station has difficulty starting up ..................................................172
Performing a cold start .......................................................................................................172
What to do if you want to change the IP Address at the Control Station ............................173
Changing or entering IP Address .......................................................................................173
How to remove the rear cover and change the battery of the operator interface?..............174
Changing the battery of Control Station unit.......................................................................174
Parts .........................................................................................................................175

Index ................................................................................................... 177

Sales and Service ............................................................................... 179

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Tables
Table 1 Main menu functions ..................................................................................................................................... 15
Table 2 Main menu tree .............................................................................................................................................. 16
Table 3 Controller status details ................................................................................................................................. 17
Table 4 Controller Setup details ................................................................................................................................. 19
Table 5 Controller modes defined ............................................................................................................................... 19
Table 6 Serial Port S1/S2 Statistics (left side of display) ............................................................................................ 23
Table 7 Serial Port S1/S2: Port Diagnostic status ....................................................................................................... 24
Table 8 Serial Port S1/S2 Settings (right side of display)............................................................................................ 25
Table 9 Protocol selection versus setup parameters for the Serial Port S1/S2 ............................................................. 26
Table 10 Ethernet Port E1/E2 details .......................................................................................................................... 27
Table 11 Ethernet Port E1/E2: Port Diagnostic status ................................................................................................ 28
Table 12 Expansion Rack Communication details ...................................................................................................... 29
Table 13 Expansion Rack Communication Status ...................................................................................................... 30
Table 14 Modbus Slave Status .................................................................................................................................... 31
Table 15 Host Connections.......................................................................................................................................... 32
Table 16 Host Connection Status Indicators................................................................................................................ 32
Table 17 Peer Connections .......................................................................................................................................... 33
Table 18 Peer Connection Status ................................................................................................................................. 34
Table 19 Rack n diagnostics ....................................................................................................................................... 37
Table 20 I/O module diagnostics ................................................................................................................................ 42
Table 21 I/O module Details....................................................................................................................................... 43
Table 22 I/O Module Error Status .............................................................................................................................. 44
Table 23 Bad module details ....................................................................................................................................... 46
Table 24 Bad Channel details ...................................................................................................................................... 47
Table 25 Redundant Overview ................................................................................................................................... 48
Table 26 Details of Rack diagnostics error status messages ....................................................................................... 51
Table 27 Details of Lead or Reserve CPU diagnostics error status messages ............................................................ 57
Table 28 AGA Parameters ........................................................................................................................................... 92
Table 29 AGA Error Codes ........................................................................................................................................ 92
Table 30 Device control display details ...................................................................................................................... 98
Table 31 Device states ................................................................................................................................................. 99
Table 32 Stage setup details ..................................................................................................................................... 102
Table 33 Ramp operator display details ................................................................................................................... 103
Table 34 Edit ramp display details ........................................................................................................................... 104
Table 35 SPP inputs and current state ...................................................................................................................... 119
Table 36 Setpoint Progammer Overview widget features ......................................................................................... 120
Table 37 SPS inputs and current state ...................................................................................................................... 133
Table 38 Loop modes ............................................................................................................................................... 149
Table 39 Calibration Errors ....................................................................................................................................... 166
Table 40 Auto Calibration Procedure ...................................................................................................................... 167
Table 41 Semi-Auto Calibration Procedure............................................................................................................... 168
Table 42 Hand Calibration Procedure ...................................................................................................................... 169
Table 43 Parts ........................................................................................................................................................... 175

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Figures
Figure 1 900 Control Station menu............................................................................................................................... 1
Figure 2 Home display ................................................................................................................................................. 5
Figure 3 Features ........................................................................................................................................................... 7
Figure 4 Examples of buttons and data entry fields ....................................................................................................... 9
Figure 5 Status bar ....................................................................................................................................................... 10
Figure 6 Status LEDs ................................................................................................................................................... 12
Figure 7 Main Menu ................................................................................................................................................... 15
Figure 8 Variable Recipe Selection Display ............................................................................................................. 118
Figure 9 Recipe Load ................................................................................................................................................ 128
Figure 10 Recipe Save ............................................................................................................................................... 128
Figure 11 IMAN loop mode ..................................................................................................................................... 149

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 Introduction

Overview
What’s in this guide
This guide contains instructions on assembly, installation, wiring, and operation of the 900 Control Station,
shown in Figure 1.

Figure 1 900 Control Station menu

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Introduction
Specifications

Typical readers of this guide

The typical users of this guide are:
• the technician who installs the Control Station,
• the engineer who configures the Control Station,
• the operator who views/controls/monitors the process.

What you can do with the Control Station

The Control Station lets you perform these tasks:
• Monitor and control a process.
• Load/Store/Run Recipes, Profiles, Schedules, Sequences.
• Display various process data such as trends, alarms, diagnostics, setpoint profiles, and control loops.
• Store process data to disk.

Specifications
Refer to 900 Control Station Specifications document #51-52-03-46.

CE Conformity (Europe)
This product is in conformity with the protection requirements of the following European Council
Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of
this product with any other “CE Mark” Directive(s) shall not be assumed.

ATTENTION

The emission limits of EN 50081-2 are designed to provide reasonable protection against
harmful interference when this equipment is operated in an industrial environment. Operation
of this equipment in a residential area may cause harmful interference. This equipment
generates, uses, and can radiate radio frequency energy and may cause interference to radio
and television reception when the equipment is used closer than 30 meters to the antenna(e).
In special cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the electromagnetic
emissions of this equipment.

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 Components

Components
PC 900 Control Station HC900 Controller

• Honeywell’s HC Designer • Lets you monitor and adjust the • Integrate loops of control with
application configures your HC900’s process through digital I/O
HC900 Controller’s process custom-built displays and pre-
configured “widgets” • Setpoint programming
• Honeywell’s Station Designer
application configures how your • Load/store/run recipes, profiles, • Setpoint scheduling
Control Station interfaces with data logs
• Sequencing
the HC900 Controller. Build
custom displays using pre- • Monitor alarms, diagnostics,
• Recipe management
configured objects (called events
“widgets”) for interfacing with • Alarm processing
• Store data logs
principal function blocks such as
loops and SPPs. Configure data • PID control, Advanced control,
logs for storage and trend autotuning, fuzzy logic
viewing.

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Preparation and startup
Site Preparation

Preparation and startup

Site Preparation
The cable that connects the Control Station to the controller module contains low voltages. Keep the cable
away from high voltage wires that can cause interference.

Control Station Mounting

See HC900 Control Station Installation document #51-52-33-157.

Noise Protection
See document 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise
Environments.

How to configure your Control Station

The Control Station is shipped from the factory unconfigured. Use Honeywell’s Station Designer
application to configure your Control Station.
The overall steps for configuration are as follows.

Step Action

1 Using Station Designer application, open .sds file, add device, update IP address and create
data tags from your HC900’s .cde configuration file.

2 In Station Designer, build custom displays to be used by Control Station for viewing and
interacting with your HC900 Controller process.

3 In Station Designer, assign data tags to the custom displays.

4 Save the Station Designer configuration as an .sds file.

5 Download the .sds file via USB or Ethernet to the Control Station.

6 Your Control Station is now configured and ready to use.

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 Preparation and startup
Startup

Startup
After connecting the Controller and Control Station and downloading your .sds file to the Control Station,
the Home display appears with 16 buttons. (Actual button text may vary.)

Figure 2 Home display

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Preparation and startup
Startup

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 Features

Overview

2 5

Figure 3 Features

Item Feature Description Details

1 Touch screen Interactive touch screen shows menus and displays. See page 8
(Optional protective film available.)

2 Keys Key functions are more generic than button functions. See page 11

3 CompactFlash For data storage and booting up from an image file. See page 11

4 Status LEDs Status of power, CompactFlash and alarms. See page 12

5 Ports Connections for data storage and communications. See page 13

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Features
Touch screen

Touch screen

Item Feature Description Details

1 Navigation and A button is an onscreen object that when touched See page 9.
data entry causes an action. Shown here are the buttons on the
Main Menu. Buttons come in various shapes, sizes
and colors but a graduated blue background is the
most common.

2 Status bar Always visible. Shows status of: See page 10.

• Logs

• Diagnostics

• Alarms

• Events

• Controller

• Language

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 Features
Touch screen

Navigation and data entry

A button is an object you touch on the display to go to another menu or display or to cause an action.
Buttons come in various shapes, colors and sizes.

2 2

3 3
4
5
1 5
1
1
1
1

Figure 4 Examples of buttons and data entry fields

Item Description Function

1 Buttons with graduated blue background appear on Touch to activate.

virtually every menu under the Menu key (page 11)
and on many displays. Various sizes, shapes and
functions.

2 Graduated blue background in the title bar of the Touch light blue title bar of object to jump to
object indicates a link to additional displays related to detailed displays for that object.
the object.
Example: Touch PID title bar to jump to loop
tuning, tuning constants, etc.

Example: Touch SPP title bar to jump to

setpoint programmer events, etc.

3 Black value or text on white unlined box. Read only. Read-only.

4 Black value or text on white lined box. Read/write. Touch to edit. A popup appears where you can
enter a new value, type text, or select from a
list of choices. See page 89

5 Grayed out text, field or button. Not accessible or Example: Loop output not adjustable in Auto
applicable under current conditions. mode.

Example: Redundant Overview button is not

active for non-redundant HC900s.

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Features
Touch screen

Status bar
The status bar is always visible at the bottom of all menus and displays.

1 2 3 4 5 6

Figure 5 Status bar

Button Description Function

1 Data Log indicator/Data Log menu button. Touch to go to Data Log

menu. See page 64.
Gray text when no data logging is occurring on the Control Station.

When data logging is occurring, the icon becomes colorful and the
text becomes black.

2 Diagnostic indicator. Touch to go to System

Diagnostics page. See page
Gray text when there is no controller diagnostic present. 36.
When a controller diagnostic is present, the button flashes.

3 Alarm indicator. Touch to go to Alarms

console or Alarm Group
Gray text when there are no active alarms. display depending on how the
Control Station was
When there is an active alarm present (either acknowledged or
configured (see Station
unacknowledged), the white background turns red and the icon
Designer manual section on
becomes colorful and the text becomes white.
Alarms). Here all alarms are
When there are any unacknowledged alarms, the button flashes. displayed, with buttons that let
When all alarms become acknowledged, the flashing stops. you mute and acknowledge
alarms.

Note: To see alarm history, go

to Alarm and Event Summary.

4 Event indicator/Alarm and Event Summary button. Touch to go to Alarm and

Event Summary, where they
Gray text when no event is present. can be viewed or cleared.
When an event occurs, a description appears in black text and the
background changes to a pale yellow.

5 Controller mode, time and date. Touch to go to Controller

Setup. See page 19.

6 Language of displayed text is indicated by flag icon. Touch to go to Language

Setup. See page 68

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 Features
Keys

Keys
Unless otherwise noted, the membrane keys on the left side of the front panel always behave as described
here.

Press key For this result

• Programmable function

• Programmable function

• Print contents of the display to a .bmp file on CompactFlash.

• Log off current user.

• Go to next display. Works only after Back key was pressed.

• Go to previous display.

• Go to Home display. This is the default display upon startup. It

contains links to displays for viewing your HC900’s process.
See page 87.

• Go to main menu. See page 15.

CompactFlash
CompactFlash socket is on the left side. Use CompactFlash card for:
• storing data logs (.csv)
• storing print screen images (.bmp)
• loading image file (.sdi).
NOTE: Maximum Compact Flash memeory size is 2GB, minimum Compact Flash size is 4MB.

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Features
Status LEDs

Status LEDs
The Status LEDs indicate:
• Run status of the Control Station
• CompactFlash card status
• Alarm status.

Figure 6 Status LEDs

Green LED Indication

Flashing Unit is in the boot loader, no valid configuration is loaded.

Steady Unit is powered and running an application.

Yellow LED Indication

Off No CompactFlash card present.

Steady CompactFlash card present.

Flashing rapidly CompactFlash being checked.

Flickering Unit is writing to the CompactFlash, either because it is storing data, or

because the PC connected via the USB port has locked the drive.

Flashing slowly Incorrectly formatted CompactFlash card present.

Red LED Indication

Flashing A tag is in alarm state.

Steady Valid configuration is loaded and no alarms are present.

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 Features
Ports

Ports
900 Control Station 10 inch model

900 Control Station 15 inch model

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Features
Ports

USB Device
The USB Device port is for downloading a configuration from Station Designer to the Control Station.
Type B connector. Note: USB 3.0 support is only available on the 900CS10.

USB Host
USB Host Port A is for exporting data logs to a USB storage device with Type A connector.
USB Host Port B is not used.

Ethernet
The Ethernet port is for fastest communication with your HC900 Controller, PC, or other devices. Use an
Ethernet switch to link multiple devices.

RS485
The RS485 port is for communication with HC900 Controller if Ethernet is not desired or available.

RS232
The RS232 ports are not recommended due to reduced performance. Port B may be used to connect to
HC900. Port A PGM Port may be connected to your PC.
NOTE: The 15" model has two Ethernet ports and two RS485 ports whereas the 10" model has one of
each.

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 Main Menu

Overview
Access
To access the Main Menu, press the Menu key.

Figure 7 Main Menu

Functions
The Main Menu is for viewing and adjusting settings for your Control Station and HC900 Controller.
Process displays are accessed under the Home key.
Table 1 Main menu functions

Menu Item Function

Controller Controller status and setup.

Communications Controller communications. Serial ports, Ethernet ports, I/O, Modbus, Hosts,
Peers.
Diagnostics Diagnostic status of controller, I/O, communications.
Station Settings File management of CompactFlash and USB device. Adjust/calibrate/clean touch
screen. View status of communication ports. Set passwords.
Log On Security manager for logging on.
Data Logging File management of Data Logs.

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Main Menu
Overview Main menu tree

Main menu tree

Access the Main Menu by pressing . The menu is organized as shown in Table 2.

Table 2 Main menu tree

See Page Main menu button Submenu
17 Controller Controller Status
Controller Setup
Summary Displays Analog Input Summary
Analog Output Summary
Analog Variable Summary
Digital Input Summary
Digital Output Summary
Digital Variable Summary
20 Serial Port S1
Serial Port S2
Ethernet Port E1
Ethernet Port E2
Expansion Rack
Communications
Modbus Slave Devices Modbus Slave Device n Modbus Slave n Status
Modbus/TCP Slave Device n Modbus/TCP Slave n Status
Host Connections Host Connection n Host Connection n Status
Peer Connections Peer Connections n Peer Connection n Status
36 Diagnostics Controller Diagnostics Rack n I/O Module Module Details
Details
I/O Module Diagnostics Rack n I/O Modules Module Details
I/O Calibration
Motor Setup
Communication Controller Communications
Diagnostics
Redundant Overview
Lead CPU Diagnostics
Reserve CPU Diagnostics
61 Station Settings View Data
Delete Data
Export Data to USB
Memory Device Utilities Download Controller
Configuration
Upload Controller
Configuration
Download Recipes
Upload Recipes
Download Security
Upload Security
Export Data Logs
Export Data to USB
Upload Database Image
Format Memory Device

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 Main Menu
Controller Status Controller

See Page Main menu button Submenu

Cellular Modem
Station Setup Languages
Adjust Display Brightness
Touch Calibration
Touch Test
Soft Key Test
Clean Screen
Station Status
Station Comm Ports
Change Passwords
62 Log On
64 Data Logging View Alarm & Event Logs
View Data Logs
View Audit Logs
Export Data Logs to USB
View Batch Groups Batch Groups Batch Header (if the
batch group selected is
not running a batch)
Batch Status (f the batch
group selected is running
a batch). The Batch
Status is for this batch
group only.
View Batch Status Batch Status (for all batch
groups)
Delete Data Log

Controller
Controller Status
This is a read-only display giving the status of various controller parameters.
Table 3 Controller status details

Item Description

Controller Type HC930, HC950, HC970, HC970R

Controller Name Configured controller name

Local Alias A locally referenced alias for the controller.

Control Firmware Revision level of the Controller software.

Revision Level

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Controller Controller Status

Item Description

Controller Mode Controller’s mode of operation:

RUN: Controller is running normally.

PROG: Controller is in Program mode.

OFLN: Controller is in Offline mode.

FAULT: A fault was found reading the Controller switch.

NO COMM: This is displayed if controller is not responding.

Frequency (Hz) Line frequency. Used for configuring the conversion time of the A/D converter.

Cycle Time (Sec) The analog control cycle time in seconds. This value is determined from the
execution time estimated from the configured control scheme. Cycle Time and
Fast Cycle Time increase (slow down) as the following increase: CPU % Used,
Fast CPU % Used, Dynamic Memory, Config Memory. Also, extensive use of
Free Form Logic blocks (as opposed to equivalent gate logic) can substantially
increase Fast Cycle Time.

CPU Percent used Calculation of percentage of time the CPU is active during the analog cycle time

Peak time (sec) Maximum time used to complete the analog cycle

Control Block Number of times that the processing of the analog control blocks exceeds the
Overruns allocated analog cycle time

Fast Logic Cycle Time Cycle Time and Fast Cycle Time increase (slow down) as the following
(Sec) increase: CPU % Used, Fast CPU % Used, Dynamic Memory, Config Memory.
Also, extensive use of Free Form Logic blocks (as opposed to equivalent gate
logic) can substantially increase Fast Cycle Time.

Fast Logic CPU Per Calculation of percentage of time the CPU is active during the processing of
Cent Used digital control blocks

Fast Logic Peak Time Maximum time used to complete the digital control cycle
(Sec)

Fast Logic CB Number of times that the processing of the digital control blocks exceeds the
Overruns allocated digital cycle time

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Controller Setup Controller

Controller Setup
The current controller mode is indicated on the bottom right of the display.
Table 4 Controller Setup details

Item Description
Set Controller Time Set the controller time and date.
and Date
Change mode of the Run Mode: Select this to resume running the process.
controller Offline Mode: Select this before performing AI calibration.
Program mode: Select this:
• Before performing AI and AO Calibration.
• To turn off all of the controller outputs while reconfiguring a control strategy.
Cold Start: Refreshes the Flash memory of the controller so that if your battery goes
dead the data in Flash is up to date. Use the Program mode for changes whenever
possible.
Write To Flash Write controller database to Flash memory. Controller must be in the Run, Run Locked,
or Offline Mode. Saves any parameters that you may have changed in the controller to
the controller’s non-volatile Flash memory. The affected parameters include:
Loop tuning parameters (gain, rate, reset, etc.)
Changes to Recipes, Profiles, Schedules, and Sequences.
If the write fails, upload the controller's configuration to the PC (using HC Designer) and
save the uploaded configuration to disk to make sure that you have captured all of the
non-volatile parameter changes.

Table 5 Controller modes defined

Mode Function Blocks Executed? Output status? Effect upon return to RUN mode?
RUN Yes Outputs updated None
OFFLINE No Outputs held Resume
PROGRAM No Outputs off Cold start

ATTENTION

You cannot change the controller mode from this display if the controller’s mode switch is in the
RUN LOCKED or PROGRAM LOCKED position. If the switch is in either of these locked
positions, this display will show the message “MODE MUST NOT BE LOCKED OR FAULT.”

TIP
• If the controller switch is set to RUN but the mode was set to PROGRAM or
OFFLINE here, following a power cycle the mode will return to RUN.
• Changing from Program to Run causes data in RAM (setpoint profiles, recipes,
schedules, sequences) to be copied to non-volatile (FLASH) memory.
• In a cold start, all data storage and display buffers are cleared and accumulated
values of some function blocks (such as totalizers) are reset.
• In a resume, all buffered data and values are retained and the process resumes
where it left off.

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Main Menu
Summary Displays About Summary Displays

Summary Displays
About Summary Displays
There are six summary displays to show the I/O blocks present in the Controller and the variables in the
configuration. The six summary displays are:
• Analog Input Summary
• Analog Output Summary
• Analog Variable Summary
• Digital Input Summary
• Digital Output Summary
• Digital Variable Summary
The Analog Input and Output Summary Displays show the following fields.
1. Physical Address of the Block (RMC)
• Rack Number
• Module Number
• Channel Number
2. Tag
3. Description
4. Value
5. Units
6. Error Status
The Analog Variable Summary Display shows the following fields:
1. Variable Number
2. Tag
3. Description
4. Value
5. Units

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About Summary Displays Summary Displays

The Digital Input Summary Display shows the following fields:

1. Physical Address of the DI Block (RMC)
• Rack Number
• Module Number
• Channel Number
2. Tag
3. Description
4. State
5. Error Status
The Digital Output Summary Display shows the same information as above plus the Type of the module.
The Digital Variable Summary Display shows following fields:
1. Variable Number
2. Tag
3. Description
4. Data

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Main Menu
Communications Menu Overview

Communications
Menu Overview

Menu Submenu

Serial Port S1 (p. 22)

Serial Port S2 (p. 22)

Ethernet Port E1 (p. 27)

Ethernet Port E2 (p. 27)

Expansion Port
Communications (p. 29)

Modbus Slave Devices (p. 31) Modbus Slave Device n Modbus Slave n Status

Modbus/TCP Slave Device n Modbus/TCP Slave n Status

Host Connections (p. 32) Host Connection n Host Connection n Status

Peer Connections (p. 33) Peer Connections n Peer Connection n Status

NOTE: The 15" control station can be programmed using only the Ethernet, serial and compact flash card.
The 900CS15's USB programming port conflicts with today’s PCs so it's advisable to use Ethernet ports for
configuration changes. This problem has been observed only with the 15" control station; the 10" control
station has not shown any problems with its USB ports.

Serial Port S1/S2

The Serial Port S1 and Serial Port S2 screens both show Statistics (Table 6) and Settings (Table 8) for those
controller serial ports.
Table 9 shows the relationship between the setup parameters and each protocol.
The controller’s Serial Port S1 can be set-up as an ELN Configuration port, a Modbus Master port, or a
Modbus Slave port. The ELN protocol allows the controller to communicate with the Hybrid Control
Designer package on the PC using the proprietary ELN protocol. The Modbus Master protocols allow the
controller to act as a Modbus Master, retrieving data from other instruments that have been configured as
Modbus slave devices. The three Modbus Slave protocols allow the controller to act as a slave to various
host devices, including a PC running HC Designer.
The information presented in Table 6 and Table 9 also applies to Serial Port S1 when a Redundant
Controller is used.

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 Main Menu
Serial Port S1/S2 Communications

Table 6 Serial Port S1/S2 Statistics (left side of display)

Item Description

Port Diagnostic Shows the overall condition of the Serial Port S1. See the list of Serial Port S1
diagnostic conditions in Table 7 on page 24.
Port Status This is the current status of the port. The possible status conditions are:
GOOD: the protocol is set to ELN.
REQUIRES SETUP: the protocol is set to one of the Modbus Slave protocols, and
the Slave Address is set to 255. Messages on the communication link are ignored
in this state.
OFFLINE: the protocol is set to one of the Modbus Slave protocols, and the Slave
Port Enable is set to DISABLE. Messages on the communication link are ignored
in this state.
ONLINE: the protocol is set to one of the Modbus Slave protocols, and the Slave
Port Enable is set to ENABLE. Messages on the communication link are being
processed in this state.
NO MODBUS SLAVE BLOCKS: the protocol is set to one of the Modbus Slave
protocols, but there are no Modbus slave function blocks present in the controller’s
configuration.
PROGRAM MODE: the protocol is set to one of the Modbus Slave protocols, but
the controller is in Program Mode. The controller does not scan the slave devices in
this state.
ELN SLAVE: the protocol is set to one of the Modbus Slave protocols, but the
controller is in Program Locked Mode. The port automatically reverts to ELN
protocol and the controller becomes a slave device whenever the mode selection
switch is placed in the Program Locked position.
SCANNING SLAVES: the protocol is set to one of the Modbus Slave protocols, and
the controller is actively scanning the slave devices attached to the port.
Messages Received The number of messages that were received and processed correctly.

Data Link Errors The number of basic link-level errors detected by the controller. If the protocol is
Modbus Master, the errors may be due to a slave device that does not reply when it
is scanned. Refer to the section “Troubleshooting Data Link Errors” (page 35) for
more information.
Application Errors The number of messages that were responded to with an exception code. For
example, application errors can be caused by (a) writing to a read-only register, (b)
accessing a register that is not supported by the slave device, or (c) using a
Modbus function code that is not supported by the slave device.
Clear Statistics This item resets the message counters for this port back to zero (Messages
Received, Data Link Errors, and Application Errors). Note: the counters will only be
reset if the controller is in Run Mode.

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Communications Serial Port S1/S2

Table 7 Serial Port S1/S2: Port Diagnostic status

Status Possible Cause Controller Action What to do
GOOD N/A N/A N/A
APPLICATION Applies to Port S2 1. Rack 1 monitor block’s At host, determine which message is
ERROR only. At least one COMPORT DIAG is set to causing the exception code and fix it.
response to a host WARNING.
resulted in an 2. Rack 1 monitor block’s
exception code or RACK OK pin is turned off.
NAK. 3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
DATA LINK A large number of 1. Rack 1 monitor block’s 1. Check baud rate.
ERROR messages are COMPORT DIAG is set to 2. Check connectors.
resulting in data link FAILED. 3. Check cable polarity.
errors. 2. Rack 1 monitor block’s 4. Isolate cable from electrical
RACK OK pin is turned off. interference.
3. SYSTEM MONITOR 5. If RS232-to-RS485 converter used,
block’s HW OK pin is check its power, switch/jumper settings,
turned off. and polarity.
4. If configured as Modbus
Master port, associated
slave blocks have their
read pin values frozen to
the last value read.
HARDWARE The DUART is failing Replace the controller CPU module.
FAILURE to operate properly.

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Serial Port S1/S2 Communications

Table 8 Serial Port S1/S2 Settings (right side of display)

Setting Description
Protocol ELN: The default protocol, used to communicate with the HC Designer
configuration software.

MODBUS MASTER: The controller acts as a Modbus Master device on the

communication link.

MB MASTER ADVANCED: The controller acts as a Modbus Master device on the

communication link. This protocol provides enhanced data throughput for
applications where the HC900 is being used with a “Modbus-to-fieldbus” gateway
device.

MODBUS SLAVE MULTI: The controller acts as a Modbus Slave device. This
protocol allows more than one slave device to be present on the communications
link (multi-drop).

MODBUS SLAVE PTP: The controller acts as a Modbus Slave device. This
protocol can be used if the controller is the only slave device on the link (Point-to-
point).

MODBUS SLAVE MODEM: The controller acts as a Modbus Slave device. This
protocol provides the extended delays that are needed to access the controller via
a modem.
Baud Rate (Bps) Select 9600, 19200, 38400, 57600 or 115200 bits per second.
Modbus Parity Select None, Odd, or Even parity.
Modbus Stop Bits Select 1 or 2 Stop Bits.
Slave Address (1-247 or This is the address of the controller on the Modbus link when one of the three
255) Modbus Slave protocols is selected. All devices on the link must have a unique
Modbus address. The address may be set to a value of 1 to 247, or it may be set
to 255. A value of 255 disables the port for this controller.
Slave Port Enable This item allows you to enable or disable the port:

ENABLE: The port will respond to communication requests.

DISABLE: The port will ignore communication requests.

Double Register Format Under the Modbus protocol, each IEEE 32-bit floating-point number requires two
consecutive Modbus registers, for a total of four bytes. The stuffing order of the
bytes within these registers differs among Modbus devices. To provide
compatibility with the various hosts, the double-register format is configurable. The
selections are:

FP B Big Endian format Byte order: 4, 3, 2, 1

FP L Little Endian format Byte order: 1, 2, 3, 4
FP BB Big Endian with byte-swap Byte order: 3, 4, 1, 2
FP LB Little Endian with byte-swap Byte order: 2, 1, 4, 3

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Communications Serial Port S1/S2

Table 9 Protocol selection versus setup parameters for the Serial Port S1/S2

Protocol selection

ELN Modbus Modbus Modbus Slave Modbus Slave

Master or Slave Point to Point Modem
Setup parameter Modbus Multidrop (PTP)
Master
Advanced

Baud Rate (BPS) X X X X X

Modbus Parity X X X NONE

Modbus Stop Bits X X X 1 BIT

Slave Address X X X

Slave Port Enable X X X

Double Register Format X X X

Note: When “Modbus Slave Modem” protocol is selected, the Modbus Parity and Modbus Stop Bits are fixed at
“None” and “1 Bit” respectively and cannot be changed.

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 Main Menu
Ethernet Port E1/E2 Status Communications

Ethernet Port E1/E2 Status

The Ethernet Port E1 and Ethernet Port E2 screens both show the following details for each Ethernet port
on the controller.

Table 10 Ethernet Port E1/E2 details

Item Description

Port Diagnostic Shows condition of Ethernet port. See Table 11 for status details.

Controller Name Configured controller name

Network Name The network name to which the controller belongs.

Local Alias A locally referenced alias for the controller.

Mac Address The controller’s Media Access Control address.

IP Address The controller’s Internet Protocol address.

Subnet Mask The controller’s subnet mask address.

Gateway IP Address The Internet Protocol address for the controller’s gateway device.

Double Register Format Each IEEE 32-bit floating point number requires two consecutive registers (four bytes,
MSB=4, LSB=1 in byte order below) starting with the register defined as the starting
register for the information. The stuffing order of the bytes into the two registers differs
among Modbus hosts. To provide compatibility, the Double register format is
configurable. Selections are:

FPB Floating Point Big Endian Format Byte order – 4, 3, 2, 1 (Default)

FP BB Floating Point Big Endian with byte-swapped Byte order – 3, 4, 1, 2

FP L Floating Point Little Endian Format Byte order – 1, 2, 3, 4

FP LB Floating Point Little Endian with byte-swapped Byte order – 2, 1, 4, 3

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Main Menu
Communications Ethernet Port E1/E2 Status

Table 11 Ethernet Port E1/E2: Port Diagnostic status

Status Possible Cause Controller Action What to do

GOOD N/A N/A N/A

SETUP ERROR Controller/network Rack 1 monitor block’s Correct the setup problem.
names determined on COMPORT DIAG is set to
network are illegal FAILED.

Rack 1 monitor block’s

RACK OK pin is turned off.

ASYS (SYSTEM
MONITOR) block’s HW OK
pin is turned off.

NO IP ADDRESS IP address is not Same as above If a DHCP server is present,

configured download a configuration that
uses DHCP.

Enter an IP address.

HARDWARE Ethernet port tests Same as above Replace CPU module.

FAILURE failed during power-up.

DHCP Failure DHCP is configured, Same as above Check the DHCP server.
and no IP address has
been granted. Download a configuration with
DHCP required.

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Expansion Rack Communications Communications

Expansion Rack Communications

Shows status of each controller expansion I/O rack.

Table 12 Expansion Rack Communication details

Item Description

Diagnostics Status Status of the rack’s communication port.

Message Count Number of message attempts to the rack.

Link Error Count Number of message attempts to the rack that resulted in failed response.

Total Count Total for all racks.

Clear Statistics Reset the messages and link error counters for all racks to zero.

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Main Menu
Communications Expansion Rack Communications

Table 13 Expansion Rack Communication Status

Status Possible Cause Controller Action What to do

GOOD Comm port is functioning N/A N/A
properly or comm port is
not used
DATA LINK The communications to a 1. Related rack monitor 1. Use the OI to determine which
FAILURE particular rack is resulting block’s RACK OK pin is rack is experiencing the comm
in a lot of communication turned off. errors. Verify that the expansion
errors. rack should be in the
2. Depending on the nature of configuration
the communication errors, the
associated rack monitor 2. Verify that the jumpers on the
block’s module diagnostics, scanner are setup for the correct
and pins could be affected. rack address.
3. Associated rack’s 3. If a hub is used, check that all
COMPORT DIAGNOSTIC is cables are properly connected to
set to FAILED. the hub, proper crossover cables
are used, and that hub is
4. Rack 1 COMPORT powered.
DIAGNOSTIC is set to
FAILED. 4. Cycle power to the rack.
5. Cycle power to the hub.
6. Replace the expansion rack’s
power supply.
7. Replace the expansion rack.
8. Replace the expansion rack’s
scanner board.
9. Replace the main CPU.
HARDWARE The power-up test of the 1. All rack monitor block XIO Replace main-CPU module
FAILURE expansion rack Ethernet PORT DIAG are set to
controller failed. HWFAIL and COMPORT
DIAGNOSTIC is set to FAIL.
2. All rack monitor block
RACK OK pins are turned off.
3. All modules in the
configuration have their
diagnostic set to
MOD_NOCOMM, their rack
monitor module fail pin is
turned on., and the rack
monitor block’s RACK OK pin
is turned off.
4. SYSTEM MONITOR
block’s HW OK pin is turned
off.
5. The statuses for the AO, AI,
DI, DO channels that are
affected are set to
BAD_CHANNEL.

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 Main Menu
Modbus Slave Devices Communications

Modbus Slave Devices

This display gives you an overview of the individual Modbus or Modbus/TCP slave devices attached to the
controller. Navigate to the desired device to see its status.

Table 14 Modbus Slave Status

Item Description
Slave Name Name of slave device.

Slave Address For Modus: 1-247 or 255. For Modbus/TCP: IP address.

In Scan Current scan status of slave device.

YES: The slave device is being scanned at its optimum rate. The scan rate is
computed by the controller.
NO: The slave device is being scanned at a reduced rate, or it is not being scanned
at all. The possible reasons are:
• SCAN ENABLED is set to NO.
• COMM QUALITY is NONE or BAD.
• the Modbus address of the slave device is set to 255.
• the slave device is not defined in the controller configuration.
• The RS-232 port protocol is not set to one of the Modbus Master protocols.

Comm Quality NONE: This slave device is not defined in the controller configuration.
GOOD: The slave device is being scanned at its optimum rate because its operation
on the communications link is acceptable.
BAD: The slave device is being scanned at a reduced rate because it has
experienced an abnormal number of failed responses. Refer to the section
“Troubleshooting a Comm Quality Problem” below.
Messages Received The number of messages that were received and processed correctly since the last
controller Cold Start.
Data Link Errors The number of basic link-level errors generated by this slave since the last controller
Cold Start. Refer to the section “Troubleshooting Data Link Errors” for more
information.
Application Errors The number of application errors generated by this slave since the last controller
Cold Start. Application errors are messages that the slave device responded to with
an exception code. For example, application errors can be caused by (a) writing to a
read-only register, (b) accessing a register that is not supported by the slave device,
or (c) using a Modbus function code that is not supported by the slave device.
Scan Enabled YES: Scanning has been enabled
NO: Scanning has been disabled

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Main Menu
Communications Host Connections

Host Connections
Table 15 Host Connections

Item Description

Connection Status Shows condition of each virtual connection.

See Host Connection Diagnostics Status Indicators, Table 16

Protocol The protocol used by the host to communicate with the controller (Modbus TCP).

IP Address The IP address of the host device that is using this connection.

Messages Received Number of messages received without errors.

Application Errors Number of message requests that resulted in an exception.

Clear Statistics Resets to zero the number of messages received and application errors.

Table 16 Host Connection Status Indicators

Status Possible Cause Controller Action What to do

GOOD N/A N/A N/A

APPLICATION At least one response to 1. Rack 1 monitor At host, determine which message
ERROR a host resulted in an block's COMPORT is causing the exception code and
exception code. DIAG is set to fix.
WARNING.

2. Rack 1 monitor
block's RACK OK
pin is turned off.

3. ASYS block's HW
OK pin is turned off

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 Main Menu
Peer Connections Communications

Peer Connections
.

Table 17 Peer Connections

Item Description

Peer Controller Name Controller name of the peer device. All peer devices must have the same network
name. All peer devices that share a common network name must have unique
controller names.

IP Address IP address of the peer. The IP address is automatically determined when a peer
device is discovered via its network and controller names.

Peer Status See Peer Connection Status Indicators, Table 18.

Messages Received Number of messages received from the peer device.

Messages Transmitted Number of messages sent to the peer device.

Write Requests Number of write event messages sent to the peer device.

Write Request Failures Number of write event messages that have not been acknowledged by the peer device
within the scan rate configured for the peer data exchange. A non-zero value means
the network is congested and message transfer is being impeded.

Producer Failures Number of times the peer device has not responded to a data exchange connection
request. Non-zero value means the peer device is not available because the controller
is in Program mode, controller power is off, or controller name does not exist in the
network. The network is defined as all devices that:

• are on the same physical network,

• are within the IP address range per the configured IP mask,

• share the same peer network name.

Clear Statistics Reset to zero the number of messages received and application errors.

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Communications Peer Connections

Table 18 Peer Connection Status

Status Possible Cause Controller Action What to do

GOOD N/A Peer is connected and N/A
updating normally
APPLICATION The peer connection N/A 1. Reset the controller to restart
ERROR could not be the UDP/IP protocol stack and
established due to an reset buffer allocations.
internal program
problem. 2. Contact Honeywell Technical
Assistance if the problem
exists.
SETUP ERROR The peer device The error will occur when Contact Honeywell Technical
indicated that the one an incompatibility exists Assistance if the status occurs.
or more data item is between peer devices with
not valid. regard to variable or signal
assignments.
This error should not
occur when exchanging
data between HC900
controllers.
PEER FAIL The assigned peer N/A 1. Check the controller name and
could not be located on network name of the peer
the network. device to assure that they
match that specific PDE block.
2. Check that the IP addresses of
the peer devices are all within
the range of the IP mask.
3. Check that the peer devices
have the same IP subnet mask.
See Network parameters for IP
mask setting.
PORT FAIL The peer data N/A 1. Reset the controller to restart
exchange IO the Ethernet IO hardware and
subsystem could not reassign processor IO
be started due to mapping.
internal resource
problem. 2. Contact Honeywell Technical
Assistance if the problem
exists.
NOT STARTED The assigned peer IO 1. If this status persists during run
connection has not yet time, check that the peer
been attempted. device is properly connected
Normal state during and that the control name and
startup and during network name is correct.
configuration mode.
This status should 2. Check that the IP masks of all
automatically change peer devices to assure that all
to GOOD after both IP addresses are within the
peer controllers are in same subnet.
the RUN mode.
3. Check that all external network
components such as switches
and routers allow passing of
UDP packets on port 502.
4. Check that the peer device is
powered on and is in RUN
mode.

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 Main Menu
Troubleshooting a Comm Quality problem Communications

Troubleshooting a Comm Quality problem

If a slave device is reporting a Comm Quality value of “BAD”, check the following items:
5. Verify that the slave device is powered-up.
6. Verify that the slave device is wired correctly.
7. Verify that the slave device has the correct slave address.
8. Verify that all slave devices on the link have a unique slave address.
9. Verify that the slave device has the correct baud rate and parity settings.
10. Verify that all slave devices on the link have the same baud rate and parity settings.
11. Verify that the slave is set-up for half-duplex operation.
12. If all slave devices report a BAD status, check the physical connection of the link to the controller’s
RS-232 port. If this connection is OK, check the connection to each slave device on the link.
13. If there is more than one slave device on the link, verify that the RS-232/RS-485 converter box is
working correctly.
14. Verify controller is set to unterminated for RS-485 communications.

Troubleshooting Data Link Errors

Data Link Errors can be caused by electrical noise, physical wiring problems, or incorrect configuration
settings. If a Master or Slave device is reporting Data Link Errors, check the following items:
15. Verify that the physical wiring of the communication link is correct.
16. Verify that the physical wiring is shielded from electrical noise.
17. Verify that all devices on the link have the correct baud rate and parity settings.
18. Verify that all terminating resistors are installed properly. Verify that the ohm-value of the
terminating resistors is correct.
19. Verify controller is set to unterminated for RS-485 communications.

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Main Menu
Diagnostics Menu Overview

Diagnostics
Touching the DIAGS indicator on the status bar will go to the System Diagnostics page so that you can see
at a glance the status of the H900 Controller. As the screen shot below shows, diagnostic information on
the CPU, Communications, and I/O Rack is displayed with green highlights indicating a good status or red
if there is a diagnostic. Touching the various buttons will direct you to the various detailed screens per the
menu tree below.

Menu Overview

Menu Submenu

Controller Diagnostics (p. 37) Rack n Diagnostics I/O Module Diagnostics Module Details (p.
(p. 42) 43)

Details.

This links to the main

Communications menu.
See page 22.

I/O Module Diagnostics (p. 42) Rack n I/O Modules (p. 42) Module Details (p. 43)

I/O Calibration (p. 159)

Motor Setup (p. 171)

Communication Diagnostics Controller Communications

This links to the main

Communications menu. See page
22.

Redundant Overview (p. 48)

Lead CPU Diagnostics (p. 56)

Reserve CPU Diagnostics (p. 56)

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Controller Diagnostics Diagnostics

Controller Diagnostics
Select a rack number to see its diagnostics. For I/O diagnostics and details, see pages 42 and 43.

Table 19 Rack n diagnostics

Item Status Possible Cause Controller Action What to do

Rack YES N/A N/A N/A
Configured?
NO N/A N/A N/A

Controller GOOD N/A N/A N/A

Status
FORCED OUTPUT A block has an output None Remove force on block output..
that is forced.
INVALID CONFIG. A configuration that An empty database is Download a valid configuration.
exceeds the loop created.
capacity of the
controller was
downloaded or an
invalid configuration
exists.
SWITCH FAULT A failure is detected in 1. All control blocks stop Replace CPU.
the switch reading. running
2. All I/O scanning ceases.
This forces the modules
into failsafe.
NO MASTER The controller The controller is not Select Modbus Master or Modbus
PORT configuration contains scanning the Modbus Master Advanced protocol for either the
at least one Modbus slave devices. RS-232 or RS-485 port.
slave block, but
neither the RS-232
nor the RS-485 port is
set up as a Modbus
Master port.

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Diagnostics Controller Diagnostics

Item Status Possible Cause Controller Action What to do

CPU Status GOOD N/A N/A N/A
WATCHDOG Watchdog reset 1. Associated rack monitor 1. Force a cold start.
ERROR resulting from block’s RACK OK pin is 2. Upgrade controller module software.
software failure turned off. 3. Replace CPU board.
2. SYSTEM MONITOR 4. Contact Honeywell Personnel.
block’s HW OK pin is
turned off.
PREFETCH CPU failed when 1. Controller performs a 1. Force a cold start.
ERROR attempting to fetch an restart 2. Isolate system from noise and force
instruction from the 2. Associated rack monitor a cold start.
prefetch register. block’s RACK OK pin is 3. Replace CPU board.
turned off.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
ADDRESS ERROR The reserved See PREFETCH ERROR.See PREFETCH ERROR.
exception occurred for
an unknown reason.
UNDEFINED Bad Instruction See PREFETCH ERROR See PREFETCH ERROR.
INSTR ERROR Detected
DATA ABORT CPU failed when See PREFETCH ERROR. See PREFETCH ERROR.
ERROR attempting to access
data.
S/W INTERRUPT Software Interrupt See PREFETCH ERROR. See PREFETCH ERROR.
ERR occurred which is not
supported by the
software.
VECTOR ERROR Corrupted interrupt Interrupt vectors were See WATCHDOG ERROR.
vectors in RAM. restored.

Memory GOOD N/A N/A N/A

Status
5 DAY BATTERY Estimated battery life 1. Associated rack monitor Replace battery.
WARNING is less than 5 days. block’s RACK OK pin is
turned off.
2. SYSTEM MONITOR
block’s HW OK pin is
turned off.
LOW BATTERY Battery voltage is low. 1. Associated rack monitor Replace battery.
block’s RACK OK pin is
turned off.
2. SYSTEM MONITOR
block’s LOW BATTERY
pin is turned on.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
FLASH ERROR Flash failed to burn 1. Associated rack monitor 1. Force a cold start.
block’s RACK OK pin is 2. Replace CPU board.
turned off.
2. SYSTEM MONITOR
block’s HW OK pin is
turned off.

I/O Status GOOD N/A N/A N/A

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Item Status Possible Cause Controller Action What to do

MODULE ERROR One of the module Select I/O from the menu Select I/O from the menu to see details
diagnostics in the to see details on the faulty on the faulty module. See I/O Module
associated rack is set module. See I/O Module Diagnostics on page 42.
to MISMATCH, BAD Diagnostics on page 42.
MODULE, BAD
CHANNEL., or
MISSING/NO COMM
(if the
communications is
failing due to the
module not
installed—could occur
if the module is
installed but CPU
can’t communicate to
it).
MODULE HI CJ One of the module Select I/O from the menu Select I/O from the menu to see details
TEMP diagnostics in the to see details on the faulty on the faulty module. See I/O Module
associated rack is set module. See I/O Module Diagnostics on page 42.
to HI CJ Diagnostics on page 42.
TEMPERATURE.
FAILURE The Controller All associated module 1. Remove modules and check for bent
module is unable to diagnostics are set to pins on connectors.
successfully MISSING/NO COMM. 2. Reinsert modules one at a time and
communicate to any note which module the diagnostic
modules that are in itsSee MISSING/NO COMM reoccurs, and replace that module.
SPI backplane. in Table 22 I/O Module 3. Cycle power to the rack.
Error Status on page 44 for 4. Replace the power supply.
further details. 5. Replace the rack.
6. Replace the CPU board.
NO COMM The Main CPU is See FAILURE. 1. Verify that the expansion rack should
unable to successfully be in the configuration
communicate to an 2. Verify that the jumpers on the
expansion rack that is scanner are setup for the correct rack
in its configuration. address.
3. Check that expansion rack is on.
4. Check the expansion rack’s status
LED for diagnostic information.
5. Check that cable is connected to
expansion rack.
6. If a hub is used, check that all cables
are properly connected to the hub,
proper crossover cables are used, and
that hub is powered.
7. Cycle power to the rack.
8. Cycle power to the hub.
9. Replace the expansion rack’s power
supply.
10. Replace the expansion rack.
11. Replace the expansion rack’s
scanner board.
12. Replace the main CPU.

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Diagnostics Controller Diagnostics

Item Status Possible Cause Controller Action What to do

BAD VERSION The Main CPU All associated module 1. Upgrade the scanner software either
determined that its diagnostics are set to by replacing the module or doing a
software is not MISSING/NO COMM. code-download.
compatible with the Refer to MISSING/NO 2. Update Main CPU software either by
scanner module. COMM diagnostic for replacing the module or doing a code
further details. download.

RTC Status GOOD N/A N/A N/A

NOT RTC not programmed 1. Time and date is set to Program RTC.
PROGRAMMED 00:00:00, January 1, 1970.
2. Associated rack monitor
block’s RACK OK pin is
turned off.
3. SYSTEM MONITOR
block’s HW OK pin is
turned off.
BAD DATA Bad date and time See NOT 1. Program RTC.
PROGRAMMED. 2. Cycle power.
3. Replace CPU.
4. Replace boards in rack.
5. Replace rack.
PROGRAMMING RTC failed to program See NOT See BAD DATA.
FAILURE PROGRAMMED.
READ FAILURE Unable to read RTC See NOT See BAD DATA.
PROGRAMMED.

Comm Port Good N/A N/A N/A

Status (Rack
1)
IO Comm
Link Status
(Rack 2-5)

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Controller Diagnostics Diagnostics

Item Status Possible Cause Controller Action What to do

Data Link Failure The communications 1. Related rack monitor 1. Use the OI to determine which rack
to a particular rack is block’s RACK OK pin is is experiencing the DLL errors. Verify
resulting in a lot of turned off. that the expansion rack should be in
DLL errors. the configuration
2. Depending on the
nature of the DLL errors, 2. Verify that the jumpers on the
the associated rack scanner are setup for the correct rack
monitor block’s module address.
diagnostics, and pins
could be affected. 3. If a hub is used, check that all
cables are properly connected to the
hub, proper crossover cables are
used, and that hub is powered.

4. Cycle power to the rack.

5. Cycle power to the hub.

6. Replace the HC900-C50 expansion

rack’s power supply.

7. Replace the HC900-C50 expansion

rack.

8. Replace the HC900-C50 expansion

rack’s scanner board.

9. Replace the main CPU.

Hardware Failure The power-up test of 1. All rack monitor block Replace main-CPU module
the expansion rack XIO PORT DIAG are set
Ethernet controller to HWFAIL.
failed.
2. All rack monitor block
RACK OK pin are turned
off.

3. All modules in the

configuration have their
diagnostic set to
MOD_NOCOMM, their
rack monitor module fail
pin is turned on., and the
rack monitor block’s
RACK OK pin is turned
off.

4. ASYS block’s HW OK
pin is turned off.

5. The statuses for the AO

and AI channels that are
affected are set to
BAD_CHANNEL.

Port A/B Cable C70R only. The I/O Controller continues to run Swap the cables so that I/O A is
Mismatch cables from CPUA but is not able to access connected to I/O on CPUA and I/O B
and CPUB are the I/O on the associated is connected to I/O on CPUB
connected to the rack
wrong ports on the
I/O scanner CPU

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Diagnostics I/O Module Diagnostics and I/O Calibration

Item Status Possible Cause Controller Action What to do

Protocol Mismatch C70R only. The Controller continues to run Upgrade the firmware in the CPU
firmware version in but is not able to access and/or scanner to be compatible
the controller CPU is the I/O on the associated versions
not compatible with rack
the firmware version
in the I/O scanner

I/O Module Diagnostics and I/O Calibration

Select a rack to see its I/O module diagnostics. For I/O Calibration, see page 159.

Table 20 I/O module diagnostics

Item Description

MODULE Slot number in the rack.

PHYSICAL TYPE NONE

AI UNIVERSAL 8-CHAN
AI LO-LEVEL 16-CHAN
AI HI-LEVEL 8-CHAN
AO CURRENT 4-CHAN
AO VOLTAGE 4-CHAN
DI DRY-CONTACT 16-CHAN
DI 120/240 VAC 16-CHAN
DI 24 VDC 16-CHAN
DO LO-CURRENT RLY 8-CHAN
DO HI-CURRENT RLY 4-CHAN
DO 120/240 VAC 8-CHAN
DO 24 VDC 16-CHAN
AI HI-LEVEL 16-CHAN
DI 24 VDC 32-CHAN
DO 24 VDC 32-CHAN
PULSE/FREQ/QUAD 4-CHAN
HIGH LEVEL AO 8 CHANNEL
HIGH LEVEL AO 16 CHANNEL
CONFIGURED AS Analog Input, Analog Output, Digital Input, Digital Output, Pulse Frequency
Quadrature

ERROR STATUS See Table 22.

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I/O Module Diagnostics and I/O Calibration Diagnostics

Table 21 I/O module Details

Item Description

MODULE Slot number in the rack.

PHYSICAL TYPE NONE
AI UNIVERSAL 8-CHAN
AI LO-LEVEL 16-CHAN
AI HI-LEVEL 8-CHAN
AO CURRENT 4-CHAN
AO VOLTAGE 4-CHAN
DI DRY-CONTACT 16-CHAN
DI 120/240 VAC 16-CHAN
DI 24 VDC 16-CHAN
DO LO-CURRENT RLY 8-CHAN
DO HI-CURRENT RLY 4-CHAN
DO 120/240 VAC 8-CHAN
DO 24 VDC 16-CHAN
AI HI-LEVEL 16-CHAN
DI 24 VDC 32-CHAN
DO 24 VDC 32-CHAN
PULSE/FREQ/QUAD 4-CHAN
HIGH LEVEL AO 8 CHANNEL
HIGH LEVEL AO 16 CHANNEL
PART NUMBER The re-order part number of the module.

FIRMWARE REV. Revision level of the firmware running on this module.

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Diagnostics I/O Module Diagnostics and I/O Calibration

I/O Module Error Status

Table 22 I/O Module Error Status

Status Possible Cause Controller Action What to do

HI CJ TEMP Possible causes of 1. Associated AI blocks that are configured 1. Improve ventilation to rack
this diagnostic are: as T/Cs set their fail pin on, their warn pin
off, and their output pin to the failsafe value. 2. Replace AI module
1. One of the two CJs
on the module is 2. Associated AI blocks that are configured
indicating a as T/Cs set their IO status to “CJ High
temperature reading Temperature” for reason 1 or “CJ Failure”
greater than 70 for possible causes 2 and 3.
degrees C.
3. Associated rack monitor block’s module
2. Both cold-junction fail pin is turned on.
sensors are failing to
convert. 4. Associated rack monitor block’s RACK
OK pin is turned off.
3. The CJs are
converting properly, 5. Associated rack monitor block’s
but their differential is HITEMP pin is turned on.
greater than 10
degrees C. 6. SYSTEM MONITOR block’s HITEMP
pin is turned on.

7. SYSTEM MONITOR block’s HW OK

pin is turned off.
MISMATCH The installed module 1. Associated blocks set their fail pin on, 1. Verify configuration
does not agree with their warn pin off, and their output pin to the
the module required failsafe value. 2. Replace module with the correct one.
for the control
strategy downloaded 2. Associated blocks set their IO status to
in the configuration “Channel No Comm”.
file.
3. Associated rack monitor block’s module
fail pin is turned on.

4. Associated rack monitor block’s RACK

OK pin is turned off.

5. SYSTEM MONITOR block’s HW OK

pin is turned off.

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I/O Module Diagnostics and I/O Calibration Diagnostics

Status Possible Cause Controller Action What to do

MISSING/NO Main CPU is unable See MISMATCH. Action is based on the RACK STATUS
COMM to communicate to indication. If RACK STATUS is not
the module for one of MODULE ERROR, then follow the
the following reasons: prescribed action defined for the RACK
STATUS diagnostic.
1. Module is not
installed For MODULE ERROR, do the following:

2. The module cannot 1. Verify configuration

communicate with the
controller CPU or the 2. Install module.
expansion rack CPU
because of a
backplane problem.

3. Module is on an
expansion rack and
the expansion rack
communications is
failing
BAD MODULE Module is reporting a See MISMATCH. User should inspect the module’s status
diagnostic condition. LED to determine the nature of the
See Table 23. problem. Table 23 describes the user
action for the various LED diagnostics.
BAD See Table 24 1. Associated block sets its fail pin on, its See Table 24
CHANNEL warn pin off, and its output pin to the
failsafe value.
2. Associated block sets its IO status as
denoted in Table 24.
3. Associated rack monitor block’s module
fail pin is turned on.
4. Associated rack monitor block’s RACK
OK pin is turned off.
5. SYSTEM MONITOR block’s HW OK
pin is turned off.

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Diagnostics I/O Module Diagnostics and I/O Calibration

Bad module details

When an I/O module’s error status is BAD MODULE, the module’s status LED on the controller is flashed
red with a number of quick strobes followed by a long off time. Table 23 outlines the potential module
diagnostics.
Table 23 Bad module details
Numberof Failure Description AI AO DI DO PFQ UserAction
Strobes
Contact AC DC Relay AC DC
1 FAIL SAFE The module is in the failsafe state √ √ √ √ √ √ √ √ √ 1. If expansion I/O rack, go to step 2. If
because it is not receiving message no expansion I/O rack, go to step 3.
requests from the CPU or Scanner 2. Check the Scanner status LED (see
at a rate that satisfies the configured Scanner Indicators in HC900 Hybrid
failsafe timeout. Controller manual, #51-52-25-107).
If it’s flashing 6 times, proceed
with step 3.
If it’s flashing some other red
status code (refer to Scanner
Indicators in HC900 Hybrid
Controller manual, #51-52-25-107)
to solve that problem first.
If it’s flashing green, the module
probably is not required in the
configuration.
If it’s not on or steady, cycle
power to the scanner.
3. Make sure the module is the correct
one for the configuration.
4. Remove the module and check for
a bent pin, then reinsert the module
5. Replace the module
6. Remove other modules and replace
one at a time until the problem
reoccurs. Most likely the last module
inserted needs to be replaced.
7.Replace the rack.
2 EAROM EA ROM Failed its checksum √ √ 1. Remove/reinsert module.
2. Replace module.
3 RAM √ √ √ √ √ √ √ √ √
4 ROM √ √ √ √ √ √ √
5 +24 V √ √ √ √ 1. Remove the module and check
for a bent pin, then reinsert the
module
2. Measure power supply voltage. If
not correct, replace power supply.
3. Replace module
4. Replace rack
6 FACTORY CAL CRC failure of primary and backup √ √ Replace module.
factory calibration
7 FIELD CAL CRC failure of field calibration √ √ 1. Remove/reinsert module.
values 2. Replace module.
8 HARDWARE General Hardware Failure √ Replace module.
(AI=convertor not working)
9 HW/SW Key The software residing on the √ √ √ √ √ Replace module
module does not match the module
type. This diagnostic should only
result in the factory.
11 Shift Register The loopback test of the shift √ √ √ √ √ √ Replace module
register failed.

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I/O Module Diagnostics and I/O Calibration Diagnostics

Bad channel details

Below is a list of conditions that can cause a BAD CHANNEL I/O module diagnostic.

Table 24 Bad Channel details

I/O Summary Error Status Description What to do

Bad Channel If the channel is an Analog Output: There is no Check terminal block
physical output device connected to this connections.
channel, or the output device is showing an
open connection. Replace module.

If the channel is a Pulse Output: The channel is

failing to output the correct value.

A BAD CHANNEL I/O module diagnostic is

posted.

Burnout Fail The sensor – T/C, RTD, or mV source -- is Check terminal block connections
failing burnout checks. A BAD CHANNEL I/O
module diagnostic is posted. Replace source element

Replace module.

Convert Fail When attempting to take a reading, the analog- Check the signal level being
to-digital (ADC) fails. This can occur if the applied to the terminals.
incoming signal is either too large or too small.
It also could result if the ADC circuit is failing. If Replace module.
the problem is the ADC circuit, most likely other
channels will have the same failure. A BAD
CHANNEL I/O module diagnostic is posted.

No Channel There is no hardware on the I/O module to

support this channel. For example, the
customer configured Channel #15 for a given
module, but there is an 8-channel module
installed in the rack. A BAD CHANNEL I/O
module diagnostic is posted.

Over Current A Digital Output module detected an excessive

amount of current on its output terminals. Note
that this message will only appear for the 32-
channel DO module. A BAD CHANNEL module
diagnostic is posted.

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Diagnostics Communication Diagnostics

Communication Diagnostics
This links to the main Communications menu. See page 20.

Redundant Overview
This display summarizes the status of all of the major components of a redundant system.

Table 25 Redundant Overview

Item Status Possible Cause Controller Action What to do

RESERVE RESERVE Normal operation N/A N/A
STATUS AVAILABLE
RESERVE NOT 1. Reserve not ) The lead controller Install reserve CPU
AVAILABLE installed in rack. will continue to
2. Power not applied control the process, Apply power to reserve CPU
to reserve CPU but failover is not
3. Neither lead nor possible.
Download a configuration and
reserve CPU has a cold start the controller
valid configuration
database
4. Firmware Perform a firmware upgrade so
mismatch (lead both CPUs have the same
and reserve CPUs version
have different
firmware revisions
5. Database not Replace the reserve CPU. If
synchronized with this doesn’t help, replace the
the lead lead CPU. If this doesn’t help,
) replace the backplane.
REDUNDANCY GOOD Normal operation N/A N/A
STATUS
NO RSM MODULE Switch on RSM is set The controller will Make sure switch is in desired
DETECTED between two positions. continue to operate position
with a missing RSM.
RSM Module is not Automatic failover is Install RSM module
inserted still possible if
required.

RSM Module has failed Replace RSM

RSM SWITCH IS Switch is indicating an The controller will ) Replace RSM
BAD invalid position continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.

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Redundant Overview Diagnostics

Item Status Possible Cause Controller Action What to do

I/O COMM ERROR Reserve CPU is unable The lead controller Verify all cabling between the
ON RESERVE to communicate with will continue to reserve CPU and the scanners.
one or more of the I/O control the process.
racks. Failover to the Replace any Ethernet switches
reserve is still between the reserve CPU and
possible if a the I/O rack(s).
subsequent failure
renders the current
lead less capable Replace the reserve CPU
than the reserve.
Replace the scanner CPU

Contact Honeywell service

DATABASE NOT Hardware failure on the The lead controller Replace the reserve CPU
SYNCHRONIZED reserve CPU will continue to
control the process,
Hardware failure on the but failover is not
possible. Replace the lead CPU
lead CPU
Replace the CPU rack backplane
Hardware failure on the Contact Honeywell service
CPU rack backplane
INVALID CONFIG. Neither CPU has a valid An empty database Download the desired
configuration database is created. configuration file and perform a
cold start.
FIRMWARE The reserve controller The lead controller Upgrade the CPU firmware so
VERSION does not have the same will continue to both the lead and reserve have
MISMATCH version of controller control the process, the same version.
firmware installed but failover is not
possible.
CONTROLLER GOOD N/A N/A N/A
STATUS FORCED OUTPUT A block has an output None Remove force on block output..
that is forced.
INVALID CONFIG. A configuration that An empty database Download a valid configuration.
exceeds the loop is created.
capacity of the controller
was downloaded or an
invalid configuration
exists.
SWITCH FAULT RMS switch is indicating The controller will Replace RSM
an invalid position continue to operate
with a bad RSM.
Automatic failover is
still possible if
required.
NO MASTER The controller The controller is not Select Modbus Master or
PORT configuration contains at scanning the Modbus Master Advanced
least on Modbus slave Modbus slave protocol for either the RS-232 or
block, but Serial Port S1 devices. RS-485 port.
is not set up as a
Modbus Master port.

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Diagnostics Redundant Overview

Item Status Possible Cause Controller Action What to do

RSM SWITCH The lead and reserve The controller will Replace the RSM
MISMATCH controller are both continue to operate
reading the switch on with a bad RSM. Replace the reserve CPU
the RSM, but are getting Automatic failover is
different values. still possible if
required. Force a failover and replace the
new reserve CPU

Contact Honeywell service

NO RSM MODULE Switch on RSM is set The controller will Make sure switch is in desired
DETECTED between two positions. continue to operate position
with a missing RSM.
RSM Module is not Automatic failover is Install RSM module
inserted still possible if
required. )

RSM Module has failed Replace RSM

BAD RSM SWITCH Switch is indicating an The controller will Replace RSM
(LEAD) invalid position continue to operate
with a bad RSM. Force a failover and replace the
Automatic failover is CPU (formerly the lead, now the
still possible if reserve)
required.
BAD RSM SWITCH Switch is indicating an The controller will Replace RSM
(RESERVE) invalid position continue to operate
with a bad RSM. Replace the reserve CPU
Automatic failover is
still possible if
required.

Item Status Possible Cause

CPU STATUS GOOD
MEMORY STATUS ERROR IN RACK 1 REFER TO Table 26 (page 51)
RTC STATUS ERROR IN RACK 2 REFER TO Table 26 (page 51)
I/O RACK COMM PORT ERROR IN RACK 3 REFER TO Table 26 (page 51)
STATUS ERROR IN RACK 4 REFER TO Table 26 (page 51)
RACK I/O MODULE ERROR IN RACK 5 REFER TO Table 26 (page 51)
STATUS ERROR IN LEAD CPU REFER TO Table 27 (page 57)
COMM PORTS ERROR IN RESERVE CPU REFER TO Table 27 (page 57)
E1/E2/S1/S2 STATUS ERROR ON SERIAL PORT S1 REFER TO Table 7 (page 24)
ERROR ON SERIAL PORT S2 REFER TO Table 7 (page 24)
ERROR ON E1 NETWORK PORT REFER TO Table 11 (page 28)
ERROR ON E2 NETWORK PORT REFER TO Table 11 (page 28)
ERROR ON SCANNER I/O LINK REFER TO Table 26 (page 51)

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Redundant Overview Diagnostics

Table 26 Details of Rack diagnostics error status messages

Item Status Possible Cause Controller Action Fix

CPU GOOD N/A N/A N/A
ADDRESS ERROR The reserved See PREFETCH See PREFETCH ERROR.
exception occurred for ERROR.
an unknown reason.
PREFETCH ERROR CPU failed when 1. Controller 1. Force a cold start.
attempting to fetch an performs a restart 2. Isolate system from noise and
instruction from the 2. Associated rack force a cold start.
prefetch register. monitor block’s 3. Replace CPU board.
RACK OK pin is
turned off.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
DATA ABORT CPU failed when See PREFETCH See PREFETCH ERROR.
ERROR attempting to access ERROR.
data.
S/W INTERRUPT Software Interrupt See PREFETCH See PREFETCH ERROR.
ERR occurred which is not ERROR.
supported by the
software.
UNDEFINED INSTR Bad Instruction See PREFETCH See PREFETCH ERROR.
ERROR Detected ERROR
WATCHDOG Watchdog reset 1. Associated rack 1. Force a cold start.
ERROR resulting from software monitor block’s 2. Upgrade controller module
failure RACK OK pin is software.
turned off. 3. Replace CPU board.
2. SYSTEM 4. Contact Honeywell Service.
MONITOR
block’s HW OK
pin is turned off.
VECTOR ERROR Corrupted interrupt Interrupt vectors See WATCHDOG ERROR.
vectors in RAM. were restored.
MEMORY GOOD N/A N/A N/A
5 DAY BATTERY Estimated battery life is 1. Associated rack Replace battery.
WARNING less than 5 days. monitor block’s
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
LOW BATTERY Battery voltage is low. 1. Associated rack Replace battery.
monitor block’s
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s LOW
BATTERY pin is
turned on.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.

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Item Status Possible Cause Controller Action Fix

FLASH ERROR Flash failed to burn 1. Associated rack 1. Force a cold start.
monitor block’s 2. Replace CPU board.
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
POWER GOOD N/A N/A N/A
SUPPLY DIAG POWER SUPPLY A scanner has I/O rack continues to Verify that the power supply is
PS-1 FAILED redundant power function normally connected to a power source
supplies installed and using the remaining
the one identified as power supply
PS-1 is not working
Failed Power Supply Replace power supply
Failed Redundant Requires unit shutdown – replace
Power Backplane redundant power backplane
detection circuit
Failed Rack backplane Requires unit shutdown – replace
status signal rack backplane.
Failed Scanner2 status Requires unit shutdown – replace
input Scanner2.
Contact Honeywell Service.
POWER SUPPLY A scanner has I/O rack continues to Verify that the power supply is
PS-2 FAILED redundant power function normally connected to a power source
supplies installed and using the remaining
the one identified as power supply
PS-2 is not working
Failed Power Supply Replace power supply
Failed Redundant Requires unit shutdown – replace
Power Backplane redundant power backplane
detection circuit
Failed Rack backplane Requires unit shutdown – replace
status signal rack backplane.
Failed Scanner2 status Requires unit shutdown – replace
input Scanner2.
Contact Honeywell Service.
POWER UNKNOWN No Rack If under power, I/O Determine and correct cause of
SUPPLY communication will switch to failsafe communication failure.
STATUS values
Loss of Comms Determine and correct cause of
communication failure.
If not powered (un- Restore rack operation
powered outputs)

Loss of AC mains Restore AC mains power, reset

breaker
Bad Power Supply Replace Power Supply
Failed Scanner2 Replace Scanner2

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Redundant Overview Diagnostics

Item Status Possible Cause Controller Action Fix

REDUNDANT P/S IS Single Power Supply Rack continues to No action required if single
NOT PRESENT configuration function properly power supply rack

Redundant Power If dual power supply is

Backplane not installed:
detected Replace Redundant
Power Backplane
Replace rack backplane
Replace Scanner2
POWER SUPPLY A scanner has I/O rack continues to Verify that the power supply
PS-1 FAILED redundant power function normally is connected to a power
supplies installed and using the remaining source
the one identified as power supply
PS-1 is not working
Failed Power Supply Replace power supply
Failed Redundant Requires unit shutdown –
Power Backplane replace Redundant Power
detection circuit Backplane
Failed Rack backplane Requires unit shutdown –
status signal replace rack backplane.
Failed Scanner2 status Requires unit shutdown – replace
input Scanner2.

Contact Honeywell Service.

POWER SUPPLY A scanner has I/O rack continues to Verify that the power supply
PS-2 FAILED redundant power function normally is connected to a power
supplies installed and using the remaining source
the one identified as power supply
PS-2 is not working
Failed Power Supply Replace power supply
Failed Redundant Requires unit shutdown –
Power Backplane replace redundant power
detection circuit backplane
Failed Rack backplane Requires unit shutdown –
status signal replace rack backplane.
Failed Scanner2 status Requires unit shutdown –
input replace Scanner2.
Contact Honeywell Service.
BOTH POWER N/A None None
SUPPLIES ARE
GOOD
LEAD CPU CPU-A CPU-A is currently the N/A N/A
POSITION lead
CPU-B CPU-B is currently the N/A N/A
lead
CPU IS MISSING Reserve CPU is not The lead controller Install reserve CPU
installed or not will continue to
powered. control the process, Apply power to reserve CPU
but failover is not
CPU rack backplane possible.
Replace CPU rack backplane
failure
Contact Honeywell Service.

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Diagnostics Redundant Overview

Item Status Possible Cause Controller Action Fix

LEAD I/O GOOD Normal operation N/A
COMM DIAG DATA LINK • Scanner2 address Controller continues 1. Verify that the address
FAILURE switches are not in to run but is not able switches on the scanner 2 are
the correct position to access the I/O on set correctly.
• An I/O cable is the associated rack 2. If a hub is used, check that all
unplugged. cables are properly connected
• Cables are defective to the hub, proper crossover
or are not properly cables are used, that the hub
shielded is powered, and it supports
• If a hub is used, it 100 Base-T.
may be powered 3. Check cable shielding for
down. proper grounding and noise
• The Scanner2 is immunity.
powered down. 4. Make sure the cables have the
• The Scanner2 is correct pin out.
defective 5. Cycle power to the Scanner 2.
6. Cycle power to the hub.
7. Cycle power to the C70R.
8. Replace the expansion rack’s
scanner module.
9. Replace the expansion rack’s
power supply.
10. Replace the expansion rack.
11. Replace the main CPU.
HARDWARE ) The I/O interface has a Controller continues Replace the CPU.
FAILURE hardware failure. to run but is not able
to access any I/O.
PORT A/B CABLE The I/O cables from Controller continues Swap the cables so that I/O A is
MISMATCH CPUA and CPUB are to run but is not able connected to I/O on CPUA and
connected to the to access the I/O on I/O B is connected to I/O on
wrong ports on the I/O the associated rack CPUB
scanner CPU
PROTOCOL The firmware version Controller continues Upgrade the firmware in the CPU
MISMATCH in the controller CPU is to run but is not able and/or scanner to be compatible
not compatible with the to access the I/O on versions
firmware version in the the associated rack
I/O scanner
LEAD I/O NO Possible causes are Controller continues See the fix defined for the LEAD
COMM COMMUNICATIONS defined by the LEAD to run but is not able I/O COMM DIAG that is being
STATUS I/O COMM DIAG that to access the I/O on reported.
is being reported. the associated rack
MARGINAL: PORT Rack communication Controller continues 1. Check cable shielding for
I/O A with CPU-A is to run but is proper grounding and noise
experiencing a high marginally immunity.
error rate accessing the I/O 2. Check connectors of all
on the associated cables.
rack 3. If a hub/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables.

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Redundant Overview Diagnostics

Item Status Possible Cause Controller Action Fix

MARGINAL: PORT Rack communication Controller continues 1. Check cable shielding for
I/O B with CPU-B is to run but is proper grounding and noise
experiencing a high marginally immunity.
error rate accessing the I/O 2. Check connectors of all
on the associated cables.
rack 3. If a hub/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables
GOOD: PORT I/O A Normal operation N/A N/A
GOOD: PORT I/O B Normal operation N/A N/A
NOT USED IN THIS None of the I/O N/A N/A
CONFIGURATION modules contained in
this rack are being
used to execute the
control configuration
that is currently running
in the controller.
RESERVE I/O GOOD N/A N/A N/A
COMM DIAG DATA LINK • Scanner2 address Controller continues 1. If LEAD I/O COMM DIAG is
FAILURE switches are not in to run but is not able also “DATA LINK FAILURE”,
the correct position to access the I/O on follow the Fix defined for that
• An I/O cable is the associated rack diagnostic.
unplugged. 2. If a hub is used, check that all
• Cables are defective cables are properly connected
or are not properly to the hub, proper crossover
shielded cables are used, that the hub
• If a hub is used, it is powered, and it supports
may be powered 100 Base-T.
down. 3. Check cable shielding for
• The Scanner2 is proper grounding and noise
powered down. immunity.
• The Scanner2 is 4. Make sure the cables have the
defective correct pin out.
5. Cycle power to the hub.
6. Cycle power to the C70R.
7. Replace the main CPU.
8. Cycle power to the Scanner 2.
9. Replace the expansion rack’s
scanner module.
10. Replace the expansion rack’s
power supply.
11.Replace the expansion
rack.

HARDWARE The I/O interface has aController continues Replace the CPU.
FAILURE hardware failure. to run but is not able
to access any I/O.
PORT A/B CABLE The I/O cables from Controller continues Swap the cables so that I/O A is
MISMATCH CPUA and CPUB are to run but is not able connected to I/O on CPUA and
connected to the wrong to access the I/O on I/O B is connected to I/O on
ports on the I/O the associated rack CPUB
scanner CPU

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Diagnostics Lead/Reserve CPU Diagnostics

Item Status Possible Cause Controller Action Fix

PROTOCOL The firmware version in Controller continues Upgrade the firmware in the CPU
MISMATCH the controller CPU is to run but is not able and/or scanner to be compatible
not compatible with the to access the I/O on versions
firmware version in the the associated rack
I/O scanner
RESERVE I/O NO Possible causes are Controller continues See the fix defined for the
COMM COMMUNICATIONS defined by the to run but is not able RESERVE I/O COMM DIAG that
STATUS RESERVE I/O COMM to access the I/O on is being reported.
DIAG that is being the associated rack
reported.
MARGINAL: PORT Rack communication Controller continues 1. Check cable shielding for
I/O A with CPU-A is to run but is proper grounding and noise
experiencing a high marginally immunity.
error rate accessing the I/O 2. Check connectors of all
on the associated cables.
rack 3. If a hub/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables.

MARGINAL: PORT Rack communication Controller continues 1. Check cable shielding for
I/O B with CPU-B is to run but is proper grounding and noise
experiencing a high marginally accessing immunity.
error rate the I/O on the 2. Check connectors of all
associated rack cables.
3. If a HUB/switch is being used,
verify that it is one that is
recommended by Honeywell
4. Replace cables.
GOOD: PORT I/O A Normal operation N/A N/A
GOOD: PORT I/O B Normal operation N/A N/A
NOT USED IN THIS None of the I/O N/A N/A
CONFIGURATION modules contained in
this rack are being
used to execute the
control configuration
that is currently running
in the controller.
I/O MODULE GOOD
DIAGNOSTICS MODULE ERROR The detailed information for the I/O MODULE DIAGNOSTICS entry in
MODULE HI CJ the table above is also shown in Table 19 in the main part of the manual,
TEMP under the “I/O” Class.
FAILURE
NO COMM
BAD VERSION

Lead/Reserve CPU Diagnostics

These displays show the status of the Lead and Reserve CPU modules in the redundant system. The same
categories of status information are shown for Lead or Reserve. The CPU Position parameter on each
display identifies which physical CPU module is currently acting as the Lead or Reserve.
Refer to Table 27 through for a description of the information contained on these displays.

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Lead/Reserve CPU Diagnostics Diagnostics

Table 27 Details of Lead or Reserve CPU diagnostics error status messages

Class Status Possible Cause Controller Action Fix

RESERVE RESERVE Normal operation N/A N/A
STATUS AVAILABLE
RESERVE NOT 1. Reserve not installed The lead controller Install reserve CPU
AVAILABLE in rack. will continue to
2. Power not applied to control the process, Apply power to reserve CPU
reserve CPU but failover is not
3. Neither lead nor possible.
Download a configuration and cold
reserve CPU has a start the controller
valid configuration
database
4. Firmware mismatch Perform a firmware upgrade so
(lead and reserve both CPUs have the same version
CPUs have different
firmware revisions
5. Database not Replace the reserve CPU. If this
synchronized with doesn’t help, replace the lead
the lead CPU. If this doesn’t help, replace
the backplane.

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Diagnostics Lead/Reserve CPU Diagnostics

Class Status Possible Cause Controller Action Fix

CPU POSITION CPU-A N/A Normal operation
CPU-B N/A Normal operation )
CPU IS MISSING Reserve CPU is not The lead controller Install reserve CPU
installed or not powered. will continue to
control the process, Apply power to reserve CPU
CPU rack backplane but failover is not
failure possible.
Replace CPU rack backplane

Call Honeywell service

CPU GOOD N/A N/A N/A
ADDRESS The reserved exception See PREFETCH See PREFETCH ERROR.
ERROR occurred for an unknown ERROR.
reason.
PREFETCH CPU failed when 1. Controller 1. Force a cold start.
ERROR attempting to fetch an performs a restart 2. Isolate system from noise and
instruction from the 2. Associated rack force a cold start.
prefetch register. monitor block’s 3. Replace CPU board.
RACK OK pin is
turned off.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
DATA ABORT CPU failed when See PREFETCH See PREFETCH ERROR.
ERROR attempting to access ERROR.
data.
S/W Software Interrupt that is See PREFETCH See PREFETCH ERROR.
INTERRUPT not supported by the ERROR.
ERR software occurred.
UNDEFINED Bad Instruction Detected See PREFETCH See PREFETCH ERROR.
INSTR ERROR ERROR
WATCHDOG Watchdog reset resulting 1. Associated rack 1. Force a cold start.
ERROR from software failure monitor block’s 2. Upgrade controller module
RACK OK pin is software.
turned off. 3. Replace CPU board.
2. SYSTEM 4. Contact Honeywell Personnel.
MONITOR
block’s HW OK
pin is turned off.
VECTOR Corrupted interrupt Interrupt vectors See WATCHDOG ERROR.
ERROR vectors in RAM. were restored.
MEMORY GOOD N/A N/A N/A
5 DAY BATTERY Estimated battery life is 1. Associated rack Replace battery.
WARNING less than 5 days. monitor block’s
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.

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Lead/Reserve CPU Diagnostics Diagnostics

Class Status Possible Cause Controller Action Fix

LOW BATTERY Battery voltage is low. 1. Associated rack Replace battery.
monitor block’s
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s LOW
BATTERY pin is
turned on.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
FLASH ERROR Flash failed to burn 1. Associated rack 1. Force a cold start.
monitor block’s 2. Replace CPU board.
RACK OK pin is
turned off.
2. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
RTC GOOD N/A N/A N/A
NOT RTC not programmed 1. Time and date is Program RTC.
PROGRAMMED set to 00:00:00,
January 1, 1970.
2. Associated rack
monitor block’s
RACK OK pin is
turned off.
3. SYSTEM
MONITOR
block’s HW OK
pin is turned off.
BAD DATA Bad date and time See NOT 1. Program RTC.
PROGRAMMED. 2. Cycle power.
3. Replace CPU.
4. Replace boards in rack.
5. Replace rack.
PROGRAMMIN RTC failed to program See NOT See BAD DATA.
G FAILURE PROGRAMMED.
READ FAILURE Unable to read RTC See NOT See BAD DATA.
PROGRAMMED.

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Diagnostics Lead/Reserve CPU Diagnostics

Class Status Possible Cause Controller Action Fix

I/O RACK GOOD Normal operation N/A
COMM PORT DATA LINK • Scanner2 address Controller continues 1. Verify that the address
FAILURE switches are not in the to run but is not able switches on the scanner 2 are
correct position to access the I/O on set correctly.
• An I/O cable is the associated rack 2. If a hub is used, check that all
unplugged. cables are properly connected
• Cables are defective or to the hub, proper crossover
are not properly cables are used, that the hub
shielded is powered, and it supports
• If a hub is used, it may 100 Base-T.
be powered down. 3. Check cable shielding for
• The Scanner2 is proper grounding and noise
powered down. immunity.
• The Scanner2 is 4. Make sure the cables have the
defective correct pin out.
5. Cycle power to the Scanner 2.
6. Cycle power to the hub.
7. Cycle power to the C70R.
8. Replace the expansion rack’s
scanner module.
9. Replace the expansion rack’s
power supply.
10. Replace the expansion rack.
11.Replace the main CPU.
HARDWARE ) The I/O interface has a Controller continues Replace the CPU.
FAILURE hardware failure. to run but is not able
to access any I/O.
PORT A/B The I/O cables from Controller continues Swap the cables so that I/O A is
CABLE CPUA and CPUB are to run but is not able connected to I/O on CPUA and I/O
MISMATCH connected to the wrong to access the I/O on B is connected to I/O on CPUB
ports on the I/O scanner the associated rack
CPU
PROTOCOL The firmware version in Controller continues Upgrade the firmware in the CPU
MISMATCH the controller CPU is not to run but is not able and/or scanner to be compatible
compatible with the to access the I/O on versions
firmware version in the I/O the associated rack
scanner
NETWORK REFER TO Table 11 Ethernet Port E1/E2: Port Diagnostic status page 28
PORT E1
NETWORK REFER TO Table 11 Ethernet Port E1/E2: Port Diagnostic status page 28
PORT E2
SERIAL PORT REFER TO Table 7 Serial Port S1/S2: Port Diagnostic status page 24
S1
SERIAL PORT REFER TO Table 7 Serial Port S1/S2: Port Diagnostic status page 24
S2

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 Main Menu
View Data Station Settings

Station Settings
View Data
Lets you view data on the CompactFlash card. Touch the + and – buttons to scroll through the folder and
file names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.

Delete Data
Lets you delete data on the CompactFlash card. Touch the + and – buttons to scroll through the folder and
file names. Touch Delete button to delete a file or folder. Touch Delete All to delete all data on
CompactFlash card.

Export Data to USB

Note. USB 3.0 support is only available on the 900CS10.
Lets you export data from the CompactFlash to USB. Insert USB memory device into Port A. (Export does
not function without USB device inserted.)
Total Memory and Free Memory are displayed for CompactFlash and USB memory device. Touch the Get
CF Status or Get USB Status buttons to update status.
Touch Export All Data button to export CompactFlash data to the USB device. USB device must have
enough free memory.
Export Selected Data button shows CompactFlash data and USB memory device data. Press >> and << to
transfer data between the two devices.

Note:
1. File/ folders can’t be copied from USB memory device to CompactFlash’s LOG folder.
2. There may be a delayed response in actions involving the USB memory device since it is an external
device.

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Station Settings Format Memory Device

Format Memory Device

Lets you format CompactFlash or USB device.
Note that the Control Station uses the FAT16 file system. You may achieve better performance if the
memory device is formatted on the Control Station as opposed to your computer.

Station Setup
Lets you:
• Change languages
• Adjust display brightness
• Calibrate the touch screen
• Test the touch screen
• Test the soft membrane keys left of the display
• Clean the screen – this disables the touch screen. Use when cleaning the screen or when replacing the
optional protective film that covers the screen.

Station Status
Shows the status of the Control Station.
• Versions of boot loader, firmware, application
• Path and name of HC900 configuration file being monitored by the Control Station
• Time and cause of last several Control Station restarts

Station Comm Ports

Shows status of the Control Station’s communication ports (Ethernet, RS232 program, RS232 Comm,
RS485).

Change Passwords
Lets you change user passwords.

Language Menu Selection

Lets you change the language on the Control Station UI. Use one of the following methods to change the
language.
• Go to Station Setup Menu > Languages.
or
• Click the flag icon present on the screen.

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Language Menu Selection Log On

Select the required language.

Log On
Enter name and password. Once logged on, your level of access to displays and functions depends on the
security credentials you were configured for.

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Alarms and Events Alarm Access

Alarms and Events

Alarm Access
Use the Alarms icon to access all the alarms present in Control Station.

Alarm Definition
• 900 Control Station shows both the HC900 Controller alarms and Station alarms on the same alarm
console.
• Station alarms can be configured for a .cde file tag present in the .sds configuration. An alarm can be
defined in the desired tag properties.
• In Controller configuration, a desired tagged point present in the controller can be designated as an alarm
point.

Alarm Indicator
• When there are no alarms present, alarm icon and text on status indicator are grayed out.
• When an alarm is active, the text is displayed in white color and the background turns red.
• Status indicator flashes when an alarm is active and not acknowledged. Acknowledge the alarm to stop
the flashing.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the indicator will
turn yellow and continue to flash until acknowledged.

Display Details
• Alarm Console - 900 Control Station shows both the HC900 Controller alarms and Station alarms on the
same alarm console.
• Alarms programmed to automatically acknowledge when the alarm clears may also be manually
acknowledged while the alarm is active, halting the flashing indications on the alarm displays.

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Alarm Groups Alarms and Events

Alarm Groups
The Alarm Groups screen shows the status of the alarm groups of the controller. Touch an Alarm Group
button to open its Alarm Group display. There is a button at the bottom of the Alarm Groups screen to
access Station alarms.

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Alarms and Events Alarm Group Indication

Alarm Group Indication

• When there are no active alarms present, the background is gray with black text indicating NORMAL.
• When any alarm within a group is active, the text is displayed in white color and the background turns
red.
• For active, non-acknowledged alarms the background turns red, text changes to Unacknowledged and
flashes.
• Once acknowledged, the alarm background remains red until the alarm condition goes away, the text
changes to Acknowledged and the background stops flashing.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the background
will turn yellow, the text will remain Unacknowledged and continue to flash until acknowledged.

Alarm Group Overview

The Alarm Group screen shows the status of each point present in the selected Alarm Group.

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Alarm Point Indication Alarms and Events

Alarm Point Indication

• When an alarm is not active, the background is white with black text indicating Normal and the alarm
indicator light is gray.
• When any alarm is active, the alarm indicator light turns red, flashes and the text changes to
Unacknowledged.
• Once acknowledged, the alarm indicator light stops flashing, remains red until the alarm condition goes
away and the text changes to Acknowledged.
• If the alarm condition goes away (clears) before the operator acknowledges the alarm, the alarm
indicator light will turn yellow and continue to flash until acknowledged. The text will change to
Cleared.

Alarm Point Detail

Following details are displayed.
• Tag name
• Last time the selected point was in alarm state
• Last time the selected point went out of alarm state
• Number of occurrences

Event Access
All the events are accessed through the Alarm and Event Summary indicator present on the bottom of all
pages.

Event Definition
• 900 Control Station shows both the HC900 Controller events and Station events on the same Alarm and
Event Summary console.
• Station events can be configured for a .cde file tag present in the .sds configuration. An event can be
defined in the Alarms tab of the desired tag properties.
• In Controller configuration, a desired tagged point present in the controller can be designated as an event
point.

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Alarms and Events Event Indication

Event Indication
• When an Event exists, the event text appears in black color and the background of Alarms and Event
Status indicator turns yellow.
• When no event exists, no text is present on status indicator and it is grayed out.

Display Details
• Alarm and Event Summary – It displays the time stamp and text of each alarm and event.

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View Alarm & Event Logs Data Logging

Data Logging

View Alarm & Event Logs

Lets you view the alarm and event logs. Touch the + and – buttons to scroll through the folder and file
names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.

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Data Logging View Data Logs

View Data Logs

Lets you view the data log files on CompactFlash. Touch the + and – buttons to scroll through the folder
and file names. Touch Open button to open a folder or file. Touch Back to go back to the top level folder.

View Audit Logs

Lets you view the audit log. The audit log is a record of actions performed by users. Touch the + and –
buttons to scroll through the folder and file names. Touch Open button to open a folder or file. Touch Back
to go back to the top level folder. Touch the Show Data Logs button to view the data logs and touch the
Show Batch Logs button to view the batch logs.

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Export Data Logs to USB Data Logging

Export Data Logs to USB

Lets you export data logs from the CompactFlash to USB. Insert USB memory device into Port A. (Export
does not function without USB device inserted.). Note: USB 3.0 support is only available on the 900CS10.
Total Memory and Free Memory are displayed for CompactFlash and USB memory device. Touch the Get
CF Status or Get USB Status buttons to update status. Touch Export All Data button to export
CompactFlash data to the USB device. USB device must have enough free memory.
Export Selected Data button shows CompactFlash data and USB memory device data. Press >> and << to
transfer data between the two devices.

File/ folders can’t be copied from USB memory device to CompactFlash’s LOG folder.

View Batch Groups & View Batch Status

(Concurrent Batch for Control Station)
The operator at the 900 Control Station can simply touch the LOGS button on the master slide to access the
Data Logging menu. (Alternately, you can touch the soft key Menu > Data Logging.) The Data Logging
menu has two buttons on it for concurrent batch. View Batch Groups and View Batch Status.
View Batch Groups Summary Display
The operator can touch the View Batch Groups button on the Data Logging menu to display the Batch
Groups display. This display shows a summary of which batch groups have a batch running in them. A
green arrow on a batch group button means a batch is running, while a red square means a batch is not
running:

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Data Logging View Batch Groups & View Batch Status

Touching a batch group button that has a batch running retrieves the details for that batch:

Touching a batch group button that does not have a batch running retrieves the batch header display so that
the identification details of the next batch can be entered. Note that in the picture which follows, the values
entered from the last batch were retained. This is Data Logger property Retain Header in Station Designer
under the Data Logger’s Groups tab, so the field values shown are not empty.

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View Batch Groups & View Batch Status Data Logging

NOTE: The batch names for the batches within a batch group (batch set) must be unique and must be
between 1 and 8 characters in length and must contain only characters that are valid in a folder name.
The other header field values can be of any length, although a maximum of 48 characters is recommended.
If you specify a very long value, note that it can overflow its data box. Just touch on a data box to the right
of a field name to specify its value. Touch the Confirm Header button when you are satisfied with your
entries:

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Data Logging Delete Data Logs

View Batch Groups Detail Display

The operator can touch the View Batch Status button on the Data Logging menu to display the Batch
Status display. This display shows detailed information for all of the batch groups. For each batch group,
it indicates whether a batch is running or not, when the batch starts, when the batch stops, and the duration
for each running and stopped batch. By touching one of the small blue batch group buttons on the left-hand
side of the display, you can view the batch header details for any batch group. Touch the Close button to
close the batch header details box:

Delete Data Logs

Lets you view one or all data log files on CompactFlash. Use the + and – buttons to navigate through the
folder and files.

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Download Configuration Files Downloading and Uploading Controller Configuration

Downloading and Uploading Controller Configuration

Lets you download the .cde configuration file directly from the Control Station onto the HC900 controller.
You can also upload the .cde configuration file from the HC900 controller to the Control Station.

Download Configuration Files

1. Go to Station Settings > Memory Device Utilities > Download Controller Configuration Display.
The Download Controller Configuration dialog box appears.

2. All the .cde files and folders present in the Compact Flash and USB Drive are listed. Select a drive to
view the files present in that drive. Press Open to open the file/folder and to show its contents. Press
Back to close the opened file/folder. Press Close to close the dialog box.
3. Select a file and press Download. The Download Controller Configuration dialog box appears.

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Downloading and Uploading Controller Configuration Download Configuration Files

4. Press Start Download to start the process. A progress bar indicates the percentage of completion.
5. Once the download is complete, the Controller Download Complete dialog box appears.

6. Select one of the following options as required and continue.

• Hot Start: Updated the configuration settings.
• Cold Start: To re-initialize the memory.
• Stay in Program Mode: Remains in program mode.
• Abort: To cancel the download operation.

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Upload Controller Configuration Downloading and Uploading Controller Configuration

In case you select Hot Start the following warning appears on the screen.

Press Yes to continue and complete the operation.

Upload Controller Configuration

1. Go to Station Settings > Memory Device Utilities > Upload Controller Configuration Display.
The Upload Controller Configuration dialog box appears.

2. All the .cde files and folders present in the Compact Flash and USB Drive are listed. Select a drive to
view the files present in that drive. Press Open to open a folder and to show its contents. Press Open
to select a file. Press Back to close the opened file/folder. Press Close to close the dialog box.

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Main Menu
Downloading and Uploading Controller Configuration Upload Controller Configuration

3. Select a file and press Upload. The Upload Controller Configuration dialog box appears.

4. Press Start Upload to start the process. A progress bar indicates the percentage of completion.
5. Once the upload is complete, the Controller Upload Complete dialog box appears.

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Upload Controller Configuration Uploading Database Image

Uploading Database Image

Lets you upload an image.sdi file from Control Station to an external device (compact flash or USB
memory device).
1. On the Memory Device Utilities menu, press Upload Database Image. Use this option to export an
image file to a memory device.

2. The Select Location for uploading database image dialog box is displayed. Select a location.

Depending on your device selection, image.sdi file is created on either compact flash or USB
memory device. On successful file upload, Successfully Uploaded Database Image message is
displayed. In case the upload fails, Error in uploading database image message is displayed.
3. When the Control Station is powered on, the image.sdi file is automatically detected from the compact
flash and starts uploading the file to the Control Station. Loading From CF message appears on the
screen.
To upload an image .sdi file from a memory stick appropriate settings must be enabled via Station
Designer, the PC configuration tool. (see manual 51-52-25-149).

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Main Menu
Uploading and Downloading Recipe Files Download Recipe Files

Uploading and Downloading Recipe Files

Using the 900 Control Station you can upload the recipe files from a controller to a USB memory device.
You can also download the recipe files present in the USB Memory device or Compact Flash card onto the
controller. You can upload and download the following recipe files.
• Variable Recipe (.rcp)
• Profile Recipe (.prf)
• Sequence Recipe (.seq)
• Schedule Recipe (.sch)

Download Recipe Files

1. Go to Main Menu > Station Settings > Memory Device Utilities > Download Recipe. The Select
Download Recipe Type dialog box appears.

2. Select a file to download. You can select Download Variable Recipe File, Download Profile Recipe
File, Download Sequence Recipe File, or Download Schedule Recipe File.
3. Browse to the file that you want to download. File can be present in C: or D: drive.
4. Click Download. The Download to Location dialog box appears. Please note that the below screen
appears only when you select Download Variable Recipe File in step 1.

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Upload Recipe Files Uploading and Downloading Recipe Files

5. Select a recipe location and press Start to proceed. Use the Previous and Next buttons to toggle
between the various recipe pages.
6. The Edit Variable Recipe page is displayed. Click Download to download the edited or selected
recipe file onto the controller.

7. Press Save to save the changes made in the recipe file. The changes are saved to the file in the
memory device.
On successful file download, File Downloaded Successfully message is displayed. In case the download
fails, an error message is displayed.
Similar method is used for downloading different types of recipe file.

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Uploading and Downloading Recipe Files Upload Recipe Files

Upload Recipe Files

1. Go to Main Menu > Station Settings > Memory Device Utilities > Upload Recipe. The Select Upload
Recipe Type dialog box appears.

2. Select a file to upload. You can select Upload Variable Recipe File, Upload Profile Recipe File,
Upload Sequence Recipe File, or Upload Schedule Recipe File.
3. Select a location to save the file. File can be saved in C: or D: drive. By default file is saved as
Upload1. However, you can overwrite the file name.

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Upload Recipe Files Uploading and Downloading Recipe Files

4. Click Upload. The Upload from Location dialog box appears. Please note that the below screen
appears only when you select Upload Variable Recipe File in step 1

5. Select a recipe location and press Start to proceed. Use the Previous and Next buttons to toggle
between the various recipe pages.
6. The Edit Variable Recipe page is displayed. Click Upload to upload the edited or selected recipe
file.

7. Press Save to save the changes made in the recipe file. The changes are saved to the file in the
memory device.
On successful file upload, File Uploaded Successfully message is displayed. In case the upload fails, an
error message is displayed.
Similar method is used for uploading different types of recipe file.

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Main Menu
Uploading and Downloading Security Settings Upload Security Displays and Functionality

Uploading and Downloading Security Settings

You can upload the security settings (password) from Control Station to memory Devices and download
them to the Control Station holding database with the same GUID.

Upload Security Displays and Functionality

1. Go to Main Menu > Station Settings > Memory Device Utilities > Upload Security. The Upload
Security Database dialog box appears.

2. Select a location and type a file name to save the security settings. The Upload button is enabled and
‘.dat’ extension is added to the file name.
3. Press Upload to upload the file to the database. The following message appears indicating the
successful upload of security file.

In case the upload fails, the following message is displayed.

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Upload Security Displays and Functionality Uploading and Downloading Security Settings

By default, Security is used as the file name. If you over write the file name, you are prompted with the
following message. Press Yes or No as required.

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Using Barcode Reader Download Security Displays and Functionality

Download Security Displays and Functionality

1. Go to Main Menu > Station Settings > Memory Device Utilities > Download Security. The
Download Security Database dialog box appears.

Note: A USB memory device or CompactFlash card must be connected to Control Station or else an error
message is displayed.
2. Browse and open the file that you want to download.
3. Press Download. The selected file gets downloaded from the selected location. A success message
appears on successful completion of file download.
In case the download fails, an error message is displayed.

Using Barcode Reader

1. Touch a data box on the Control Station. A keypad appears.
2. Scan a bar code. Data appears in the entry area of keypad pop-up.
If the bar code reader includes carriage return and line feed, the keypad pop-up goes away and the data
appears in the data box.
If carriage return and line feed are not included in the scan, the user touches the Enter button on the
keypad, the pop-up goes away, and the data appears in the data box.

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Overview
Access
Press the Home key to access an array of 16 buttons. See example below. Your actual buttons may vary.
Each button takes you to a display that was custom-configured for your HC900’s process.

Widget displays
Your Control Station’s process displays were configured using a variety of objects such as figures,
symbols, text boxes, and widgets. A widget is a graphical object designed to work with a specific function
block type in your HC900’s process configuration. For example, some widgets, like Digital Pushbutton,
perform a simple on/off function for monitoring and controlling a digital signal. Other widgets have many
functions. For example, a loop PID widget lets you not only view and adjust the loop’s SP and output, but
also lets you jump to detailed displays for the loop (such as loop setup, trending, tuning, alarm setpoints,
and output limiting).

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Overview Widget displays

The table below lists all the widgets that may appear on your displays. Your actual displays may vary.

Widget type See page

Pushbuttons, signals and variables 90

AGA8DL & AGA8GS 91

4-Selector Switch 97

Device Control 98

Hand/Off/Auto Switch 100

Stage 101

Ramp 103

Alternator 105

Calendar Event 109

Wireless transmitters 113

Setpoint Programmers 119

Setpoint Schedulers 133

Sequencers 141

Loops (A/M Bias, Carbon, On/Off, PID, 3 Position Step Control) 147

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How to edit a parameter Overview

How to edit a parameter

On all displays, a white box with black border indicates an editable parameter. In the example below,
Profile Name is editable. A white box with no border is read-only (for example, Profile Number).

When you touch the box a popup appears. See popup types below.

Popup type Example Details

Text entry Functions like

typical keyboard.

Alphanumeric Functions like

entry typical numeric
keypad.

Menu
Use to
scroll through
available choices.

Buttons common to all popups:

Cancel change or exit without saving changes.

Save changes.

Tab to other writable fields on the display.

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Pushbuttons, signals and variables

Pushbuttons, signals and variables

This table shows the widgets that are simplest in appearance and function.

Example Widget type Function

Analog Pushbutton Push button to change

displayed value.

Digital Pushbutton Push button to toggle displayed

state.

Analog Signal Read-only shows value of

analog signal. No actions.

Digital Signal Read-only shows state of a

digital signal. No actions.

Analog Variable Touch value to edit.

Digital Variable Touch state to edit.

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AGA8DL & AGA8GS

AGA8DL & AGA8GS

The Detail method (AGA8DL) uses the gas analysis of up to 21 components. From the gas analysis, the
super-compressibility factor, gas density at flowing and standard conditions, and gas relative density at
standard conditions are calculated for input into the AGA calculation for the meter type chosen. Used when
accurate gas analysis is available either via an on-line gas analyzer or from laboratory measurements. The
Detail method can handle up to 21 gas components typically found in natural gas. If this information is
available, the Detail method is preferable, as accurate results are obtainable over a wider range of
conditions than the Gross method.
The Gross method (AGA8GS) is used to approximate natural gas by treating it as a mixture of three
components, equivalent hydrocarbon component, Nitrogen and Carbon Dioxide. It is typically used for dry,
sweet (no H2S) natural gas. There are two methods used: Gross Method 1 calculates the super-
compressibility and gas density from knowledge of the relative density, heating value and carbon dioxide,
hydrogen and carbon monoxide components. Gross Method 2 calculates the super-compressibility and gas
density from knowledge of the relative density, Nitrogen, carbon dioxide, hydrogen and carbon monoxide
components.

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AGA8DL & AGA8GS

Table 28 AGA Parameters

Parameter Description

TF Temperature at flow in units selected by the UNITS configuration parameter.

PF Pressure at flow in units selected by the UNITS configuration parameter.

HW Differential pressure in the units selected by the UNITS configuration

parameter. (Only required if the meter block is AGA3.)

RHOTP Density at flow temperature and pressure conditions in units selected by the
UNITS configuration parameter.

RHOB Density at base conditions in units selected by the UNITS configuration

parameter.

RHOS Density at standard conditions in units selected by the UNITS configuration

parameter.

FPVS Super-compressibility factor

GRS Real Gas relative density at 60 deg F/14.73 PSI

(Mgas*Zair)/(Mair*Zgas)

where Zair = .9995844 and Mair = 28.96256

HV Heating Value in units selected by the UNITS configuration parameter.

ERR On when calculation status is indicating an error condition. See Status.

WARN On when calculation status is indicating a warning condition. See Status.

STATUS Use the Status number to cross-reference the error or warning. See Table 29
AGA Error Codes.

Table 29 AGA Error Codes

Status Block type Severity Description

number
0 ALL Good OK – NO ERRORS OR WARNINGS ENCOUNTERED
1 AGA 8 - DETAIL Error PRESSURE HAS A NEGATIVE DERIVATIVE
2 AGA 8 - DETAIL Warning DENSITY IN BRAKET EXCEEDS MAXIMUM DEFAULT
PROCEDURE USED
3 AGA 8 - DETAIL Error MAXIMUM ITERATIONS EXCEEDED IN BRAKET
4 AGA 8 - DETAIL Error MAXIMUM ITERATIONS IN DDETAIL EXCEEDED
5 AGA 8 - GROSS Error THE ROOT WAS NOT BOUNDED IN DGROSS
6 AGA 8 - GROSS Error NO CONVERGENCE IN DGROSS
7 AGA 8 - GROSS Error VIRGS SQUARE ROOT NEGATIVE
8 AGA 8 - GROSS Error COMBINED VALUES OF GRGR, X[2] AND HV NOT
CONSISTENT
9 AGA 8 - GROSS Error INVALID TERM IN VIRGS
12 AGA 8 - GROSS Error FLOWING PRESSURE (PF) <= 0.0 PR > 1740.0 PSIA
13 AGA 8 - GROSS Error FLOWING TEMPERATURE (TF) < 14.0 OR > 149.0 DEG F

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Status Block type Severity Description

number
14 AGA 8 - GROSS Error HEATING VALUE (HV) < 477.0 OR > 1211.0 BTU/FT^3
15 AGA 8 - GROSS Error GAS RELATIVE DENSITY (GRGR) < 0.55 OR > 0.870
16 AGA 8 - GROSS Error MOLE FRACTION FOR N2 < 0.0 OR > 0.50
OR FOR CO2 < 0.0 OR > 0.30
OR FOR H2 < 0.0 OR > 0.10
OR FOR CO < 0.0 OR > 0.03
17 AGA 8 - GROSS Error REFERENCE TEMPERATURE < 32.0 OR > 77.O DEG F
18 AGA 8 - GROSS Error REFERENCE PRESSURE < 13.0 OR > 16.0 PSIA
22 AGA 8 - GROSS Warning FLOWING PRESSURE (PF) <=0.0 OR > 1200.0 PSIA
23 AGA 8 - GROSS Warning FLOWING TEMPERATURE (TF) < 32.0 OR > 130.0 DEG F
24 AGA 8 - GROSS Warning HEATING VALUE (HV) < 805.0 OR > 1208.0 BTU/FT^3
25 AGA 8 - GROSS Warning GAS RELATIVE DENSITY (GRGR) < 0.55 OR > 0.800
26 AGA 8 - GROSS Warning MOLE FRACTION FOR N2 < 0.0 OR > 0.20
OR FOR CO2 < 0.0 OR > 0.20
OR FOR H2 < 0.0 OR > 0.0
OR FOR CO < 0.0 OR > 0.0
32 AGA 8 - DETAIL Error FLOWING PRESSURE (PF) < 0.0 OR > 40,000. PSIA
33 AGA 8 - DETAIL Error FLOWING TEMPERATURE (TF) < -200 OR > 760 DEG F
36 AGA 8 - DETAIL Error MOLE FRACTION FOR METHANE < 0.0 OR > 1.0
FOR NITROGEN < 0.0 OR > 1.0
FOR CARBON DIOXIDE < 0.0 OR > 1.0
FOR ETHANE < 0.0 OR > 1.0
FOR PROPANE < 0.0 OR > 0.12
FOR WATER < 0.0 OR > 0.10
FOR H2S < 0.0 OR > 1.0
FOR HYDROGEN < 0.0 OR > 1.0
FOR CARBON MONOXIDE < 0.0 OR > 0.03
FOR OXYGEN < 0.0 OR > 0.21
FOR BUTANES < 0.0 OR > 0.06
FOR PENTANES < 0.0 OR > 0.04
FOR HEXANES + < 0.0 OR > 0.10
FOR HELIUM < 0.0 OR > 0.03
FOR ARGON < 0.0 OR > 1.0
37 AGA 8 - DETAIL Error REFERENCE TEMPERATURE < 32.0 OR > 77.0 DEG F
38 AGA 8 - DETAIL Error REFERENCE PRESSURE < 13.0 OR > 16.0 PSIA
39 AGA 8 - DETAIL Error SUM OF MOLE FRACTIONS < 0.98 OR > 1.020
42 AGA 8 - DETAIL Warning FLOWING PRESSURE (PF) < 0.0 OR > 1750. PSIA
43 AGA 8 - DETAIL Warning FLOWING TEMPERATURE (TF) < 17 OR > 143 DEG F

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AGA8DL & AGA8GS

Status Block type Severity Description

number
46 AGA 8 - DETAIL Warning MOLE FRACTION FOR METHANE < 0.45 OR > 1.0
FOR NITROGEN < 0.0 OR > 0.5
FOR CARBON DIOXIDE < 0.0 OR > 0.3
FOR ETHANE < 0.0 OR > 0.1
FOR PROPANE < 0.0 OR > 0.04
FOR WATER < 0.0 OR > 0.0005
FOR H2S < 0.0 OR > 0.0002
FOR HYDROGEN < 0.0 OR > 0.1
FOR CARBON MONOXIDE < 0.0 OR > 0.03
FOR OXYGEN < 0.0 OR > 0.0
FOR BUTANES < 0.0 OR > 0.01
FOR PENTANES < 0.0 OR > 0.003
FOR HEXANES + < 0.0 OR > 0.002
FOR HELIUM < 0.0 OR > 0.002
FOR ARGON < 0.0 OR > 0.0
49 AGA 8 - DETAIL Warning SUM OF MOLE FRACTIONS < 0.9999 OR > 1.0001
52 AGA 3 - ORIFICE Error FLOWING PRESSURE WAS <= 0.0 OR > 40000. PSIA
53 AGA 3 - ORIFICE Error FLOWING TEMPERATURE < -200. OR > 760. DEG F
55 AGA 3 - ORIFICE Error ORIFICE DIAMETER WAS >= 100.0 INCHES
56 AGA 3 - ORIFICE Error PIPE DIAMETER WAS >= 100.0 INCHES
57 AGA 3 - ORIFICE Error FLOWING OR STANDARD DENSITY WAS <= 0.0
LBM/FT^3
58 AGA 3 - ORIFICE Error DIFFERENTIAL PRESSURE WAS <= 0.0 INCHES H2O
65 AGA 3 – ORIFICE Error SUPERCOMPRESSIBILITY FACTOR WAS <= 0.0
66 AGA 3 – ORIFICE Error RELATIVE DENSITY AT STANDARD CONDITIONS WAS <
0.07 OR > 1.52
68 AGA 3 – ORIFICE Error COMPRESSIBILITY FACTOR AT STANDARD
CONDITIONS <= 0.0
69 AGA 3 – ORIFICE Error BETA RATIO (DO/DM) <= 0.0 OR => 1.0
75 AGA 3 – ORIFICE Warning ORIFICE DIAMETER WAS < = 0.45 INCHES
76 AGA 3 – ORIFICE Warning PIPE DIAMETER WAS <= 2.0 INCHES
77 GENERAL Error ERROR INVALID COMPANION BLOCK
CONFIG INTERCONNECTION
78 GENERAL Error METER/COMPRESSIBLITY BLOCK UNITS ARE
CONFIG INCONSISTENT
79 AGA 3 - ORIFICE Warning BETA RATIO (DO/DM) WAS < 0.1 OR > 0.75
99 GENERAL N/A Block is disabled – process value outputs are set to 0 and
OPERATION error/warning pins are turned off.

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AGA Detail Gas Components AGA8DL & AGA8GS

AGA Detail Gas Components

Accessed from the AGA8 Detail widget, this display shows the values of the 21 gas components and other
setup parameters. You can edit the local values here.

Item Description

Active Gas Component Local values: Uses Local Values of gas components.
Values
Remote values: Uses the block’s Remote Values (input pin values from an online
analyzer).

Override Range Error Under certain situations, the gas component values may exceed the expanded range
recommended by the AGA 8 Report. In Override mode a flow rate will be calculated. It
should be noted that calculated flow rates for conditions where the expanded range is
exceeded are outside of the recommended uncertainty values for AGA 8 calculations.

Sum of New Local When you edit the New Local Values this shows the sum of all 21 values. Values must
Values total 1.0 (100%).

Gas Component This column lists the 21 gas components.

Local Values This column lists the local value of each component.

Remote Values This column lists the remote value of each component (via the AGA block input).

New Local Values This column lets you enter new local values. Values must total 1.0 (100%). After
entering new values, Apply New Local Values.

Apply New Local Values Select to transfer the New Local Values to the Local Values. These values do not take
effect unless Active Gas Component Values is set to Local Values, above.

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AGA8DL & AGA8GS AGA8 Gross Setup

AGA8 Gross Setup

Accessed from the AGA8 Gross widget, this display shows the values of the 4 gas components and other
setup parameters. You can edit the local values here.
Item Description

Active Gas Component Local values: Uses Local Values of gas components.
Values
Remote values: Uses the block’s Remote Values (input pin values from an online
analyzer).

Override Range Error Under certain situations, the gas component values may exceed the expanded range
recommended by the AGA 8 Report. In Override mode a flow rate will be calculated. It
should be noted that calculated flow rates for conditions where the expanded range is
exceeded are outside of the recommended uncertainty values for AGA 8 calculations.

Gross Method Used Method 1 calculates the super-compressibility and gas density from knowledge of the
relative density, heating value and carbon dioxide, hydrogen and carbon monoxide
components.

Method 2 calculates the super-compressibility and gas density from knowledge of the
relative density, Nitrogen, carbon dioxide, hydrogen and carbon monoxide
components.

Setup for Method 1&2

Relative Density Gas Relative Density

Relative Density Ref Relative density reference temperature in units selected by the UNITS configuration
Temperature parameter.

Relative Density Ref Relative density reference pressure in units selected by the UNITS configuration
Pressure parameter.

Setup for Method 1 Only

Heating Value Heating value in units selected by the UNITS configuration parameter.

Calorimeter Ref Temp Calorimeter reference temperature in units selected by the UNITS configuration
parameter.

Calorimeter Ref Pres Calorimeter reference pressure in units selected by the UNITS configuration
parameter.

Combustion Ref Temp Combustion reference temperature in units selected by the UNITS configuration
parameter.

continued

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4-Selector Switch

Item Description

Gas Component Values

Gas Component This column lists the 4 gas components. Each of the 4 gas component fractions is
configured with either a constant fraction value derived from a lab report (local) or from
an on-line gas chromatograph (remote).

Local Values This column lists the local value of each component.

Remote Values This column lists the remote value of each component (via the AGA block input).

New Local Values This column lets you enter new local values. Values must total 1.0 (100%). After
entering new values, Apply New Local Values.

Sum of New Local When you edit the New Local Values this shows the sum of all 4 values. Values must
Values total 1.0 (100%).

Apply New Local Values Select to transfer the New Local Values to the Local Values. These values do not take
effect unless Active Gas Component Values is set to Local Values, above.

4-Selector Switch

This display has four banks of functions (A, B, C, D). Each function has 4 buttons that act as a 4-position
rotary switch, with one and only one state in effect at any time for that function.
To operate, press the desired state button for each function. When pressed, the buttons turn yellow to
indicate the selected state.

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Device Control

Device Control
The Device Control function block is normally used to control pumps. Based on certain events the device
will be placed into the appropriate state.

Table 30 Device control display details

Item Description

State READY, PRESTART, STARTING, RUNNING, STOPPING, DISABLED, or

FAILED. READY (off state) is the initial state of the block. See Table 31
Device states.

Seconds Current Timer value. READ ONLY – Counts down to zero.

• The Start Delay Timer is active in the Prestart state

• The Stop Delay Timer is active in the Stopping state

• The Feedback timer is active in the Starting state while the Feedback
input pin is OFF.

• The Feedback timer is active in the Running state (if the Feedback
input turned on in the starting state.)

Run Request Green when device is requested to be put in the Starting or Running state.

Active Green when state is Running or Stopping.

Failed Red when the control is in the Failed state (the controlled device reported
a failure or did not start up in time; device is being monitored for a manual
or automatic reset).

Reset Select to reset the control when it is in the FAILED state to return it to the
READY state.

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Device Control Setup Device Control

Table 31 Device states

MONITORED DEVICE STATES
EVENTS
READY PRE- STARTING RUNNING DISABLED STOPPING FAILED
(Note 1) START (Notes 1,2)
Run Request X X
turns ON
Run Request X X X
turns OFF
Disable (ON) X X X X X
Disable (OFF) X
Feedback from X X
Device
Device (ERR) X X X X
Fail ON
Device (ERR) X
Fail OFF Note 3
Reset (Rising X
Edge)
Start Delay X
Timer Expires
(edge)
Feedback Timer X X
Expires (edge)
Stop Delay X
Timer Expires
(edge)
Note 1: If a device fails while in the state of READY or DISABLE, the device failure is not recognized until the
control goes into the PRESTART state.
Note 2: There are restrictions when the control goes into the Disable state from the Running State. The device is
immediately turned OFF without a Stop Delay. When the disable turns OFF, the control changes to the Ready
state.
Note 3: ERR Off (device fail) is monitored in Failed state, only if a) failed input caused the failure, and b) Auto Reset
is enabled.

Device Control Setup

Touch the blue title bar to access the setup display.

Item Description

START DELAY Current start delay time in seconds

STOP DELAY Current stop delay time in seconds

FEEDBACK FAIL DELAY Current feedback fail delay time in seconds

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Hand/Off/Auto Switch

Hand/Off/Auto Switch

The Hand – Off – Auto (HOA) switch permits state change requests. The block states are: Hand (manual
operation from an operator interface), Auto (default – requests are operated automatically), or Off (relay to
be switched to Bypass, Hand, or Auto), or Bypass (external manual operation of a device).
The HOA switch is also used with the Device Control function block to comprise a Pump Control
algorithm which is used to manipulate the state of a controlled device (pump).

Item Description

Feedback state State of the feedback signal. If connected to a Device Control block, this
shows the status of the device. See Table 31 Device states on page 99.

When the HOA block is used in conjunction with a Device Control block,
the feedback is typically referenced to the (STI) status output pin of the
Device Control block.

Current state indicator The rotary dial and yellow button indicate the selected state (Hand, Off,
Auto. Use buttons to change state. If the current state is BYPASS, any
requests to change the state are ignored.

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Stage

Stage

The Stage function block provides differential On/Off control and is typically used to monitor pressure and
flow for controlling pumps and operating valves.
There are four individual stages grouped together in the function block. The block monitors from one to
two analog inputs (PV1, PV2) which are common to all four stages, compares them for each stage by a
configurable comparator, and provides On/Off control outputs for the four stages based on configurable
setpoints for each stage. Each stage can be individually enabled and forced ON or OFF.

Item Description
PV1 PV1 input pin of the function block (pressure)
PV2 PV2 input pin of the function block (flow)
Status Enabled = stage is enabled. Disabled = stage output is off. This condition
overrides the Override status. When Status = Enabled the stage algorithm
is reevaluated to determine the state of Output (request).
Output Output of the stage. Off, On, or Disabled.
Override Override On input pins and Override Off input pins of the function block.
None, On, or Off.

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Stage Stage setup display

Stage setup display

Touch the blue title bar to open the setup display and edit parameters for each stage.

Table 32 Stage setup details

Item Description

ON delay time Delay prior to latching the output ON

OFF delay time Delay prior to latching the output OFF

ON Compare: Setpoint Setpoint used with ON comparator – No range limit

OFF Compare: Setpoint Setpoint used with OFF comparator – No range limit

Interlock with Prev Stage Set to YES to prevent a stage’s output from turning ON until the previous
stage has turned ON.

Interlock with Next Stage Set to YES to prevent a stage’s output from turning OFF until the output of
the next stage in sequence has turned OFF.

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Ramp

Ramp

The Ramp function block is typically used for variable speed, valve position, and chemical feed control
applications to reduce the output value as more external devices are enabled.
For example, if one pump is running at 100 % and a second pump is enabled, the output value may be re-
scaled to 50 % by the pump 2 enable signal.
The ramp block references an analog signal, and using four separate scales multiplexed together, provides a
single analog output over a programmed range.

Table 33 Ramp operator display details

Item Description

INPUT PV input pin of function block

OUTPUT Output pin of function block

STATUS Enable (YES) or Disable (NO) of the ramp.

OVERRIDE OFF, LOW, or HIGH – Override status of each ramp input pin.

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Ramp Ramp setup display

Ramp setup display

Touch the blue title bar to edit the parameters for each ramp.

Table 34 Edit ramp display details

Item Description

OUT SCALE HIGH High output limit after rescale. Range: Full scale +/– within PV range
limits.

OUT SCALE LOW Low output limit after rescale. Range: Full scale +/– within PV range limits.

IN HIGH LIMIT Input high limit value applied to the PV after signal lag. Range: Full scale
+/– within PV range limits.

IN LOW LIMIT Input low limit value applied to the PV after signal lag. Range: Full scale
+/– within PV range limits.

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Alternator

Alternator

The Alternator is typically used to alternate the starting sequence of a group of pumps, valves, filters, etc.
Each block accepts up to 16 inputs and controls up to 16 outputs.
There are four unique alternation styles used to control the output starting sequence so that you can limit
the amount of repeat or continuous usage of a single device (pumps, valves, etc.). If an output device fails,
or has been disabled, then an alternate device will be used in order to meet the requested demand. You may
specify the alternators active outputs and the order in which the outputs are manipulated.

Item Description

Status OK, DISABLED, or HIGH

State OFF or RUN

Style ROTARY, FOFO, FIXED, or DIRECT

NOTE: If the current style is DIRECT, the OUT number corresponds to the
Input sequence that requests the OUT to turn ON. With any other style,
the OUT number corresponds to the number of IN’s (DMND) that need to
be ON to turn the OUT on.

Demand Input count, between 0 and 16

On Delay (Sec) Delay time used before turning ON the next output in the sequence.
Range: 0-99999 seconds

Off Delay (Sec) Delay time used before turning OFF the next output in the sequence.
Range: 0-99999 seconds

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Alternator Alternator Setup display

Alternator Setup display

Touch the blue title bar to edit the setup parameters.
Item Description

Input Status On or Off.

Output Status Blank – Normal operating output (no designation)

DNR – Device Not Ready (see Alternator Operator display for example)

Output Sequence Integer between 0 and 16

“0” indicates the output is not in the Output sequence.

Advance Advances the output sequence. Not available for style DIRECT.

Edit Select to edit the sequence. See Alternator Edit Setup.

Alternator Edit Setup display

Item Description

Make/Break MAKE – (Make before Break) Next output in the sequence is activated
before deactivating an output.

BREAK – (Break before Make) The output is removed before advancing

the sequence and activating the next output.

MAKE/BREAK is READ ONLY.

Max Out Maximum number of outputs used.

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Alternator Edit Setup display Alternator

Item Description

Style A style is a method used to control the cycling of the 16 outputs. If

different style is selected, the change will not occur until all outputs are in
the OFF state.

DIRECT: Monitors up to 16 inputs and maps them, using the user

adjustable map order on the Output tab, directly to the outputs. If the
Inputs selected are 1, 2, 3, 4, 5, 6 and the Output order mapped is 6, 3, 4,
1, 5, 2; when Input 3 is activated, Output 4 is enabled; or if Input 1 is
activated then Output 6 is enabled.

ROTARY: Uses the sum of the 16 inputs that are set to ON to determine
the required demand for outputs. The output order is managed in a Last
ON/First OFF basis (LOFO). If the Inputs selected are 1, 2, 3 and the
mapped sequence is 1, 2, 3 the alternator sequence changes when NO
outputs (pumps) are required or there is a request to Advance (see
Advance). Depending on the capacity required, Outputs 1, 2, 3 come on in
order. When the demand falls, Output 3 goes OFF, then Output 2, then
Output 1. When Output 1 turns off, the Rotary sequence advances and
Output 2 starts the next cycle. If an input pin is set to "not available", then
that output is forced to OFF and the next available output in the mapping
order is turned ON. If the previously bypassed output later becomes
enabled, then it will not be used until the demand increases.

FOFO Uses the sum of the 16 inputs that are set to ON to determine the
required demand for outputs. The output order is managed in a First
ON/First OFF basis (FOFO). If 3 Inputs are ON (no mapping), the
Alternator sequence changes (first one in the list moves to the end of the
list) as the inputs turn OFF or, when there is a request for Advance (see
Advance). If an input pin is set to "not available", then that output is forced
to OFF and the next available output is turned ON. If the previously
bypassed output later becomes enabled, then it will not be used until the
demand increases.

FIXED Uses the sum of the 16 inputs that are set to ON to determine the
required demand for outputs. The output order is managed in a
FirstON/First OFF basis (FOFO). If the Inputs selected are 1, 2, 3, 4 and
you map a fixed sequence 4, 2, 3, 1 the sequence will not change unless
you select the Advance feature (see Advance). It takes a direct command
(OFF to ON signal) before the output order map rotates to the 2, 3, 1, 4
sequence. If an output pin is not available then that output is forced OFF
and the next available output in the mapping order is turned ON. If the
previously bypassed output later becomes enabled, then it will not be
used until the demand increases.

Input Status On or Off.

Output Status Blank – Normal operating output (no designation)

On or Off.

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Alternator Alternator Edit Setup display

Item Description

Output Sequence Integer between 0 and 16

“0” indicates the output is not in the Output sequence.

Examples of reasons to change it include:

• If you are having trouble with a motor or pump (e.g., a bearing is going
bad) and you want to limit the amount of time it is used.

• If you have 3 motors and one uses more electricity than another, you
may want to use two small motors first before you use the one large
motor. This could be handled by changing the sequence.

• Taking a pump out of service for maintenance.

After editing, save the output sequence.

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Calendar Event

Calendar Event

The Calendar Event compares user-entered time-and-date setpoints to the real-time clock to generate digital
Event outputs. These Event outputs can be integrated into a control strategy to activate time-synchronized
activities. For example, the Event outputs can be used to schedule when to turn lights on and off in an
office building. Each Calendar Event block supports up to eight Event outputs.
In addition, the block allows you to configure up to five sets of time-and-date setpoints, called Setpoint
Groups. These Setpoint Groups can be used to activate different sets of time-and-date setpoints to handle
different conditions. Using the example of office building lights, Setpoint Groups can be used to activate a
different set of time-and-date setpoints for each season of the year (Spring, Summer, Fall, and Winter).
Each Calendar Event block supports five Setpoint Groups. The screen shown above is an example of one of
these Setpoint Groups. You can select which Setpoint Group is in effect; the values in each column will
change according to the Setpoint Group you select. Each Setpoint Group is editable.
The block also allows you to configure up to 16 Special Days. On these Special Days the Calendar Event
Block will override its normal Event processing for a 24-hour period. For example, you can configure
selected Event outputs to remain off on designated holidays.

Item Description
Event Name The names assigned to Events 1 through 8.

Event Type The configured Event Type for Events 1 through 8. Choices:

DISABLE – The Event is Disabled

5 - DAY – The Event will occur at the same time Monday through Friday.
7 - DAY – The Event will occur at the same time every day of the week, Sunday
through Saturday.
DAY OF WEEK – The Event will occur once a week at the configured time.
MONTHLY – The Event will occur once every month at configured date and time.
YEARLY – The Event will occur once a year at the specified date and time.

Time/Month/Day This is the currently active time-and-date Setpoint value for Events 1 through 8.

Feedback The value of the Feedback Signal for Events 1 through 8. The assignment of a
feedback signal is optional. If no feedback signal is assigned this column of the
display will be blank.

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Calendar Event Calendar Event Block Menu

Calendar Event Block Menu

Touch the blue title bar to access the the top-level menu for the Calendar Event Block, below.

From here you can access the buttons that will allow you to edit Event Setpoints, select the active Setpoint
Group, and view or edit Special Days.

Item Description

Edit Event Setpoints Select the Setpoint Group you wish to edit. See Edit Event Setpoints.

Set Active Setpoint This shows the five Setpoint Group buttons. The currently active Setpoint
Group is highlighted in yellow. Touch any button to activate a different
Setpoint Group.
Edit Special Days Select this to edit one of the 16 Special Days.
View Special Days Event Setup Select this item to see how the Events will behave when a Special Day
occurs (see page 112).

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Edit Event Setpoints Calendar Event

Edit Event Setpoints

This menu allows you to edit the setpoints within a Setpoint Group.

Item Description

Event Name Configured name for each event. Read only.

Event type Configured Type for each Event. Read only.

DISABLE – The Event is Disabled.

5 - DAY – The Event will occur at the same time Monday through Friday.

7 - DAY – The Event will occur at the same time every day of the week, Sunday
through Saturday.

DAY OF WEEK – The Event will occur once a week at the configured time.

MONTHLY – The Event will occur once every month at configured date and time.

YEARLY – The Event will occur once a year at the specified date and time.

Hours Select a value between 0 and 23. This menu item will not appear if the configured
Event Type is DISABLE.
Minutes Select a value between 0 and 59. This menu item will not appear if the configured
Event Type is DISABLE.
Month Select a Month of the Year. This menu item will only appear when the configured
Event Type is MONTHLY.
Day This menu item will only appear when the configured Event Type is MONTHLY,
YEARLY, or DAY OF WEEK.
When Event Type = YEARLY or MONTHLY, Select a value between 1 and 31.
When Event Type = DAY OF WEEK, select a value between Sunday and
Saturday.
When Event Type = MONTHLY, entering a value of “31” means “the last day of the
month”, even for months with less than 31 days.

Set Active Setpoint Group

The currently selected button is highlighted yellow. Select any group to activate it. The button will turn
yellow and the selected setpoint group will be displayed on the main widget.

Edit Special Days

This menu allows you to edit any of the 16 Special Days. Note that the word “OFF” will be displayed in
place of the Month and Day when the Special Day is disabled.

Item Description

MONTH Select a Month of the Year (or a value of OFF to disable the Special Day).

DAY Select a value between 1 and 31 (or a value of OFF to disable the Special Day).

Note: If either the MONTH or the DAY has a value of OFF, the Special Day is
disabled. Both the MONTH and the DAY must be set to a legal value to activate
a Special Day.

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Calendar Event View Special Days Event Setup

View Special Days Event Setup

The Calendar Event Block can be configured to override its normal Event processing when any of the 16
Special Days occurs. This override will remain in effect for the 24-hour period associated with the Special
Day. This feature can be used to force selected Event outputs to remain off on designated holidays, for
example.
This display allows you to see how the eight Event outputs will behave when a Special Day occurs.

Item Description

Event Name Name of Events 1 through 8

Setpoint Handling This title is displayed when the Special Day Mode is configured as “Use
Alternate Event Times”

Alternate Setpoint Displays the Alternate Setpoint Times (Hours:Minutes). This information will
only appear if the Special Day Mode is configured as “Use Alternate Event
Times”.

Special Day Mode Event output behavior

Disable Output The Event output is disabled on Special Days (for the entire 24 hour period).

Use Alternate Setpoint On Special Days, the Event output will trigger at the Alternate Setpoint Time
shown on this display.

Normal The behavior of the Event output is not overridden on Special Days. The
Event output will trigger the way it normally triggers, based on the
configuration of the currently active Setpoint Group.

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 Process Displays
XYR5000 Base Radio Wireless transmitters

Wireless transmitters
XYR5000 Base Radio

This read-only widget allows the HC900 controller to act as a Modbus master device and communicate
with XYR5000 base radios via the serial port of the controller. For attached transmitters there is a separate
XYR5000 transmitter widget which is connected to the base radio block via the address output.
Item Description

Status Last read value of base radio. Offline or Online.

Transmitters expected Number of Expected Transmitters communicating to the base station.

Transmitters communicating Number of Transmitters actually communicating with the base radio.

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Wireless transmitters XYR5000 Transmitter

XYR5000 Transmitter

Item Description

Transmitter status Transmitter online status. Online or offline.

System status System error condition. Error or Good.

Sensor #1 Data Primary Sensor Value.

Sensor #2 Data Secondary Sensor Value.

Sensor #3 Data Tertiary Sensor Value.

Battery Status Low or Good.

Alarm Status On or Off

Overrange Status Sensor over range condition. Over range or OK.

Sensor Status Error or Good.

Switch Input #1 On or Off

Switch Input #2 On or Off

Touch the blue title bar to open the XYR5000 Transmitter Setup display. This shows the Square root of
primary Differential Transmitter output status: On or Off.

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XYR6000 Transmitter Wireless transmitters

XYR6000 Transmitter

Five parameters—PV1, PV2, PV3, PV4 and Device Status—are read from the XYR6000 transmitter.
Item Description

Device status Transmitter online status. Online or offline.

Diagnostic status System error condition. Error or Good. When status is Error, press the blue
title bar to see the details of diagnostics.

• Battery: Low or Good.

• External power: Error or Good

• Electrical: Error or Good.

• Mechanical: Error or Good

• Configuration: Error or Good

• Calibration: Error or Good

• Memory: Error or Good

• Firmware: Error or Good

• Watchdog Timer: Error or Good

Radio status Error or Good

PV1, PV2, PV3, PV4 Value of each Process Variable

Input Status Error or Good

Output Status Error or Good

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 VARIABLE RECIPES

Overview
Description
A Variable Recipe is a list of Grouped Variables that define the values (ingredient quantities) needed to
make a product or run a particular batch. The items represent Analog and/or Digital Points that were
assigned in the Function Block Configuration and are identified by their Variable Names. Variable Recipes
have these basic attributes:
Recipe Number - A unique number assigned for each recipe that is configured. Numbers are assigned
during configuration or through an upload/download operation. They may have been assigned in any
sequence with gaps between numbers, but no two recipes can be given the same number.
Recipe Name - A descriptive name assigned to the recipe consisting of letters or numbers with no spaces,
up to 8 characters.
Recipe Description – Additional text used to identify the recipe, up to 16 characters.
Recipe Variables - A list of Variables and their values for each recipe, up to 50 variables each.

Variable Recipe Load vs. Variable Recipe Upload/Download

Recipes are stored in the memory of the HC900 controller in a recipe pool. Variable recipes may be read
(uploaded) from the pool into the displays of the operator interface where they may be viewed, edited,
exported and duplicated before being returned (downloaded) to the recipe pool of the controller. (see
Uploading and Downloading Recipe Files in a previous section)

Once the variable recipe is in the controller’s recipe pool, a Variable Recipe Load widget is used from the
operator interface to select a recipe from the pool and have its values transferred to the various analog and
digital variables in the controller’s configuration. See Figure 8.

NOTE: The contents of the variable recipe cannot be edited from the recipe selection widget. For editing,
the recipe must be uploaded, modified, then downloaded to the controller.

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Overview

Figure 8 Variable Recipe Selection Display

To transfer the values of a variable recipe from the recipe pool of the controller to the various analog and
digital variables in the controller configuration, touch the desired recipe on the display, a yellow highlight
will verify your selection, then press the LOAD RECIPE button on the display widget.

Hint: When making variable recipes, users may wish to include a variable that will be used to identify the
recipe number. The value of this variable may then be added to the Variable Recipe Load display to
receive verification that the desired recipe operation has been executed in the controller. See Figure 8

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 Setpoint Programmers
Overview

Setpoint Programmers

Overview
Description
A setpoint programmer supplies a time-varying setpoint to a control loop. A program contains multiple
segments; each segment can be a ramp or a soak and has digital switches called “events.” This menu lets
you edit setpoint program segments, segment events, or other parameters and save the changes to the
controller’s memory.
Each program contains multiple segments. Each segment of the program may be a ramp or soak except the
last segment must be a soak.
Multiple programs can be running concurrently. Programmers can run any of the profiles in controller
memory. Once loaded from memory into the Setpoint Programmer (SPP) function, these profiles are
referred to as “programs.” Any program can be edited and saved as a profile in one of the “slots” in the
controller’s memory.
In addition to the main output value, a second analog value is available for each step of the program. This
output is a fixed soak value, which may be used as an input to another function or to provide a setpoint
value for a secondary control loop in the process.
A Setpoint guarantee function (known as guaranteed hold) is provided that holds the program if a process
variable exceeds a predefined deviation from setpoint. Selections allow setpoint guarantee to be active for
the entire program, for soak segments only, or for user specified segments.
Up to 3 Process Variables may be configured as inputs to the block for setpoint guarantee.
The program may be changed (with some exceptions) from the current state to a new state by the operator
as well as by inputs to the SPP block. Table 35 lists the resulting states.
Table 35 SPP inputs and current state

Input Current State

READY HOLD RUN GHOLD STOP

RESET READY READY RUN READY READY

HOLD HOLD HOLD HOLD HOLD STOP

RUN RUN RUN RUN GHOLD STOP

GHOLD READY HOLD GHOLD GHOLD STOP

With regard to changing program state, if more than one function block input is on in the same execution
cycle, RESET has priority over HOLD and RUN, and GHOLD has priority over RUN.
Also, function block inputs will override inputs from the Control Station, which occur during the same
execution cycle. Finally, state changes from the Control Station are processed on the basis of the “last
change wins.”

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Overview

Setpoint Programmer Overview widgets

Setpoint Programmer data is displayed on the Setpoint Programmer widgets.

Setpoint Programmer Setpoint Programmer with jump

Shows status of the Setpoint Programmer’s Shows status of the Setpoint Programmer’s
current profile. Use buttons to advance to next current profile. Use buttons to advance to next
step, run, hold, or reset. step, run, hold, or reset. Touch blue title bar to
jump to SPP Operate display.

Table 36 Setpoint Progammer Overview widget features

Item Description
Title Name of the selected programmer block. Touch the blue title bar (if
available) to jump to the SPP Operate display. See page 122.

Profile number Location of this profile in controller RAM.

Profile name Name of the selected profile.

State READY: Profile is at the beginning of segment and is ready to run. All
events are OFF.

HOLD: Profile is paused at the setpoint value shown.

RUN: Profile is executing normally.

GHOLD: Profile is paused because of excessive deviation.

STOP: Profile has reached the end of the last segment.

DISABLE: Profile is prevented from starting until the programmer disable

control is ON.

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Overview

Item Description
Segment Current segment

Type Type of current segment: ramp or soak

Elapsed Time elapsed in the segment

Remain Time remaining in the indicated segment

Advance Push button to cause the program to jump to the next segment.

When the program is already in the last segment, the advance request is
ignored.

Programs cannot be advanced to the first segment. Current state must

either READY or HOLD.

PV Value of Process Variable.

SP Value of setpoint.

Units Engineering units of the setpoint.

Run Touch to start a program that is in HOLD or READY state.

Hold Touch to put program in HOLD.

Reset Touch to reset a HOLD or STOP program to the first segment. Any edits
made to the program are lost unless they were SAVED. See SAVE on the
display.

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Setpoint Programmers
Setpoint programmer – Pre Plot Display

Setpoint programmer – Pre Plot Display

Go to Home page > Custom Display.

General Description
 This display graphically indicates a user’s ramp and soak profile for a Setpoint Programmer function
block. When the associated Setpoint Programmer function block is running, Process Variable # 1 input
(PV1) of the associated function block is plotted against the pre-plot of the Setpoint Profile.
 To supplement the Setpoint profile pre-plot, the display contains the following buttons and information:
• Setpoint Programmer Function Block tag Name and Description
• Setpoint Profile recipe name and Description
• Current Segment number
• Current segment Type (Ramp/Soak)
• Segment Time Remaining
• Program Elapsed Time
• Buttons used to Run, Hold, Advance and Reset a Programmer
• Status of the Setpoint Programmer Events (1-16)
• Current Primary SP value
• Current Primary PV value
• Primary PV Engineering Units
• Current Auxiliary SP Value
• Current Auxiliary PV Value

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Setpoint programmer – Pre Plot Display

• Auxiliary PV Engineering Units

• Current PV2 value
• Current PV3 value
• Primary button to select Primary PV graph
• Auxiliary button to select Auxiliary PV graph
• Setpoint Programmer current Status
• Set Point indicator to indicate color of Setpoint plot
• Process Variable indicator to indicate color of Process Variable plot
• Operate Display button to navigate to associated Setpoint Programmer Operate Display
 As shown below a second pre-plot indicates the profile of the SPP Auxiliary Setpoint output profile
(soaks only). The SPP Process Variable # 4 input (PV4) is plotted against the Auxiliary Setpoint
output pre-plot graph.

Setpoint Programmer Pre-Plot Graph attributes

1. The content of the pre-plot graph is determined by reading the profile content of the Setpoint
Programmer function block. Time is presented on the X axis and the SP value is presented on the Y
axis of the graph.
2. The amount of time contained within the pre-plot graph is determined by:
a) The number of user programmed segments in the profile (The user may use from 2 to 50 of the
available segments for his program.)
b) The time units specified for the profile (minutes or hours)

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Setpoint programmer – Pre Plot Display

c) The sum of the amount of time specified for each segment of the profile (Note: setpoint ramps may be
programmed in units of time (hours or minutes) or by Rate and values (e.g. ramp from 100 to 500 at
450 units per hour.)
3. The Y axis limits (SP) for the graph are entered by the user in Station Designer at the time of display
configuration.
4. The SP limits and intermediate values are presented on the left edge of the pre-plot graph.
5. The pre-plot graph presents the entire contents of the setpoint profile on a single display graph.
6. The color of the pre-plot trend line is alterable by the user. The default color shall be yellow.
7. When a Setpoint Programmer is reset, the pre-plot is re-drawn using the Setpoint Programmer profile
content.
8. The pre-plot profile is re-drawn following an on-line edit of the profile.

Process Variable Trend Plot attributes

1. Process Variable #1 of the Setpoint Programmer function block is plotted on the same graph as the
Setpoint pre-plot.
2. The Process Variable plot uses the time units determined by the Setpoint profile pre-plot.
3. PV plotting on the graph begins when the Programmer is placed in the Run mode.
4. The Process Variable trend stops plotting when the Setpoint Programmer is in the Hold mode and
resumes when returning to the Run mode from the Hold mode.
5. The Process Variable plotting stops when the programmer is in the Stop mode.
6. The Process Variable plot remains on the graph until the Setpoint Programmer is Reset.
7. Once started, the Process Variable plotting continues in the background if another display is accessed.
(Allows the user to periodically check the program progress while viewing and operating his process
from other displays of the interface.)
8. The color of the PV trend line is user selectable. The default color shall be Aqua.

Special cases and actions

1. Recycle – A Recycle of a Setpoint Programmer is pre-determined by the user as part of his profile. A
Recycle is when the program exits one segment, but before entering the next segment, it returns to the
start of a previous segment and duplicates a portion of the profile. The user can specify the number of
times he would like the program to recycle before continuing to the end of the program. If the recycle
quantity is set to zero, the recycle quantity is infinite and the program will recycle until reset.
Following a Recycle event, the Process Variable plot is cleared and redrawn. The PV plot starts plotting
from the beginning of the start recycle segment. The PV plot (line) leading up to the recycle event is
plotted on the graph to the left of the new start location on the graph.
2. Jog – A jog of the setpoint program is initiated by a digital input to the Setpoint Programmer function
block. The setpoint program will immediately go to the start of the Jog-to segment when the digital
input turns ON. The Jog-to segment is determined by the user when creating his ramp/soak profile.
The Jog-to segment can cause the program to go to a higher or lower segment number from its current
segment.
Following a Jog-to event, the Process Variable plot starts plotting from the beginning of the Jog-to
segment.

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 Setpoint Programmers
Setpoint programmer Operate

3. Advance – Advance is an action that can be initiated manually from the SPP user interface or from the
control strategy via a digital input to the SPP function block. The Setpoint Programmer must be in the
Hold state to accept an Advance input. Advance is a single shot action and each rising edge of the
input will cause the program to advance one segment through its sequence. Advance may be used
through multiple actions to completely cycle through a program and restart at a previous segment.
Following an Advance action, the Process Variable plot starts plotting from the beginning of the segment
determined by the Advance action.

Auxiliary SP and PV Pre-plot

1. The actions and responses of the Auxiliary PV4 and the Auxiliary SP pre-plot graph will be the same
as the PV1 value on the SPP profile pre-plot graph for the special cases above.
2. The default colors of the Auxiliary SP Pre-plot and PV are the same as the Setpoint Profile colors.
(Yellow and aqua).

Setpoint programmer Operate

This widget may be accessed either from a Home display button or by jumping from the Setpoint
Programmer Overview widget.
It shows the details of the profile currently running in the Setpoint Programmer. You can also load a
different profile from memory into the Setpoint Programmer, edit the current profile, and save the edited
profile to any slot (profile number) in memory.

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Setpoint programmer Operate

Item Description
Title Name of the selected setpoint programmer block.

SP Profile Information

Profile Number Memory location of the profile that is being run by the Setpoint
Programmer.

Profile Name Name of the selected profile.

Profile Description Description of the selected profile.

Total Elapsed Time Total time the profile has been in Run, Hold and GHold states.

State READY: Profile is at the beginning of segment and is ready to run. All
events are OFF.

HOLD: Profile is paused at the setpoint value shown.

RUN: Profile is executing normally.

GHOLD: Profile is paused because of excessive deviation.

STOP: Profile has reached the end of the last segment.

DISABLE: Profile is prevented from starting until the programmer disable

control is ON.

Segment Information

Segment number Current segment

Elapsed Time Time elapsed in the segment. Run time only.

Time Remaining Time remaining in the segment.

Segment Type Text shows type of current segment: ramp or soak.

The current and next segment types are shown graphically. In the above
example, the current segment is ramping up, the next segment is a soak.

Operation Buttons

Run Start a program that is in HOLD or READY state.

Hold Put program in HOLD.

Advance Jump to the next segment.

When the program is already in the last segment, the advance request is
ignored.

Programs cannot be advanced to the first segment. Current state must

either READY or HOLD.

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Setpoint programmer Operate

Item Description
Reset Reset a HOLD or STOP program to the first segment. Any edits made to
the program are lost unless they were saved. See Save To Profile
Number.

PVs and SPs

PV (left) Value of primary process variable.

SP (left) Value of primary setpoint.

PV (right) Value of auxiliary process variable (PV4)

SP (right) Value of auxiliary setpoint

PV2 Value of process variable #2

PV3 Value of process variable #3

Profile load/view/edit/save

Load From Profile List Loads a profile from memory into the Setpoint Programmer. Program
must be in READY state.

See Figure 9 Recipe Load. You are presented with a list of profiles
(recipes) in controller memory. Scroll to the desired profile and touch to
highlight it. Touch Load Profile button to load the selected profile into the
setpoint programmer. The loaded profile overwrites the current profile
from the programmer.

To erase the currently loaded profile from the Setpoint Programmer,

select <Clear Profile> and load it. Any profile edits are lost unless you
save them first with Save To Profile Number.

Start at segment After loading, the program will start at this segment. Subsequent runs will
start at Segment #1. If the segment number is within a loop, the profile
cycles through the looped segments according to the number of loop
cycles.

Save To Profile Number Saves the currently running profile (and any edits) to a selected slot in
controller memory. Scroll to the desired slot in the controller’s profile
memory. Once saved, it can be loaded and run later. See Figure 10
Recipe Save.

View/Edit Profile Press to view/edit the current profile. Edits take effect immediately in the
current profile but they are not saved to profile memory. (To save your
edits, see Save To Profile Number.) When the profile is RESET, any edits
are lost unless they are first saved with Save To Profile Number. See
View/Edit profile on page 129.

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Setpoint Programmers
Setpoint programmer Operate

1. Select Load From Profile List

4. Selected recipe is loaded

and ready to run.

2. Select a recipe you want to run.

3. Touch Load Profile.

Figure 9 Recipe Load

1. Select Save To Profile Number

2. Select a position to save recipe to.

3. Touch Save Profile.

4. Current recipe with edits

is saved to Controller
memory

Figure 10 Recipe Save

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 Setpoint Programmers
View/Edit profile

View/Edit profile
This display lets you view or edit parameters of the currently working profile. Edits affect only the
currently working program (not the profile in memory) and are lost if the profile is Reset, unless you Save
Profile to Memory.

ATTENTION

Program must be in READY state to be edited.

Item Description

View/Edit Segments Button Accesses View/Edit Profile Segments (page 131) where you can edit each
segment.

Profile number Memory location of the profile that is being run by the Setpoint
Programmer.

Profile Name Name of the selected profile.

Profile Description Description of the profile.

Ramp Type TIME: Each ramp segment’s time is the TIME allotted to the profile’s
output to reach the next soak segment’s value in hours or minutes.

OR

RATE: Each ramp segment’s time specifies the RATE at which that
profile’s output will reach the next soak segment, where the rate is
specified in EU/hour or EU/minute.

Make this selection before entering any Ramp during Profile Edit.

NOTE: When Ramp unit is configured for TIME, entering “0” will imply an
immediate step change in setpoint to the next soak.

Time Units This selection assigns the time units (hours or minutes) for the ramp type
selected.

For Time ramp type: Time = Hours or Minutes

For Rate ramp type: Rate = EU/Hour or EU/Minutes

Primary Output Label Label associated with the PV.

Primary Engineering Units Engineering Units of the PV

Guaranteed Hold High Limit The profile will hold if a PV deviates more than this amount above the
profile setpoint.

Guaranteed Hold Low Limit The profile will hold if a PV deviates more than this amount below the
profile setpoint.

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Item Description

Guaranteed Hold Type Guaranteed Hold, if enabled here, will hold the profile value if a PV to the
profile (typically a control loop’s PV) deviates specified amounts above or
below the profile output.

None: No segments have guaranteed hold enabled.

Per Seg: Lets you select specific segments for guaranteed hold where
you set up the profile ramps and soaks.

All Soaks: All soak segments will have a guaranteed hold enabled.

All Segs: All segments will have guaranteed hold enabled.

Loop Start Segment The first segment of the loop.

Loop End Segment The last segment of the loop.

Loop Cycles Number of times the loop segments will execute. Zero (0) means the
segments will be repeated forever.

Jog Segment Segment to which the program will jump to when the JOG discrete input is
pulsed.

Restart Rate This recovery ramp rate is provided in the event of a power loss while a
program is running. The Restart Rate value is used to return the process
to the last operating setpoint prior to power loss.

Auxiliary Output Label A second analog value is available for each segment of the program. It is
a fixed soak value and can be used to provide a setpoint value for a
secondary control loop in the process.

Auxiliary Engineering Units This is the engineering unit text associated with the AUX OUT.

Fast Forward Fast Forward is a way to check for proper functioning of the profile’s
events and outputs, without having to wait for the profile to execute at its
normal speed. When FAST FORWARD is ON, the program will run at a
speed 60 times faster. When FAST FORWARD is OFF, the program will
run at normal speed.

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 Setpoint Programmers
View/Edit Profile Segments

View/Edit Profile Segments

This display lets you edit the profile segments (setpoints and events) of the working program. Edits do not
affect profiles in memory unless you save them.

ATTENTION

Program must be in READY, HOLD, or STOP state before segments can be edited.

TIP

• Edits are allowed to any segment of the program, including the current segment.
• If edit is to current segment and segment is a ramp:
- If the ramp type is edited, then the time remaining is recalculated and the ramp
rate is adjusted accordingly.
- If the ramp rate is edited, then the time remaining is adjusted accordingly.
- Changes to the ramp starting setpoint will be ignored for the current execution of
the segment, but will be used for subsequent execution if the segment is included
in a loop.
• If edit is to current segment and segment is a soak:
- Changes to the soak setpoint will result in a step change.
- Changes to the time will cause recalculation of the segment time remaining. If
the result is less than or equal to 0, the program will advance to the next segment
upon returning to RUN state.
• If the current segment is a ramp and the starting value of the following segment is
changed, then the time remaining in the ramp segment will be adjusted accordingly
but the ramp rate will remain unchanged.
• Edits to soak setpoints will result in a step change at the next segment unless the
starting value of that segment is changed to the same value as well.

Edit Type and Value

Press the Edit Type and Value button to display the setpoint parameters below.
Item Description

Profile number Memory location of the profile that is being run by the Setpoint
Programmer.

Profile Name Name of the selected profile.

Profile Description Description of the profile.

Segment # Segment being edited.

Segment Type Ramp or Soak. Last segment must be a soak.

Starting Value Starting value of the segment.

Time/Rate Range = 0.00 hr. to 999.99 hr. or 0.00 min. to 999.99 min. The function of
this value depends on the Ramp Type.

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Item Description

Auxiliary Value Select a fixed soak value for this segment.

Guar Hold Select ON to enable setpoint guarantee if Guaranteed Hold Type is Per
Segment.

Edit Events
Press the Edit Events 1-8 and Edit Events 9-16 buttons to display the event parameters.
You can configure 1 to 16 segment events to turn ON or OFF at the beginning of each segment. Segment
events are digital switches that provide ON/OFF outputs. When a segment event is turned ON, it remains
ON until the end of the segment at which time it is turned OFF unless it is configured to turn ON in the
next segment. Note that segment events are not interrupted by soak time delays when the process variable
is outside the guaranteed soak band. Events turn ON as soon as the previous segment is completed even if
the process variable has not reached the soak setpoint.

TIP

Events can be edited only while program is in READY state.

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 Setpoint Scheduler

Overview
A setpoint schedule produces multiple setpoint outputs on a common time base. A setpoint schedule
contains multiple segments. Each segment contains multiple ramp or soak setpoints, multiple auxiliary soak
outputs, and multiple events. The last segment setpoint is always a soak (because there is no subsequent
setpoint to ramp to).
The Setpoint Scheduler can run any of the schedules in controller memory. Any schedule can be edited and
saved in one of the “slots” in the controller’s memory.
A Setpoint guarantee function (known as guaranteed hold) is provided that holds the Scheduler if a process
variable exceeds a predefined deviation from setpoint. Guaranteed hold is set on a per-segment basis and
can be set for high deviation, low deviation, high and low deviation, or none.
The schedule may be changed (with some exceptions) from the current state to a new state by the operator
as well as by inputs to the Scheduler function block in the controller configuration. Table 37 lists the
resulting states.
Table 37 SPS inputs and current state

Input Current State

READY HOLD RUN GHOLD STOP DISABLE

RESET READY READY RUN READY READY READY

HOLD HOLD HOLD HOLD HOLD STOP HOLD

RUN RUN RUN RUN GHOLD STOP RUN

GHOLD READY HOLD GHOLD GHOLD STOP READY

With regard to changing schedule state, if more than one function block input is on in the same execution
cycle, RESET has priority over HOLD and RUN, and GHOLD has priority over RUN.
Also, function block inputs will override inputs from the Control Station, which occur during the same
execution cycle. Finally, state changes from the Control Station are processed on the basis of the “last
change wins.”

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Setpoint Scheduler Operate

Setpoint Scheduler Operate

This widget may be accessed from a Home display button. It shows the details of the schedule currently
running in the Setpoint Scheduler. You can also load a different schedule from memory into the Setpoint
Scheduler, edit the current schedule, and save the edited schedule to any slot (schedule number) in memory.

Item Description
Title Name of the selected scheduler block.

Schedule Information

Schedule number Memory location of the schedule that is being run by the Setpoint
Scheduler.

Schedule name Name of the selected schedule.

Schedule Description Description of the schedule.

Total Elapsed Time Total time the schedule has been in Run, Hold and Ghold states.

State READY: Schedule is at the beginning of segment and is ready to run. All
events are OFF.
HOLD: Schedule is paused at the setpoint value shown.
RUN: Schedule is executing normally.
GHOLD: Schedule is paused because of excessive deviation.
STOP: Schedule has reached the end of the last segment.
DISABLE: Schedule is prevented from starting until the Scheduler disable
control is ON.

Segment Information

Segment number Current segment

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Item Description
Elapsed Time Time elapsed in the segment. Run time only.

Time Remaining Time remaining in the segment.

Recycles Remaining Number of recycles remaining, according to the highest numbered

segment so far encountered in the schedule.

Example:

Segment #30 has recycle count = 10 and recycle segment #5. Therefore,
the first time the schedule reaches Segment #30, the schedule will recycle
(repeat) Segments #5 through #30 ten times. During the first recycling, it
will display “10”, during the second recycling it will display “9”, etc.

Operation Buttons

Run Start a schedule that is in HOLD or READY state.

Hold Put schedule in HOLD.

Advance Jump to the next segment.

When the schedule is already in the last segment, the advance request is
ignored.

Schedules cannot be advanced to the first segment. Current state must

either READY or HOLD.

Reset Reset a HOLD or STOP schedule to the first segment. Any edits made to
the schedule are lost unless they were saved. See Save To Schedule List.

PVs and SPs

SP1 through SP8 Value of all setpoints

PV1 through PV8 Value of all PVs.

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Setpoint Scheduler Operate

Item Description
Schedule load/view/edit/save

Load From Schedule List Loads a schedule from memory into the Setpoint Scheduler. Schedule
must be in READY state.

You are presented with a list of schedules (recipes) in controller memory.

Scroll to the desired schedule and touch to highlight it. Touch Load
Schedule button to load the selected schedule into the scheduler. The
loaded schedule overwrites the current schedule in the programmer.

To erase the currently loaded schedule from the Setpoint Scheduler,

select <Clear Schedule> and load it. When the schedule is cleared, any
edits are lost unless you saved them first with Save To Schedule List.

See Figure 9 Recipe Load on page 128. All recipe types (profiles,
sequences, schedules) are saved the same way.

Start at segment After loading, the schedule will start at this segment. Subsequent runs will
start at Segment #1. If the segment number is within a recycle loop, the
schedule cycles through the looped segment according to the recycle
count.

Save To Schedule List Saves the currently running schedule (and any edits) to a selected slot in
controller memory. Scroll to the desired slot in the controller’s schedule
memory. Once saved, it can be loaded and run later.

See Figure 10 Recipe Save on page 128. All recipe types (profiles,
schedules, sequences) are saved the same way.

View/Edit Schedule Press to view/edit the current schedule. Edits take effect immediately in
the current schedule but they are not saved to schedule memory. When
the schedule is RESET, any edits are lost. To save your edits, see Save
To Schedule List. See View/Edit schedule on page 137.

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 Setpoint Scheduler
View/Edit schedule

View/Edit schedule
This display lets you edit parameters of the selected schedule. Edits affect only the currently working
schedule, not the schedule in memory, unless you save the schedule .

ATTENTION

Schedule must be in READY state to edit the values on this display.

Item Description

View/Edit Segments Button Accesses View/Edit Schedule Segments (page 138) where you can edit
each segment.

Schedule Information

Schedule number Memory location of the schedule that is being run by the Setpoint
Programmer.

Schedule Name Name of the selected schedule.

Schedule Description Description of the schedule.

Time Units This selection assigns the time units (hours or minutes) that applies to all
segments.

Jog Segment Segment to which the schedule will jump to when the JOG discrete input
is pulsed.

Guaranteed Hold Limits This lets you specify the amount of deviation needed between a setpoint
and its PV for the schedule to automatically switch to GHOLD state. If any
setpoint’s guarantee hold limit is exceeded, the entire schedule enters
GHOLD state (all setpoints, auxiliary setpoints, and segment events
freeze on their current value or state) until none of the limits are
exceeded, whereupon the schedule will resume RUN state.

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Setpoint Scheduler
View/Edit Schedule Segments

View/Edit Schedule Segments

This display lets you view and edit segment parameters.
• Setpoints
• Auxiliary Setpoints
• Time and Recycles
• Guaranteed Hold
• Events
Edits do not affect schedules in memory unless you save them.

ATTENTION

Schedule must be in READY or STOP state before segments can be edited from this menu.

TIP
• Edits are allowed to any segment of the schedule, including the current segment.
• If edit is to current segment:
− Changes to the setpoint will result in a step change.
− Changes to the time will cause recalculation of the segment time remaining. If the
result is less than or equal to 0, the schedule will advance to the next segment.
• If the starting value of the following segment is changed, then the ramp rate in the
current segment will be adjusted accordingly but the time remaining will remain
unchanged.

Edit Setpoints
This display lets you edit the 8 setpoint values for each segment. All values are as of the beginning (not
end) of the segment. The last segment must be a soak.

Edit Auxiliary Setpoints

This display lets you edit the 8 auxiliary setpoint values for each segment. All values are as of the
beginning of the segment.

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View/Edit Schedule Segments

Edit Time & Recycles

Item Description
Time Enter the amount of time for the segment to last (in Time Units shown).
Range 0-9999.

Recycle Count Enter the number of times a schedule is to be repeated. 1-999. 0=infinite.

Example:

Segment #30 has recycle count = 10 and recycle segment #5. Therefore,
the first time the schedule reaches Segment #30, the schedule will recycle
(repeat) Segments #5 through #30 ten times. During the first recycling, it
will display “10”, during the second recycling it will display “9”, etc.

Recycle Segment # Enter the segment number at which a recycle will start.

Edit guarantee hold

This lets you specify the conditions under which a segment will GHOLD when deviation exceeds the
guarantee hold limits. If any setpoint’s guarantee hold limit is exceeded, the entire schedule enters GHOLD
state (all setpoints, auxiliary setpoints, and segment events freeze on their current value or state) until none
of the limits are exceeded, whereupon the schedule will resume RUN state.

Item Description

Guar Hold 1 through Guar Hold 8 OFF: Segment will not GHOLD when the PV deviates from SP by its
guarantee hold limit.

HIGH: Segment will GHOLD if PV deviates above SP by more than the

SP guarantee hold limit.

LOW: Segment will GHOLD if PV deviates below SP by more than the SP

guarantee hold limit.

HIGH/LOW: Segment will GHOLD if PV deviates above or below SP by

more than the SP guarantee hold limit.

Edit segment events

This lets you edit the state of up to 16 events for the selected segment. You can configure 1 to 16 segment
events to turn ON or OFF at the beginning of each segment. Segment events are digital switches that
provide ON/OFF outputs. When a segment event is turned ON, it remains ON until the end of the segment
at which time it is turned OFF unless it is configured to turn ON in the next segment.

TIP

Events can be edited only while schedule is in READY state.

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 Sequencers

Overview
The Sequencer function block controls the states of up to 16 digital outputs and one analog output. Each
combination of output states represents a "State” of the Sequencer block, such as PURGE, FILL, HEAT, or
COOL. Each function block supports up to 50 States. The user sets up these states during the configuration
of the function block.
The user-configurable program that runs within the Sequencer function block is called a “Sequence.” Each
Sequence contains up to 64 “Steps”; each Step activates one of the 50 States supported by the function
block. Note that the same State can be used by more than one Step within a Sequence.
Each Step within a Sequence may be configured to advance to any other Step based on time (hours or
minutes), digital event (2 per Step), or manual advance. A separate jog function is also provided.
The controller maintains a pool of 20 user-configurable Sequences in its memory. The Sequences in the
pool can be assigned to run within any of the Sequencer function blocks. Once it has been loaded into a
Sequencer function block, a Sequence can be modified through the menus provided on this Control Station.
A modified Sequence can also be saved back to the pool for later recall, if desired.

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Sequencers
Sequencer Operate

Sequencer Operate

This widget may be accessed from a Home display button. It shows the details of the sequence currently
running in the Sequencer. You can also load a different sequence from memory into the Sequencer, edit the
current sequence, and save the edited sequence to any slot (sequence number) in memory.

Item Description
Title Name of the selected Sequencer block.

Sequence Information

Sequence Number Memory location of the sequence that is being run by the Sequencer.

Sequence Name Name of the selected sequence.

Sequence Description Description of the sequence.

Total Elapsed Time Total time the sequence has been in Run and Hold states.

State Description of the current step’s state.

Mode READY: Sequence is at the beginning of step and is ready to run.

HOLD: Sequence is paused at the setpoint value shown.
RUN: Sequence is executing normally.
STOP: Sequence has reached the end of the last step.

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Sequencer Operate

Item Description
Step Information

Step number Current step number

Elapsed Time Time elapsed in the step. Run time only.

Time Remaining Time remaining in the current step.

Advances to step The sequence will Advance to this step.

Operation Buttons

Run Run a sequence that is in HOLD or READY state.

Hold Put sequence in HOLD.

Advance Advance to the step indicated by Advances to Step.

When the sequence is already in the last step, the advance request is
ignored.

Sequences cannot be advanced to the first step. Current state must

either READY or HOLD.

Reset Reset a HOLD or STOP sequence to the first step. Any edits made to the
sequence are lost unless they were saved. See Save To Sequence
Number.

Sequence load/view/edit/save

Load From Sequence List Loads a sequence from memory into the Sequencer. Sequencer must be
in READY state.

You are presented with a list of sequences (recipes) in controller memory.

Scroll to the desired sequence and touch to highlight it. Touch Load
Sequence to load it into the Sequencer. Loading a sequence overwrites
the current sequence from the Sequencer.

To erase the currently loaded sequence from the Sequencer, select

<Clear Sequence> and load it. When the sequence is cleared, any edits
are lost unless you saved them first with Save To Sequence Number.

See Figure 9 Recipe Load on page 128. All recipe types (profiles,
sequences, schedules) are saved the same way.

Start at step After loading, the sequence will start at this step. Subsequent runs will
start at Step #1.

Save To Sequence List Saves the currently running sequence (and any edits) to a selected slot in
controller memory. Scroll to the desired slot in the controller’s sequence
memory. Once saved, it can be loaded and run later.

See Figure 10 Recipe Save on page 128. All recipe types (profiles,
schedules, sequences) are saved the same way.

View/Edit Sequence Press to view/edit the current sequence. Edits take effect immediately in
the current sequence but they are not saved to sequence memory. When
the sequence is RESET, any edits are lost unless you saved them first
with Save To Sequence Number. See View/Edit Sequence on page 144.

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Sequencers
View/Edit Sequence

View/Edit Sequence

This display lets you edit parameters of the selected sequence. Edits affect only the currently working
sequence, not the sequence in memory, unless you save the sequence.

ATTENTION

Sequence must be in READY state to edit the values on this display.

Item Description

View/Edit Steps button Accesses View/Edit Sequence Steps (page 145) where you can edit each step.

Sequence Information

Sequence number Memory location of the sequence that is being run by the Sequencer.

Sequence name Name of the selected sequence.

Sequence Desc Description of the sequence.

Jog to Step When the sequencer’s JOG input is triggered, the sequencer will jump to the start
of this step then continue.

Time Units Hours or minutes.

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View/Edit Sequence Steps

View/Edit Sequence Steps

This display lets you view and edit step parameters.
• Time/Events
• Auxiliary
• Outputs 1-8 and 9-16
Edits do not affect the sequence in memory unless you save the sequence.

ATTENTION

Sequence must be in READY or STOP state before steps can be edited.

Edit Time/Events

Item Description

Step Step number

State Enter a State Number to assign to the step. 1-50.

State Name Name of state. A unique State, “State 0”, can be used to indicate the last step in a
Sequence. The Sequencer function block will go to Stop mode when it encounters any
Step whose State is State 0.

Timer Duration Length of the step in Time Units. When Timer Duration expires, the sequence will jump to
Timer Next Step.

If you specify a “next step” of zero, the Sequence will STOP when its “next step” trigger is
received. For example, if Step 1 has a Timer Duration of one minute and a “Timer Next
Step” of zero, the Sequence will stay in Step 1 for one minute and then STOP.

If you specify a Timer Duration value of zero, the Sequence will remain at that Step until
Event 1 or Event 2 occurs, or an Advance input or command is received.

Timer Next Step When Timer Duration expires, the sequence will jump to Timer Next Step.

Event Signal 1 When Event Signal 1 is triggered the sequence will jump to Event 1 Next Step.

Event 1 Next Step When Event Signal 1 is triggered the sequence will jump to Event 1 Next Step.

Event Signal 2 When Event Signal 2 is triggered the sequence will jump to Event 2 Next Step.

Event 2 Next Step When Event Signal 2 is triggered the sequence will jump to Event 2 Next Step.

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Sequencers
View/Edit Sequence Steps

Edit Auxiliary

Item Description

Advance Next Step When manually advanced the sequence will jump to this step.

Aux Output Value of auxiliary analog output

View Outputs 1-8/9-16

These buttons take you to displays that show the state of each step’s 16 outputs. Read only.

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 Loops

Overview
Loop widgets
.

Each loop type has its own widget, shown above. From left to right the widgets are:
• Auto/Manual Bias
• Carbon
• On/Off
• PID
• TPSC (Three Position Step Control)
Each widget displays the PV (aqua), SP or Bias (yellow), and Output (green). Use the A/M button to switch
between Auto and Manual. Use the SP Select button to change between LSP (local set point) and RSP
(remote set point).You can change the SP, Bias and Output values/states when LSP and Manual modes are
selected.
Touch the blue title bar at the top of the widget to jump to the Loop Setup display for more details.

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Loops
Loop Setup

Loop Setup
Overview
All the loop widgets let you jump to the Loop Setup display. See example below.

Above is an example of the PID Loop Setup display. At left is the loop widget, with operable buttons and
parameters.
At bottom is a loop trend. The points on the trend typically correspond to PV, SP and Output, whose pen
colors match the values on the left (aqua, yellow, green). Additional points of different colors may be
visible, depending on configuration. Use the gray buttons at the bottom to navigate and zoom.
At the top are buttons that take you to detailed popups for various loop parameters. Buttons are accessible
depending on the loop type, shown below.

Loop type
Button PID ON/OFF 3 POS CARBON A/M BIAS
Control Setup (p. 150) X X X X X
Loop Tuning (p. 151) X X X
Tuning Constants (p. 155 X X X
Alarm Setpoints (p. 156) X X X X X
High Output Limiting (p. 157) X X
X indicates button is accessible

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Loop Setup

Loop modes
All loop displays indicate the current operating mode of the selected loop. Loop modes are described in
Table 38.
Table 38 Loop modes

Loop mode Meaning

AUTO RSP Loop is controlling the process and Remote Setpoint is selected.
MAN RSP Loop output can only be changed manually. Remote Setpoint is selected.
IMAN RSP IMAN (Initialization Manual) occurs with Cascade loops only.
Figure 11. Secondary Cascade is in MAN or LSP, therefore Primary Cascade
output is tracking Secondary Cascade’s PV. Remote Setpoint is selected.
LO RSP LO (Local Override): loop output is tracking the loop’s Output Tracking value.
Remote Setpoint is selected or High Limit Override Status Is ON.
AUTO LSP Loop is controlling the process and Local Setpoint is selected.
MAN LSP Loop output can only be changed manually. Local Setpoint is selected.
IMAN LSP IMAN (Initialization Manual) occurs with Cascade loops only.
Figure 11. Secondary Cascade is in MAN or LSP, therefore Primary Cascade
output is tracking Secondary Cascade’s PV. Local Setpoint is selected.
LO LSP LO (Local Override): loop output is tracking the loop’s Output Tracking value.
Local Setpoint is selected or High Limit Override is ON.

PID Primary PID Secondary

RSP

BCI BCO

When PID Secondary is in Manual

or when Local Setpoint is selected,
PID Primary mode is IMAN. IMAN
causes the PID Primary output to
track the PID Secondary PV.

Figure 11 IMAN loop mode

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Loops
Loop Setup

Loop control setup

The Loop Control Setup Display shows parameters of the selected loop. The table below lists all
parameters for all loop types. Items marked with * are visible depending on loop type.

Item Description

Local Setpoint* Value of Local Setpoint.

Remote Setpoint* Value of Remote Setpoint. This value is changeable only if it is configured as a
second Local Setpoint (LSP2). It is read-only if it is connected to a function
block within the configuration.

Failsafe Output Loop’s output during a failure.

SP High Lim* Highest allowable setpoint value.

SP Low Lim* Lowest allowable setpoint value.

SP Rate Up Lim* Highest allowable rate at which a setpoint changes to a higher value.

SP Rate Down Lim* Highest allowable rate at which a setpoint changes to a lower value.

PV High Lim Highest allowable PV value.

PV Low Lim Lowest allowable PV value.

Out High Lim* Highest allowable loop output value.

Out Low Lim* Lowest allowable loop output value.

Autotune Out High Lim* Highest value of the output beyond which the motor no longer affects the
process.

Autotune Out Low Lim* Lowest value of the output beyond which the motor no longer affects the
process.

Ratio Gain * Gain value for a ratio loop.

Ratio Bias * Local bias value in engineering units. Enterable only if it is configured for local
bias. It is read-only if it is configured for remote bias.

Motor Deadband % * Value of adjustable deadband in %.

Motor Traverse Time (Sec) * Motor travel time in seconds.

Hysteresis* Loop alarm’s hysteresis. 0 to 10% of PV range.

Furnace Factor* Lets you adjust the % Carbon as measured by the controller to agree with the
results of actual shim stock tests. This adjustment may be needed to correct
for specific furnace characteristics such as atmosphere differences, probe
location, and furnace leaks.

Anti-Sooting* Lets you adjust the anti-sooting factor, which limits the %C working setpoint of
the downstream control block to a value which will not permit sooting to occur
in the furnace. When anti-sooting is ON, then the anti-sooting factor is
calculated as a linear translation of probe temperature to %C clamped at
0.75% and 2.0%. When anti-sooting is OFF, then the factor is fixed at 2.0% for
all temperatures.

% Hydrogen* Lets you adjust % hydrogen, one of the factors in the dewpoint calculation. The
dewpoint calculation is a function of the mV input (IN) from the oxygen probe,
temperature of the probe, and %H. The equations used are probe-type
dependent and are supplied by the manufacturer.

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Loop Setup

Item Description

Local % CO* Lets you adjust % Carbon measurement to compensate for variations in the
amount of CO in the carrier gas.

Remote % CO* % Carbon measurement from the function block input within the configuration.

* Visibility depends on loop type.

TIP

• The controller will ignore entry of Local Setpoint if tracking is on and if the loop is
in Manual mode.
• Ratio Bias is enterable only if it is configured for local bias. It is read-only if it is
configured for remote bias.

Loop Tuning
This display lets you set up and start the loop Accutune III tuning function. When initiated, the controller
will start controlling to the setpoint while it identifies the process, calculates the tuning constants, and
begins loop control with the correct tuning parameters.

Item Description

Tuning Status Inactive – The Accutune III tuning process is not active.

Tuning – The Accutune III tuning progress is active.

Fuzzy Overshoot Select ON to activate Fuzzy Overshoot Suppression to minimize overshoot after a
setpoint change or a process disturbance.

Select OFF to disable Fuzzy Logic.

The fuzzy logic observes the speed and direction of the PV signal as it approaches
the setpoint and temporarily modifies the internal controller response action as
necessary to avoid an overshoot. There is no change to the PID algorithm, and the
fuzzy logic does not alter the PID tuning parameters. This Item can be independently
Enabled or Disabled as required by the application to work with “TUNE” On-Demand
tuning.

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Loop Setup

Item Description

Accutune III Type DISABLE - Disables ACCUTUNE III.

CYCLE TUNING - Tuning parameter values are derived from the process response
to the resultant action of causing the PV to oscillate about the Setpoint value. This
tuning method uses the measured ultimate gain and period to produce tuning
parameter values. Cycle tuning does not distinguish between process lags and
always results in gain based on PV amplitude and calculates values of Reset and
Rate based on time of the SP crossings (The Reset value is always 4x the Rate
value.) This method does not require a stable process initially and the process may
be moving.

SP TUNING – Setpoint Tuning based on the process response to a Setpoint change.

When initiated, the control loop is put into an initial temporary manual state until the
process characteristics are identified. This period may last up to a minute. During
this time the Tune status shows Not Ready, and then an initial output step is made
using the preconfigured size and direction parameters along with the preset output
value. The resultant process action is used to determine the tuning parameters and
once the process identification has completed, the loop is returned to automatic
control.

Switch Tune Set Tune Set 1 uses Gain #1, Rate #1, and Reset #1.

Tune Set 2 uses Gain #2, Rate #2, and Reset #2.

PV Adaptive Tuning Tuning method that continuously learns the process as PV deviations are observed
and adapts the tuning parameters to the process response.

DISABLE - Disables PV Adaptive tune.

ENABLE - This method adapts a tuned process to changing system characteristics

over time, when the PV deviates from the Setpoint by a certain amount for any
reason. This method adapts a tuned process to changing system characteristics
over time. It operates by observing a previously tuned process for changes in the
system such as changes in deadtime or other process characteristics that can make
a tuned process become unstable, unresponsive or over responsive. When the PV
deviates from the SP by a certain amount for any reason, the adaptive tuning
algorithm becomes active and begins to observe the resulting PV action. If the
process becomes unstable and oscillates, PV Adaptive Tuning eventually brings the
process into control by retuning parameter values (as needed) using a systematic
approach defined by an expert based method of tuning rules. Should the process not
oscillate but be observed as too fast or sluggish, a different expert rules set is
applied to result in the slowing down or speeding up of the process by adjusting
certain tuning parameter values. This method continuously learns the process as PV
deviations are observed and adapts the tuning parameters to the process response.

Tuning Criteria NORMAL - Very conservative tuning designed to calculate critically damped tuning
parameter values that produce no overshoot.

FAST - More aggressive tuning than Normal. Designed to calculate under damped
parameter values providing faster control to the setpoint but may have some
overshoot.

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Item Description

Accutune Status ACCUTUNE III Status and Error prompts:

NOT READY - This is shown:

- When the control mode is Manual.

- For a Setpoint Tune when the difference between the PV and Setpoint is
greater than 3%.

- When a Setpoint Tune is initiated and the PV is determined, by the adaptive

logic to not have enough “historical data”, or the PV is moving too much to begin a
Setpoint Tune. Either of these conditions will result in the Not Ready status and the
Setpoint Tune algorithm will then wait until the PV is determined to be ready for the
Setpoint Tune to begin.

READY - Indicates that the PV is at lineout in regards to the Setpoint. Lineout occurs
when the PV is within 0.2% of the Setpoint value.

TUNE RUNNING - Accutune lll process still active.

ID FAILURE - SP Tune failed to properly identify the process. This usually occurs
when SP Tune is initiated with a process that is moving. Retry the SP Tune making
sure that the process is stable and not moving in any direction.

SP ERROR - For Cycle Tuning this occurs for Duplex, Manual Tuning when the SP
value is not in the proper range. For cool side tuning the SP must be less than 48%
and for heat side tuning the SP must be greater then 52% of the PV range. For SP
Tune this error condition occurs if the deviation between the PV and SP is greater
than 3% of the PV range when SP Tune is initiated. Retry the SP Tune after
adjusting the deviation to be less than 3%.

GAIN ERROR - This error condition occurs when the process gain value (Kpg) is not
within the range of 0.10 to 10. Adjust this value to 1.00 and retry the SP Tune
making sure that the process is stable and not moving in any direction.

OUTPUT ERROR - For SP Tune this occurs when the initial output is not within the
configured output limits. Check the SP step direction and size to make sure they are
correct or modify the SP to use a value closer to the PV middle range.

PV ADT RUNNING - PV tuning is active monitoring the process.

ABORT - Current Accutune III process was aborted. An active Accutune III process
will be aborted is if the loop is placed in the Manual mode.

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Item Description

Duplex Tuning Selection of three tuning actions when performing a Cycle Tuning procedure on a
Duplex control loop.

DISABLE - Duplex type tuning is disabled and simplex type tuning is used instead.
The resultant is blended tuning which is derived from the process response to
cycling the output between the low and the high output limits. The calculated tuning
parameter values are stored for each side.

MANUAL - Tuning must be initiated manually for each side. The current LSP or RSP
value is used as the target SP for the desired heat or cool side tuning. For the heat
side, the output cycles between 50 percent and the high output limit and for the cool
side the output cycles between 50 percent and the low output limit. Tuning values
are calculated and stored only for the side tuned.

AUTOMATIC - Heat and Cool tuning are sequentially performed automatically.

During the operation of this tuning the target SP used is the mid point between the
high output limit and 50 percent for the heat side and the low output limit and 50
percent for the cool side. During tuning for each side the cycling of the output results
in the PV oscillating around the target SP value. From the data gathered during the
oscillations, tuning values are calculated and stored for each side. After tuning on
both sides is completed, the process SP is returned to the value of the last SP used
prior to the initiation of the tuning procedure.

SP Step Change Configuration parameter for Setpoint Tuning. Select a value between 5 and 15%.
This defines the value of the initial Setpoint step change that is used as the target
Setpoint value for process identification.

SP Tune Step Direction Configuration parameter for Setpoint Tuning. The selection of UP or DOWN results
in the Setpoint change value added to or subtracted from the present Setpoint value.

Process Gain Configuration parameter for Setpoint Tuning. Gain identification value for the
process. Select a value between 0.10 and 10.0. Normal value is 1. This value is
used to estimate the size of the initial output step for a Setpoint Tune.

Start Tune Select this to begin the Accutune III process.

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Tuning constants
This display shows the tuning constants for the selected loop.

Item Description

Switch Tune Set Lets you select the active tune set (Tune Set 1 or Tune Set 2). Determines
which set of Gain/PB, Rate, and Reset parameters are used by the loop.

Gain #1 Or #2 * Gain is the ratio of the output change (%) over the measured variable change
(%) that caused it. Gain = 100/Proportional Band.

Proportional Band (Pb) # 1 Or #2 PB is the percent of the range of the measured variable for which a
* proportional controller will produce a 100% change in its output.

Rate #1 Or #2 Rate affects the controller’s output whenever the deviation is changing; and
affects it more when the deviation is changing faster.

Reset #1 Or #2 Reset, or integral time, adjusts the controller’s output according to the size of
the deviation (SP - PV) and the time it lasts. The amount of corrective action
depends on the value of Gain. Reset is measured as how many times
proportional action is repeated per minute (repeats/minute) or how many
minutes before one repeat of the proportional action occurs (minutes/repeat).

Feedforward Gain** Applies Gain to the feedforward variable (FFV).

Manual Reset** Manual Reset is only applicable if you do not use Reset. It allows correction of
output to account for load changes to bring the PV up to setpoint.

* Either Gain or Proportional Band is displayed but not both.

** Visible for PID and Carbon loop types only.

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Alarm setpoints
This display shows the loop’s setpoints and alarm types. A loop can have two alarms; and each loop alarm
can have two setpoints and types.

Item Description
Alarm 1 Setpoint 1 The value at which the alarm will activate.
Alarm 1 Type 1 No Alarm
PV High - Alarm when PV is greater than the alarm setpoint
PV Low - Alarm when PV is less than the alarm setpoint
Dev High - Alarm when PV - SP is greater than the alarm setpoint.
Dev Low - Alarm when SP - PV is greater than the alarm setpoint.
SP High - Alarm when SP is greater than the alarm setpoint
SP Low - Alarm when SP is less than the alarm setpoint
Out High - Alarm when output is greater than the alarm setpoint
Out Low - Alarm when output is less than the alarm setpoint
Alarm 1 Setpoint 2 same as Alarm 1 Setpoint 1
Alarm 1 Type 2 same as Alarm 1 Type 1
Alarm 2 Setpoint 1 same as Alarm 1 Setpoint 1
Alarm 2 Type 1 same as Alarm 1 Type 1
Alarm 2 Setpoint 2 same as Alarm 1 Setpoint 1
Alarm 2 Type 2 same as Alarm 1 Type 1
Alarm Hysteresis Affects the point at which an alarm clears. For Out High and Out Low
alarms, hysteresis is % of the loop’s output span. For all other alarm
types, it is % of PV span.
PV High - Alarm clears when PV is less than the alarm setpoint by the
amount of hysteresis.
PV Low - Alarm clears when PV is greater than the alarm setpoint by the
amount of hysteresis.
SP High - Alarm clears when SP is less than the alarm setpoint by the
amount of hysteresis.
SP Low - Alarm clears when SP is greater than the alarm setpoint by the
amount of hysteresis.
Out High - Alarm clears when output is less than the alarm setpoint by
the amount of hysteresis.
Out Low - Alarm clears when output is greater than the alarm setpoint by
the amount of hysteresis.
Dev High - Alarm clears when PV - SP is less than the alarm setpoint by
the amount of hysteresis.
Dev Low - Alarm clears when SP - PV is less than the alarm setpoint by
the amount of hysteresis.

TIP

These Loop Alarm parameters are used to set the conditions under which loop alarms occur;
they do not generate the alarm. To generate the alarm, AL1 and AL2 pins of loops should be
connected to the Signal Tags in HC Designer. These signal tags can be configured to generate
alarms in Station Designer.

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High Output Limiting

On PID loops this feature prevents potentially damaging the product or the process by exposing material to
excessive thermal shock caused by applying the maximum PID output during initial startup or product
changeover. High output limiting is enabled by the Track digital input, and when active, limits the PID
output to a value present on the Track analog input for a user specified time period. After the time period
expires, the output limit ramps up at a user specified rate to the normal (non-override) high PID output
limit. The operator interface will indicate an OVERRIDE status at the bottom of the loop displays when
the High Output Limit is active.
The Output limiting feature is also available for Carbon Potential loops but the output limiting action is
only active after the process temperature limit has exceeded the user specified Low Temperature Limit,
which forces the output to 0% or 50% for duplex outputs.

Item Description

Loop type Loop type is PID or CARBON

High Output Limit Override Enable YES: Changes the operation of track command and track value to output
limit enable and output limit value.

NO: Normal output high limit is used.

High Output Limit Override Status ON: Digital input controlling output limiting is ON.

OFF: Digital input controlling output limiting is OFF.

Current High Output Limit % Current output high limit. When in override status, this changes
according to loop’s tracking value and ramp rate. It will never exceed the
loop’s normal (non-override) high output limit.

Time In Override Elapsed time that High Output Limit Override Status is ON and High
Output Limit Override Enable is YES. It will continue counting even after
the loop’s normal output high limit is reached. It resets to zero when the
Override Status changes to NO (i.e., when loop’s discrete Output Track
Command turns off).

Delay Time (Mins) Enter number of minutes. When override status is ON, the delay time
elapses before the override output limit begins to ramp up at the
specified rate. Delay time of zero causes the override high output limit to
track the loop’s tracking value until override status is OFF.

Ramp Rate (%/Min) Enter %/minute rate at which the output limit will (after delay time) ramp
up to the normal non-override high limit. Rate of zero causes override
limit to track the loop’s tracking value during the delay time, after which
high output limit steps without ramping to the normal output high limit.

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Overview

This display lets you select the type of calibration. You must change the controller mode before calibrating.

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AI Calibration

AI Calibration
Overview
Analog inputs are factory calibrated to +/- 0.1% of span unless specifically noted in the range
specifications. A field calibration may be performed on any analog input on a point-by-point basis to
optimize measurement accuracy. The factory calibration parameters are retained in non-volatile memory
and may be re-installed to undo a field calibration using selections from the calibration procedure.
Both Factory and field calibration information is stored on the Analog Input module itself. Therefore, once
a module has been calibrated it can be moved to any slot position or any rack without being recalibrated.
However, the controller will automatically restore a channel’s Factory calibration settings under the
following conditions:
• The channel is reconfigured to use a different gain setting. This may happen if you change the input type
of the channel (for example, change from a TC to a Voltage or RTD input type).
• The AI module detects an error in its stored field calibration information. In this case, factory
calibration is restored for all of the channels on the affected module.
Note that you must configure a channel’s input type and range before you try to calibrate it. The
calibration will be performed against the gain setting associated with the input type and range. If you
change the input type after calibrating, the module will automatically restore the Factory calibration
settings for that channel. If necessary, you can use the PC Designer’s Monitor Mode feature to determine
whether a given channel is using Factory or field calibration.

Calibration equipment
• For best results use a calibration source accurate to 1 microvolt.
• You must use a voltage source and copper lead-wire for channels that are configured as thermocouple
and voltage inputs. Do not use a compensated calibrator and TC extension lead-wire to calibrate TC
channels.
• Note that Cold Junction sensor and Analog Input calibrations are performed separately; you do not have
to calibrate the CJ sensors before calibrating your TC input channels.
• If you are calibrating current-type inputs (0-20 ma or 4-20 ma) and you are using an external shunt
resistor, we recommend that you calibrate the channel using a current-source with the actual shunt
resistor installed on the terminals. This will allow you to calibrate out any inaccuracies in the shunt
resistor. A high-precision shunt resistor should always be used.

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AI Calibration

Calibrate AI channel
Calibrate AI Channel guides you through a procedure for calibrating an analog input channel. Perform the
steps in the order of the menu. Refer to the example AI calibration procedure.

Item Description

Instrument Status and This displays the status at each step of calibration. In order of appearance:
Instructions Ready
Connect AI 0% Reference
0% AI Cal Input
Connect AI 100% Reference
100% AI Cal Input
Save AI Calibration
AI Cal Failed (red) or Done (green)
Analog Input calibration may fail for the following reasons.
-The physical connection to the calibration source is bad.
-The selected Rack, Module, and Channel does not exist, or does not support AI
calibration.
-The selected input does not support the electrical range that you are trying to calibrate.
For example, the 16-channel high-level AI module does not support a range of 0-2
volts.
Reference Indicates numeric input reference value and engineering units. Also indicates an invalid
module or channel.
Rack Number Enter the rack number, module number, and channel number of the AI to be calibrated,
Module Number then press Select Input.
Channel Number

Select Input Select this to verify that the selected rack/module/channel is installed in the controller.

Calibrate 0% Input Set the calibration source to the value shown next to Reference, then select this to
calibrate. Calibration takes 30 seconds. Status will indicate when calibration is
complete.
Calibrate 100% Input Set the calibration source to the value shown next to Reference, then select this to
calibrate. Calibration takes 30 seconds. Status will indicate when calibration is
complete.
Save Select this to save the channel calibration.

After calibration, return the Controller to Run mode. Use IO Calibration display (page 159) or Controller
Mode button (page 10).

Cancel Calibration
You can stop the calibration process at any time by pressing the Cancel Calibration button. The status goes
to “ready” and the previous calibration is restored.

Restore AI factory calibration

This restores the selected channel to its factory calibration settings. Enter the rack, module, and channel to
be restored, then press Restore Factory Calibration. Status will show “Restore AI Input”, then green
“Done” or red “Restore AI Failed.” After calibration, return the Controller to Run mode. Use IO
Calibration display (page 159) or Controller Mode button (page 10).

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CJ Calibration

CJ Calibration
Each analog input card has two Cold Junction (CJ) sensors that are used in making thermocouple
measurements. These sensors may be re-calibrated in the field if desired to optimize thermocouple
measurement accuracy using the following procedure.

ATTENTION

An inaccurate CJ calibration will affect the accuracy of your thermocouple measurements. If

you are going to perform CJ calibration, you must use a very accurate temperature-measuring
device. It is also important that you allow the temperature around the controller’s terminal
block to stabilize for 10 minutes or more before you take the CJ temperature reading.

Perform the steps in the order shown in the following table.

Item Description

Instrument Status And This displays the status at each step of calibration. In order of appearance:
Instructions Ready
Measure CJ Temperature & Enter
CJ Cal Input
CJ Cal Failed (red) or Done (green)
Save CJ Calibration

Reference Indicates CJ temperature reading in Degrees C. Also indicates an invalid module or

channel.

Rack Number Enter the rack number, module number, and channel number of the CJ sensor to be
Module Number calibrated. Channel 1 is the top CJ sensor, Channel 2 is the bottom sensor.
Channel Number

Select CJ Input Select this to verify that the displayed module and channel are correct.

User Measured CJ Place your temperature-measuring device at the terminal that is closest to the selected
Temperature (Deg C) CJ sensor. Allow the environment around the terminal block to stabilize for at least 10
minutes before taking the temperature reading. Enter the measured temperature here,
in Degrees C.

Calibrate CJ Select this to start calibration. Calibration takes 30 seconds. Status will indicate when
calibration is complete.

Save Cal Select this to save the calibration.

After calibration, return the Controller to Run mode. Use IO Calibration display (page 159) or Controller
Mode button (page 10).

Cancel Calibration
You can stop the calibration process at any time by pressing the Cancel Calibration button. The status goes
to “ready” and the previous calibration is restored.

Restore CJ factory calibration

This restores the selected cold junction sensor to its factory calibration settings. Enter the rack, module and
channel, then press Restore Factory Calibration. Status will show “Restore CJ Input”, then green “Done” or
red “Restore CJ Failed.” After calibration, return the Controller to Run mode. Use IO Calibration display
(page 159) or Controller Mode button (page 10).

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AO Calibration

AO Calibration
ATTENTION

You should not access the Hybrid Control Utilities Calibrate Controller Analog I/O display while
the IO calibration display is being displayed, or vice versa. Calibration can't be done as long as
both displays are shown; user must exit either display to do a calibration.

Analog outputs are factory calibrated to +/- 0.1% of span. A field calibration may be performed on any
analog output on a point-by-point basis to optimize accuracy. The factory calibration parameters are
retained in non-volatile memory and may be re-installed to undo a field calibration using selections from
the calibration procedure.
Both Factory and field calibration information is stored on the Analog Output module itself. Therefore,
once a module has been calibrated it can be moved to any slot position or any rack without being
recalibrated.

Item Description

Instrument Status And This shows the status of the calibration. In order of appearance statuses are:
Instructions Ready
Measure AO 0% Output & Enter
0% AO Output
Measure AO 100% Output & Enter
100% AO Output
AO Cal Failed (red) or Done (green)
Save AO Calibration

Reference Indicates output reference value and engineering units. Also indicates an invalid
module or channel.

Rack Number Enter the rack, module, and channel of the AO channel to be calibrated.
Module Number
Channel Number

Select Output Select this to verify that the selected module is installed in the controller.

Measured Values (mA) Measure the actual output (as mA, mV or Volt) and then enter the measured value in
mA here.

Calibrate 0% Output Select this to calibrate. Status will indicate when calibration is complete.

Calibrate 100% Output Select this to calibrate. Status will indicate when calibration is complete.

Save Select this to save the channel calibration.

After calibration, return the Controller to Run mode. Use IO Calibration display (page 159) or Controller
Mode button (page 10)

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AO Calibration

TIP

• The range of an Analog Output is either 0-20 mA or 4-20 mA. If you are using an
external resistor to convert the current output to a voltage output, you can calibrate
the AO channel with the resistor in place. However, you must still enter the 0 and
100 percent calibration values in milliamps; you cannot enter volts or millivolts.
• AO calibration fails when the value entered by the user is outside of the following
limits:
− For 4 mA dc, the value entered must be between 3.3 and 4.7 mA dc.
− For 20 mA dc, the value entered must be between 19.3 and 20.7 mA dc.

Cancel Calibration
You can stop the calibration process at any time by pressing the Cancel Calibration button. The status goes
to “ready” and the previous calibration is restored.

Restore AO factory calibration

This restores the selected AO channel to its factory calibration settings. Enter the rack, module, and
channel of the AO channel to be restored, then press Restore Factory Calibration. Status will show “Restore
AO Input”, then green “Done” or red “Restore AO Failed.”
After calibration, return the Controller to Run mode. Use IO Calibration display (page 159) or Controller
Mode button (page 10).

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PPO Motor Calibration

PPO Motor Calibration

Overview
This lets you calibrate a PPO motor three ways:
• Auto – Controller positions the motor and captures the positions. See page 167.
• Semi-Auto – Controller positions the motor and the user captures the positions. See page 168.
• Hand – User positions the motor by hand and captures the positions. See page 169.
The calibration of a motor is similar to that of an AI or AO. However, the motor calibration values are
stored as part of the PPO block’s configuration data, not on the AI card itself. Therefore, to retain these
motor calibration values, you must upload the configuration and save it to disk after motor calibration has
been performed.
The basic motor calibration procedure is as follows:
• move the motor to its 0% position and wait until the feedback signal has stabilized.
• capture the 0% feedback value.
• move the motor to its 100% position and wait until the feedback signal has stabilized.
• capture the 100% feedback value.
• measure the true motor speed by:
d) moving the motor for a fixed period of time.
e) measuring the position feedback delta.
f) computing a motor speed from this data.
This value will override any previously configured value.
• save the calibration values as part of the PPO block’s configuration data.
After calibration, return the Controller to Run mode. Use IO Calibration display (page 159) or Controller
Mode button (page 10).

Calibration Status Information

Instrument Status and Instructions – this field indicates the current status of the calibration procedure.
NOTE: If a status of “Calibration Failed” is displayed, take the appropriate corrective action,
and then repeat the calibration procedure again, beginning at Step 1. See “Calibration Errors”
for more information.
Time required for current step is shown in % complete. Once this becomes 100% then only
Controller will allow to proceed.
Feedback Value– this field shows the motor feedback value [a value between 0.0 and 1.0]. This value
should change whenever the motor is actually moving.
Calibration Block– Select the PPO to be calibrated.

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Cancel Calibration
You can stop the calibration process at any time by pressing the Cancel button. The status goes to “ready”
and the previous calibration is restored. The motor will stop moving when this button is pressed. In order
to resume calibration you must start over.

Calibration Errors
The following errors may be reported during the calibration process. Errors are displayed in red. Take the
appropriate corrective action and repeat the calibration procedure from the beginning.

Table 39 Calibration Errors

Instrument Status and Cause Corrective Action

Instructions

Calibration Failed The calibration was not Go back to Step 1 and repeat
performed in the correct the calibration process
sequence.

The selected motor position has Go back to the SELECT

not been configured. MOTOR TO CALIBRATE
display and reselect the desired
motor.

Calibration Failed – Bad AI The AI channel being used for Check for correct wiring and
the position feedback signal has correct AI input type.
failed in some way.

Calibration Failed – Bad Feedback The value of the feedback signal Check for reversed wiring of
is out of range for the calibration the feedback signal. Forward
being performed. motor movement should
produce increasing feedback
values.

Calibration Failed – Wrong AI The firmware on the AI module Obtain a new AI module from
Version does not support PPO motor your supplier.
control using a slide wire for the
position feedback.

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Auto Calibration Procedure

Table 40 Auto Calibration Procedure

Step Action

1 Select block for calibration.

Select “Auto”.

Status – Ready

2 Select “Start”

Status – this field will change as the controller automatically performs the various steps of the
motor calibration process described in Step 3 below.

Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]

Percent Complete – indicates the progress of each step [0 to 100%]

3 RESULT:

• Status – Wait…Motor Moving To 0% Position.

Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should decrease until the 0% position is reached.
Percent Complete – indicates the progress of this step [0 to 100%]

• Status – Wait…Calculating 0% Feedback Value.

Feedback Value – indicates the current position of the motor.
Percent Complete – indicates the progress of this step [0 to 100%]

• Status – Wait…Motor Moving To 100% Position.

Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should increase until the 100% position is reached.
Percent Complete – indicates the progress of this step [0 to 100%]

• Status – Wait…Calculating 100% Feedback Value.

Feedback Value – indicates the current position of the motor.
Percent Complete – indicates the progress of this step [0 to 100%]

• Status – Wait…Calculating Motor Speed.

Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]

• Status – Wait…Saving Calibration Values.

Percent Complete – indicates the progress of this step [0 to 100%].

• Status – Calibration Completed.

4 Once calibration is completed, select one of the following choices from the Motor Position
popup: Position Motor at 0%, Position Motor at 100, Don’t Move Motor.

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Semi-Auto Calibration Procedure

ATTENTION
The steps of the Semi-Auto Calibration Procedure must be performed in the order described
below. You must wait for each step to complete before selecting and activating the next step.
You can restart the procedure at any time by canceling the calibration and beginning again at
Step 1.

Table 41 Semi-Auto Calibration Procedure

Step Action

1 Select block for calibration.

Select “Semi-Auto”.
Status – Ready
2 Select “Start”
• Status – Wait…Motor Moving To 0% Position.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should decrease until the 0% position is reached.
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Motor Is At 0% Position
3 Select “Calibrate 0%”
• Status – Wait…Calculating 0% Feedback Value.
Feedback Value – indicates the current position of the motor [0.0 to 1.0].
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – 0% Feedback Value Captured
• Status – Wait…Motor Moving To 100% Position.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should increase until the 100% position is reached.
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Motor Is At 100% Position
4 Select “Calibrate 100% Position”
• Status – Wait…Calculating 100% Feedback Value.
Feedback Value – indicates the current position of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – 100% Feedback Value Captured
5 Select “Calibrate Speed”. A warning display will appear:
WARNING
MOTOR SPEED CALIBRATION
WILL MOVE MOTOR BETWEEN
THE 0% AND 100% CALIBRATION POINTS.
PRESS OK TO START
ELSE PRESS CANCEL
6 Press OK to start the Motor Speed Calibration.
• Status – Wait…Calculating Motor Speed.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Motor Speed Calibration Complete

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 I/O Calibration
PPO Motor Calibration

Step Action

7 Select “Save Cal”. The following information will appear in a popup:

Feedback At 0% - a value corresponding to the motor’s 0% position [0.0 to 1.0]

Feedback At 100% - a value corresponding to the motor’s 100% position [0.0 to 1.0]
Motor Speed (In Seconds). This is the motor speed that was detected during Motor Speed
Calibration. This is the time it takes the motor to travel from its calibrated 0% position to its
calibrated 100% position.

Select OK to save calibration, else select Cancel.

• Status – Wait…Saving Calibration Values.
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Calibration Complete
8 Once calibration is completed, select one of the following choices from the Motor Position
popup: Position Motor at 0%, Position Motor at 100, Don’t Move Motor.

Hand Calibration Procedure

ATTENTION
The steps of the Hand Calibration Procedure must be performed in the order described below.
You must wait for each step to complete before selecting and activating the next step.

Table 42 Hand Calibration Procedure

Step Action
1 Select block for calibration.
Select “Hand”.
Status - Ready
2 Select “Start”
• Status – Please Move Motor To 0% Position.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should increase when the motor is moved in the forward direction, and decrease when the
motor is moved in the reverse direction.
Percent Complete – will remain at 0% during this step.
Move the motor by hand to the 0% position. When complete, go to step 3.
3 Select “Calibrate 0%”
• Status – Wait…Calculating 0% Feedback Value.
Feedback Value – indicates the current position of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – 0% Feedback Value Captured
4 • Status – Please Move Motor To 100% Position.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]. This value
should increase when the motor is moved in the forward direction, and decrease when the
motor is moved in the reverse direction.
Percent Complete – will remain at 0% during this step.
Move the motor by hand to the 100% position. When complete, go to step 5.

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I/O Calibration
PPO Motor Calibration

Step Action
5 Select “Calibrate 100”
• Status – Wait…Calculating 100% Feedback Value.
Feedback Value – indicates the current position of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – 100% Feedback Value Captured
6 Select “Calibrate Speed”. A warning will appear:
WARNING
MOTOR SPEED CALIBRATION
WILL MOVE MOTOR BETWEEN
THE 0% AND 100% CALIBRATION POINTS.
PRESS OK TO START
ELSE PRESS CANCEL
7 Press OK to start the Motor Speed Calibration.
• Status – Wait…Calculating Motor Speed.
Feedback Value – indicates movement and direction of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Motor Speed Calibration Complete
8 Select “Save Cal”. The following information will appear:
Feedback At 0% - a value corresponding to the motor’s 0% position [0.0 to 1.0]
Feedback At 100% - a value corresponding to the motor’s 100% position [0.0 to 1.0]
Motor Speed (In Seconds). This is the motor speed that was detected during Motor Speed
Calibration. This is the time it takes the motor to travel from its calibrated 0% position to its
calibrated 100% position.
9 Press OK to Save Calibration.
• Status – Wait…Saving Calibration Values.
Feedback Value – indicates the current position of the motor [0.0 to 1.0]
Percent Complete – indicates the progress of this step [0 to 100%]
• Status – Calibration Completed

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 I/O Calibration
Motor Setup

Motor Setup
The Motor Setup display lets you set the motor’s Deadband, Travel Time, Low Output Limit, and High
Output Limit.
Item Description

Select PPO Block Select a motor.

Dead Band Deadband is an adjustable gap between forward and reverse motor operation (the range
over which the output can change before a relay is energized).

Travel Time Travel time is the time it takes the motor to travel from its calibrated 0% position to its
calibrated 100% position.

Output Low Limit Low limit for the motor position.

Output High Limit High limit for the motor position.

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 Maintenance

Troubleshooting
What to do if the Control Station has difficulty starting up
If the Control Station does not power up properly or if you have difficulty in downloading a configuration
to the Control Station, a "cold start" is a handy way of starting over cleanly.

ATTENTION

A cold start clears the Control Station memory. You will need to re-load the Control Station’s
configuration. Refer to Station Designer documentation for details on Downloading to a device.

Performing a cold start

Step Action

1 Disconnect power from the unit.

2 Press and hold the F1 and F2 keys, then power up the unit while continuing to hold the F1 and
F2 keys.

3 Wait until the display says “Soft-Key 1 to clear database”, then release the F1 and F2 keys.

4 Press the F1 key to clear the database.

The following message will appear with the default IP address:

“ INVALID DATABASE

IP Address is 192.168.1.253 with TCP/IP download enabled on port 789.

MAC Address is…

Hold 1st and 4th keys on power-up to configure IP”

5 Re-load the Control Station configuration. See Station Designer manual 51-52-25-149 for
details on Downloading to a device.

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What to do if you want to change the IP Address at the Control Station
For a new Control Station that does not have a valid database, proceed with step 1 in the table below. If the
Control Station has a valid database and you want to change the existing IP address, the database memory
must first be cleared by performing the cold start procedure listed above. Once the database has been
cleared, the following procedure may be used to enter a new IP Address at the Control Station.

Changing or entering IP Address

Step Action

1 Disconnect power from the unit.

2 Press and hold the F1 and the fourth Soft Key (Logoff for 900CS10 and F4 for 900CS15)
simultaneously and hold them down while applying power.

3 Keep the keys pressed until a pop-up keypad appears. Enter an IP Address that has the same
subnet as your PC and the HC900 Controller and a unique fourth number. Press the green
arrow to enter the IP Address.

4 The following message will appear with the newly entered IP Address:

“ INVALID DATABASE

IP Address is 192.168.1.nnn with TCP/IP download enabled on port 789.

MAC Address is…

Hold 1st and 4th keys on power-up to configure IP”

5 Using the new IP Address, download a Station Designer database file to the 900 Control
Station by means of the Link menu.

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How to remove the rear cover and change the battery of the operator interface?
A battery is used to keep time when the unit is without power. Typical accuracy of the Control Station time
keeping is less than one minute per month drift. The battery of an operator interface unit does not affect the
unit’s memory, all configurations and data is stored in non-volatile memory.
Symbol Definition

EXPLOSION HAZARD - The area must be known to be non-hazardous

before servicing/ replacing the unit and before installing or removing I/O
wiring and battery.
BATTERIES MUST BE UL RECOGNIZED (UL RECOGNIZED
COMPONENT DIRECTORY CATEGORY BBCV2) LITHIUM BATTERIES
TYPE CR2025 MANUFACTURED BY SANYO ENERGY CORP. OR
VARTA BATTERIE AG OR PANASONIC.

EXPLOSION HAZARD - Do not disconnect equipment unless power has

been disconnected and the area is known to be non-hazardous.

CAUTION: RISK OF ELECTRIC SHOCK

The inverter board, attached to the mounting plate, supplies the high
voltage to operate the backlight. Touching the inverter board may result in
injury to personnel.
CAUTION:
The circuit board contains static sensitive components. Before handling the
operator interface without the rear cover attached, discharge static charges
from your body by touching a grounded bare metal object. Ideally, handle
the operator interface at a static controlled clean workstation. Also, do not
touch the surface areas of the circuit board. Dirt, oil, or other contaminants
may adversely affect circuit operation.

Changing the battery of Control Station unit

Step Action

1 Remove power cabling. Remove the rear cover of the unit. To remove the cover, remove all of
the screws on the rear of the unit that are marked with an arrow but not the one screw marked
with the earth ground symbol. Lift the top side, hinge the cover, thus providing clearance for the
connectors on the bottom side of the PCB.

2 Install in the reverse manner. Remove the old battery* from the holder and replace with the new
battery.

3 Replace the rear cover, cables, and re-apply power.

* Please note that the old battery must be disposed of in a manner that complies with your local waste
regulations. Also, the battery must not be disposed of in fire, or in a manner whereby it may be damaged
and its contents come into contact with human skin.

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Parts
EXPLOSION HAZARD

Substitution of components may impair suitability for Class I, Division 2.

Replace parts with appropriate Honeywell parts only. Failure to do so may result in
explosion causing death or serious injury.

To order parts below, see the contact information in the front of this manual.

Table 43 Parts

Description Order part number

Clear protective film for touch screen 50038816-501 for 900CS10-

00 and 50038816-502 for
900CS15-00

Replacement backlight 50038818-501 for 900CS10-

00 only

Replacement touch screen 50038820-501 for 900CS10-

00 only

CompactFlash card (for data logging) 50040636-002

Adapter plate (for replacing 1042 OI) 50039118-501

USB programming cable 50038817-001

Ethernet cable 51451432-010

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 Index

A F
Access function block details.............................................. 9 Floating Point Big Endian ................................................ 27
Alarms ........................................................................ 10, 12 Floating Point Little Endian ............................................. 27
Alternator ........................................................................ 105 Four Selector Switch ........................................................ 97
Autotuning Output Low Limit Value.............................. 150
H
B Hand/Off/Auto Switch ................................................... 100
bias High output limiting .............................................. See Loop
ratio ............................................................................ 150 HOA display .................................................................. 100
Buttons ................................................................................ 9 How to
change a value................................................................ 9
enter data or change setting............................................ 9
C enter new value .............................................................. 9
Calibrate AI .................................................................... 160 jump to related display ................................................... 9
cold junction ............................................................... 162 How to enter text ................................................................ 9
Calibrate AO ................................................................... 163
Calibration
restore to AI factory ................................................... 161
J
restore to AO initial .................................................... 164 Jump to related display ....................................................... 9
restore to CJ factory ................................................... 162
Change a value.................................................................... 9
Cold Start K
of HC900 defined ......................................................... 19 Keys ................................................................................. 11
cold start of Control Station .................................... 173, 174
cold start of HC900 ........................................................... 19
Communications L
Ethernet port E1/E2 status ............................................ 27
expansion rack ........................................................ 29, 30 Lead CPU Diagnostics ..................................................... 56
host connections ........................................................... 32 Lead or Reserve CPU diagnostics error status messages.. 57
Peer Connections status ................................................ 33 LEDs ................................................................................ 12
CompactFlash ............................................................. 11, 12 Loop
Controller mode ................................................................ 10 alarm setpoints ........................................................... 156
Controller setup ................................................................ 10 control setup............................................................... 150
Controller status ................................................................ 17 high output limiting ................................................... 157
modes ......................................................................... 149
tune constants............................................................. 155
D
Data entry, how to............................................................... 9 M
Data Log ........................................................................... 10
Device control................................................................... 98 Main menu
Diagnostics ....................................................................... 10 tree ............................................................................... 16
Redundant Overview .................................................... 48 Maintenance ................................................................... 173
mode
controller modes defined.............................................. 19
E Mounting ............................................................................ 5
Events ............................................................................... 10
Setpoint schedule........................... See Setpoint schedule

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 P
parts
replacement ................................................................ 176
PID
high output limiting .................................................... 157
pushbuttons, analog and digital......................................... 90

R
Rack diagnostics error status messages............................. 51
Ramp display .................................................................. 103
Redundant Controller Diagnostics error status messages . 48
replacement parts ............................................................ 176
Reserve CPU Diagnostics ................................................. 56

S
Sequencers ...................................................................... 141
Setpoint program
edit.............................................................................. 129
edit segments .............................................................. 131
fast forward ................................................................ 130
overview ..................................................................... 119
states ................................................... 120, 126, 134, 142
Setpoint schedule
clear from scheduler ........................................... 110, 111
defined ........................................................................ 133
edit.............................................................................. 137
edit guarantee hold ..................................................... 139
edit segment events .................................................... 139
edit segments .............................................................. 138
edit setpoints............................................................... 138
operate menu .............................................. 110, 111, 112
overview ..................................................................... 133
popup menu ................................................ 110, 111, 112
save............................................................................. 110
setup ........................................................................... 134
signals, analog and digital ................................................. 90
Site preparation ................................................................... 5
Stage ............................................................................... 101
Startup................................................................................. 6

T
Text entry............................................................................ 9
Troubleshooting
difficulty starting ........................................................ 173

V
variables, analog and digital ............................................. 90

W
Warm Start
defined .......................................................................... 19

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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 NORTH AMERICA SOUTH AMERICA

(TAC) hfs-tac- Phone: + 80012026455 or +44 Honeywell Process Solutions, Honeywell do Brazil & Cia
support@honeywell.com (0)1202645583 Phone: 1-800-423-9883 Phone: +(55-11) 7266-1900
FAX: +44 (0) 1344 655554 Or 1-800-343-0228 FAX: +(55-11) 7266-1905
Australia
Honeywell Limited Email: (Sales) sc-cp-apps- Email: (Sales) ask- Email: (Sales) ask-
Phone: +(61) 7-3846 1255 salespa62@honeywell.com
ssc@honeywell.com or ssc@honeywell.com or
FAX: +(61) 7-3840 6481 or (TAC) hfs-tac-
(TAC) hfs-tac-
Toll Free 1300-36-39-36 (TAC) hfs-tac- support@honeywell.com
support@honeywell.com
Toll Free Fax: 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
Honeywell Field Prtoducts
512 Virginia Drive
Fort Washington, PA 19034
www.honeywellprocess.com

51-52-25-148 Rev.7 March 2013 Printed in USA