How to Specify HC900 Controllers

Hybrid Control Designer

1042 Operator Interface

HC900 Controller

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General Guidelines:
The HC900 Hybrid Controller is sold in modules and components that are assembled on-site.
After the type and quantity of I/O and the quantity of I/O racks needed for the installation based
on the distribution of I/O have been determined, use the procedure below to specify the
appropriate hardware and software components.

UMC900 Hardware

Rack

I/O

Power CPU
Supply Terminal
Boards

Selecting a Controller Rack(s)

The size and quantity of controller racks required is determined by the total number of I/O cards
used in a specific location. Generally expansion racks are needed if the quantity of I/O cards
exceeds 12 for the control strategy, or they may be optionally selected if a cost savings exceeding
$1200 to $1400 can be obtained through reduced wiring. The total I/O for a single controller is
limited to 512 total I/O, 256 analog inputs and 64 analog outputs.

1 2 3 4 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12

Power Supply
Processor

To select a rack(s), first total the number of I/O cards needed by taking the total I/O by type and
dividing it by the number of channels per card, rounding up the result to the next largest whole
number. The table below indicates the card density by type:

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 Card Type Channels per card I/O needed Cards needed
Analog Input 8
Analog Output 4
Digital Input Contact 16
type
Digital Input VDC 16
Type
Digital Input VAC 16
Type
Digital Output VDC 16
type
Digital Output VAC 8
Type
Digital Output Relay 8
Type
Total Cards Needed

After determining the total number of I/O cards, determine the number of controller racks needed.
If the total number of I/O cards needed is 12 or less, and the users enclosure for the rack can
accommodate rack sizes up to 22.5 inches wide, the I/O can be mounted in a single rack. Specify
a rack size large enough to accommodate the total number of I/O cards from the table below:

Total number of I/O cards I/O cards per rack Rack Model Number
From 1 to 4 4 900R04 0001
From 1 to 8 8 900R08 0001
From 1 to 12 12 900R12 0001

If the total number of I/O requires more than 12 cards, or if the users enclosure cannot
accommodate rack sizes up to 22.5 inches wide, more than one rack will be needed. Determine
the total number of racks and rack sizes based on the number of I/O cards that are to be located in
a specific location. Use the table above to select the appropriate rack size for each location. The
total number of racks supported by a single controller is 5, one for the main controller and 4
remote racks.

Optional Shield Terminal Connections

If shielded field wiring will be used for I/O, a separate optional shield termination connector may
be added to the controller rack to allow local termination of the shields. One shield terminal kit
containing two shield connectors will accommodate up to four (4) consecutive I/O modules. To
specify optional shield terminal strips, specify the quantity needed using the kit number in the
table below.

Shield Terminal strip Package of 2 900TSS-0001

Selecting a Rack Power Supply

A separate 120/240 VAC power supply must be ordered for each rack that was specified above.
The single power supply supports operation on either 120 or 240 volts, AC. Specify power
supplies using the following model numbers:

60 Watt Power Supply One per rack 900P01 - 0001

28 Watt Power Supply One per rack 900P02 - 0001

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The P02 Power Supply is lower cost but has I/O quantity & type limitations for the individual
rack(s). For multiple rack HC900 configurations, you can have a mixture of P01 and P02 power
supplies. The limitations apply to the I/O cards within the rack containing a P02 power supply.
Reference the below chart to determine if you can use the P02 Power Supply for each rack.

Selecting a Controller CPU

A single controller CPU is required for the main controller rack. The HC900 card racks allocate
one location for the CPU. This location does not count against the total number of slots available
for I/O points. Four CPU selections are available. Selection #1 includes the controller CPU,
Hybrid Control Designer Configuration Software on CD and a second CD containing the system
documentation. This selection is recommended for first time users of the system. Selection #2
contains the Controller CPU only. This selection should be used for units 2 through n of multi-
unit orders or when the user already has a current version of Hybrid Control Designer software
and documentation. Selections 3 & 4 offer a more economical solution for smaller applications
where requirements do not exceed 8 PID loops, 400 function blocks, a single rack of I/O and fast
scan times below 53 ms. Specify a model number from the table below.

Selection Description Model Number

1 Controller CPU, Hybrid Control Designer 900C51-0020
Configuration Software, Documentation on CD
2 Controller CPU only 900C52-0020
3 Controller CPU, Hybrid Control Designer 900C31-0020
Configuration Software, Documentation on CD
4 Controller CPU only 900C32-0020

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Selecting Scanner Modules
If the amount of I/O for the application requires more than one rack, racks 2, 3, 4 and 5 of the
system will require a Scanner Module in place of the CPU module. Scanner modules replace CPU
modules in remote racks and its slot location does not count against the total available I/O slots of
the rack. Specify one (1) scanner module for each controller expansion I/O rack using the model
number below:
Description Application Model Number
Scanner Module Remote rack interface module 900C53-0020

Selecting Input and Output Modules

As a general rule, any I/O module can be inserted into any location in a controller rack or remote
rack. In practice, the assembly guidelines offer recommendations on how to position I/O into a
rack to minimize the effects of temperature within the rack.

Choose from the following I/O modules to satisfy the applications requirements:

Card Type Channel Density Model Number

Analog Input (Universal) 8 point 900A01 0002
Analog Output (020, 420 mA) 4 point 900B01 0001
Digital Input, Contact Type 16 point 900G01 0001
Digital Input , 24VDC 16 point 900G02 0001
Digital Input, 120/240 VAC 16 point 900G03 0001
Digital Output, Relay Type 8 point 900H01 0001
Digital Output, 24VDC type 16 point 900H02 - 0001
Digital Output, 120/240 VAC type 8 point 900H03 - 0001

I/O Card Temperature Influence

The HC900 Controller has an ambient temperature rating of 60 degrees C, however, for
maximum reliability some I/O de-rating or selective adjustments should be made when the
controller is to be operated in environments above 55 degrees C. These adjustments may lessen
the total number of I/O cards of a specific type that should be installed in a controller rack.

The following de-ratings apply when operating above 55 degrees C.

1. For 240 VAC digital inputs, limit the number of ON inputs per module to 12 at any given
time or provide open card slots on both sides of the digital input module.
2. Limit the maximum number of analog output modules per rack to 10.

Selecting I/O Terminal Boards

Terminal boards must be ordered separately for each I/O module. Two terminal board styles are
available, the Euro style and the Barrier Style. Each of the two styles is available as a high
current type (tinned contacts) and a low current type (gold contacts). Choose an appropriate
terminal board assembly for each type of I/O Module.

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 EURO Style BARRIER Style

Specify one each of the following terminal board types for I/O modules:
Analog Inputs, Analog Outputs, Contact Digital Inputs, DC Digital Inputs, DC Digital Outputs.

Terminal Board (Black Color) Euro Style 900TEK - 0001

Terminal Board (Black Color) Barrier Style 900TBK - 0001

Specify one each of the following terminal board types for I/O modules:
AC Digital Input, AC Digital Output, Relay Output

Terminal Board (Red color) Euro style 900TER - 0001

Terminal Board (Red Color) Barrier style 900TBR - 0001

Remote Termination Panels (RTPs)

As an alternative to the standard Euro or Barrier style terminal boards, pre-wired terminal board
assemblies, called RTPs, are available. RTPs are available for all I/O types except for
Thermocouple (T/C) inputs.

Analog Input Remote Terminal Panel 900RTA - L001

Relay Output Remote Terminal Panel 900RTR - H001
DI, DO, AO Remote Terminal Panel 900RTS - 0001
Low Voltage RTP Cable (1.0M, 3.28ft.) 900RTC - L010
Low Voltage RTP Cable (2.5M, 8.2ft.) 900RTC - L025
Low Votage RTP Cable (5.0M, 16.4ft.) 900RTC - L050
High Voltage RTP Cable (1.0M, 3.28ft.) 900RTC - H010
High Voltage RTP Cable (2.5M, 8.2ft.) 900RTC - H025
High Votage RTP Cable (5.0M, 16.4ft.) 900RTC - H050

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Unused I/O slot Covers
It is recommended that unused I/O slots in the controller rack be covered with a connector style
cover. Specify the number of Filler Covers needed to cover unused slots using the number below.

I/O Filler Cover Cover unused slots 900TNF - 0001

Selecting Cables , Connectors Hubs and Switches

Plantscape, SpecView or
3rd party software

Honeywell or commercial
hub or switch
Direct Ethernet 10 base T
Null Modem Cable

Direct Ethernet RS485 Crossover Ethernet Cable

10 base T Twisted pair with shield PS
24VDC Honeywell Hub
PS Power
Supplies Direct Ethernet
10 base T

RS232 Configuration port cable:

If the controller will be configured using its standard RS 232 port, specify a 9 pin to 9 pin null
modem cable to make this connection to a PC:
Null Modem cable Controller to Configuration PC 51404755 - 501

RS232
Null Modem Cable

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PC to HC900 Direct via Ethernet
When connecting a PC to the HC900 controller Ethernet port, an Ethernet Cross-over cable is
required.

Plantscape, SpecView,
Workbench or
3rd party software

Cross-overEthernet 10 base T
24VDC Power supply For connection to a PC without using a Hub
PS and user supplied wiring

RS485, User supplied

twisted pair with shield
(up to 2000 ft)

Specify one 20 foot Ethernet crossover cable for the connection between a PC and the UC900
Controller using the number below:
Cross-over Ethernet Cable 20 feet long 51451996-020

Note: If longer or shorter cable lengths are required, Honeywell recommends the user purchase
the needed Ethernet cable from commercial suppliers. A few such suppliers and products are:

HPN Black Box Amp/Tyco * BELDEN

Shielded Cat 5 Straight
0,9m (3 Ft) 51451432-003 EVNSL20-0003
1,2m (4 Ft) 557827-2
1,8m (6 Ft) 51451432-006 EVNSL20-0006 557827-3
3,0m ( 10Ft) 51451432-010 EVNSL20-0010
3,1m ( 12 Ft) 557827-5
6,1m (20 Ft) 51451432-020 EVNSL20-0020 557827-7

Shielded Cat 5 Crossover

0,9m (3 Ft) 51451996-003 CBUT45187-0003
1,8m (6 Ft) 51451996-006 CBUT45187-0006
3,0m ( 10Ft) 51451996-010 CBUT45187-0010
6,1m (20 Ft) 51451996-020 CBUT45187-0020

Rs-485 cable
2-Wire Shielded 300V Twinax NA 9271

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HC900 Controller to HC900 Controller, or HC900 to Switch via Ethernet
If a HC900 controller is to be directly connected to another HC900 controller for peer to peer
communications, or if a HC900 controller is connected to a Hub or switch for peer to peer
communications between up to eight (8) controllers, a direct 10 Base T Ethernet cable is used.

Direct Ethernet
10 base T
100 meters, (328 feet)

HC900 Controller HC900 Controller

Peer to Peer

Commercial Hub or Switch

Direct 100 meters (328

Eth
10 baset T f t)
100 meters (328
f t)

Peer to Peer
C t ll

Select one of the cables below for each of the network connections in the above architectures.

Direct Ethernet cable 10ft. 51451432-010

Direct Ethernet cable 20ft 51451432-020
Note: If longer or shorter cable lengths are required, Honeywell recommends the user purchase
the needed Ethernet cable from commercial suppliers. See a few such suppliers above.

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HC900 to Remote I/O via Ethernet
A HC900 controller can support one direct connected expansion rack for distances up to 100
meters, 328 feet between racks. When more than one remote rack is used, an Ethernet hub is
required to provide a star connection between the controller and the remote racks. The maximum
number of remote racks supported by a single HC900 controller is four (4). The maximum
distance between the controller and one hub is 100meters, 328 feet, and hub to remote racks is
100 meters, 328 feet, for a maximum distance of 200 meters, 656 feet.

HC900 Controller

Direct Ethernet
10 base T
100 meters, (328 feet)

Remote Rack

Remote Rack

HC900 Controller

100 meters (328 feet)

Ethernet Crossover Cable

Honeywell Hub
Remote
100 meters (328 feet) Direct Ethernet Rack
10 base T

Remote Rack
Remote Rack
Multiple Remote Racks

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The maximum distance between the controller and the most distant remote rack may be up to 300
meters, 984 feet using two cascaded hubs as indicated below.

Controller

Crossover cable
100 meters (328 feet)

Honeywell Hub

Crossover Cable
Crossover Cable
100 meters (328 feet)
100 meters (328 feet)
Honeywell Hub

Direct Cable Direct cable

100 meters (328 feet) 100 meters (328 feet)

Remote
Remote
Rack
Rack

Controller

Crossover Cable
100 meters (328 feet)

Crossover Cable Honeywell Hub

100 meters (328 feet)

Remote
Direct Cable Rack
100 meters (328 feet)

Remote
Rack

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Select one of the cables below for each of the remote I/O connections in the above architectures.

Direct Ethernet cable 10 feet long 51451432-010

Direct Ethernet cable 20 feet long 51451432-020
Cross-over Ethernet Cable 20 feet long 51451996-020

Note: If longer or shorter cable lengths are required, Honeywell recommends the user purchase
the needed Ethernet cable from commercial suppliers.

Remote I/O Ethernet Hub 4 connections, up to 3 remote 51452051 - 001

racks (Industrial model)

Note: Use of non-qualified commercial hubs or switches is not supported for Remote I/O
connections. Specify a Honeywell Hub when two or more remote racks are needed.

The Honeywell Hub requires 24VDC power at 130mA. If 24VDC power is not available, specify
the Honeywell power supply accessory below or substitute a commercially available power
supply with appropriate voltage and current specifications.

24 VDC Power Supply 24 VDC @ 1.3A 51452041-501

Product Documentation
A Compact Disk (CD) containing documentation on the HC900 product is provided with the
controller CPU assembly 900C51-0011 & 900C31-0011. The CD provides all documentation in
PDF format and supports printing of each manual separately. If extra copies of the
documentation on CD are desired, specify one each of the model numbers below for the needed
CDs.

Controller and OI Contains manuals: 51-52-25-105, 51- 900ME1 - 0020

documentation on CD 52-25-106, 51-52-25-107, 51-52-25-
108, 51-52-25-109

If hard copy manuals are desired, these may be ordered as a complete set or as individual
manuals. To specify a complete set of hard copy manuals, specify the model number below.

Controller and OI Contains manuals: 51-52-25-105, 51- 900ME2 - 0020

documentation, paper 52-25-106, 51-52-25-107, 51-52-25-
copy 108, 51-52-25-109

To select individual manuals, specify the appropriate number.

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Controller Manual 51-52-25-107
1042 Operator Interface Manual 51-52-25-108
Hybrid Control Designer Configuration Software 51-52-25-110
Function Block Reference Guide 51-52-25-109
Communications Manual 51-52-25-111

Software
Hybrid Control Designer Configuration Software The configuration software will be included
with the Controller CPU assembly if model number 900C51-0011 or 900C31-0011 is specified.
If additional copies are needed, specify one the model number below.

Hybrid Control Designer Includes configuration 900W01 - 0020

Configuration Software software CD and
documentation CD

559 & 1042 Operator Interface

The 559 & 1042 Operator Interface units may be used with the HC900 controller through an
RS485 port located on the controller CPU module. Only one Operator Interface may be
connected to a single controller. Use the appropriate model selection guide, Number 51-51-16-77
to specify the interface and desired options. Note that separate 24VDC power is needed to use
the 559 & 1042 Operator Interface with the HC900 controller. If 24 VDC power is available in
the equipment panel, a minimum of 1A will be needed to support the Operator Interface. If
separate power is not available, specify the 24VDC power supply (Part # 51452041-501) that is
available in the HC900 Hybrid Controller Accessories Model Selection Guide, Number 51-51-16-
72.

Connection of the Operator Interface to the HC900 controller is with a commercially available
communication cable. A 50 foot length of cable is provided with the Operator Interface. The
Operator Interface may be mounted up to 2000 feet away from the controller. Longer lengths of
communication cable must be purchased from commercial vendors. The recommended cable is a
single twisted pair with shield, Belden 9271 or equivalent.

If the floppy disk (or Zip drive)of the Operator Interface is to be used to store process data, a data
analysis software program will be needed for a PC to allow the import and analysis of the data.
Specify SDA software from the 1042 OI model selection guide. The documentation for SDA
software is not included in the HC900 documentation set but is supplied separately when the
software is ordered.

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