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C300 Controller Users Guide EPDOC-XX11-En-410

Honeywell Experion System - Murdoch Research Repository

Nov 13, 2016 Honeywell C300 Simulated Controller and Control Execution Environment 29 2 C300 Controller Users Guide EPDOC XX11 en 430 3

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ntroller Users Guide EPDOC-XX11-En-410

Description

Honeywell Process Solutions

Experion PKS

C300 Controller User's Guide EPDOC-XX11-410A R410 March 2012

Release 410 Honeywell

Notices and Trademarks Copyright 2012 by Honeywell International Sárl

Release 410 March 2012 While this information is presented in good faith and believed to be accurate,

Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers

In no event is Honeywell liable to anyone for any indirect,

special or consequential damages

The information and specifications in this document are subject to change without notice

Honeywell,

PlantScape,

Experion PKS,

and TotalPlant are registered trademarks of Honeywell International Inc

Other brand or product names are trademarks of their respective owners

Honeywell Process Solutions 1860 W

Rose Garden Lane Phoenix,

AZ 85027 USA 1-800 822-7673

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

About This Document This guide provides information that will assist you in planning and designing activities,

and troubleshooting of C300 Process Controllers in an Experion system

Release Information Document Name C300 Controller User's Guide

Document ID

Release Number

Publication Date

EPDOCXX11410A

March 2012

Document Category Operations

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

Support and Other Contacts

Support and Other Contacts United States and Canada Contact: Phone:

Fascimile: Mail:

Honeywell Solution Support Center 1-800-822-7673 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

MS L17 1860 W

Rose Garden Lane Phoenix,

85027 USA

Europe,

Middle East,

and Africa (EMEA) Contact: Phone: Fascimile: Mail:

Honeywell TAC – EMEA +32-2-728-2345 +32-2-728-2696 TAC-BE02 Hermes Plaza Hermeslaan,

1H B-1831 Diegem,

Belgium t [email protected]

Pacific Contact: Phone: Fascimile: Mail:

Honeywell Global TAC – Pacific 1300-364-822 (toll free within Australia) +61-8-9362-9559 (outside Australia) +61-8-9362-9564 Honeywell Limited Australia 5 Kitchener Way Burswood,

Australia [email protected]

India Contact: Phone: Fascimile: Mail:

Honeywell Global TAC – India +91-20- 6603-2718/19 1800-233-5051 +91-20- 6603-9800 Honeywell Automation India Ltd 56 and 57,

Hadapsar Industrial Estate Hadapsar,

Pune –411 013,

India Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

Contact: Phone: Fascimile: Mail:

Honeywell Global TAC – Korea +82-80-782-2255 (toll free within Korea) +82-2-792-9015 Honeywell Co

Ltd 4F,

Sangam IT Tower B4-4 Block 1590,

DMC Sangam-dong,

Mapo-gu Seoul,

121-835,

Korea [email protected]

People’s Republic of China Contact: Phone:

Honeywell Global TAC – China +86- 21-2219-6888 800-820-0237 400-820-0386 Honeywell (China) Co

Ltd 33/F,

Tower A,

City Center,

Shanghai 200051,

People’s Republic of China [email protected]

Singapore Contact: Phone: Fascimile: Mail:

Honeywell Global TAC – South East Asia +65-6823-2215 +65-6445-3033 Honeywell Private Limited Honeywell Building 17,

Changi Business Park Central 1 Singapore 486073 [email protected]

Japan Contact: Fascimile: Mail:

Honeywell Global TAC – Japan +81-3-6730-7228 Honeywell K

K New Pier Takeshiba,

South Tower Building 20th Floor,

Minato-ku Tokyo 105-0022,

Japan [email protected]

Elsewhere R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

Support and Other Contacts

Call your nearest Honeywell office

World Wide Web Honeywell Process Solutions website: https://www

Training Classes Honeywell Automation College: http://www

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

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

Definition ATTENTION: Identifies information that requires special consideration

TIP: Identifies advice or hints for the user,

often in terms of performing a task

REFERENCE

REFERENCE

CAUTION

Indicates a situation which,

may result in equipment or work (data) on the system being damaged or lost,

or may result in the inability to properly operate the process

CAUTION: Indicates a potentially hazardous situation which,

may result in minor or moderate injury

It may also be used to alert against unsafe practices

CAUTION symbol on the equipment refers the user to the product manual for additional information

The symbol appears next to required information in the manual

WARNING: Indicates a potentially hazardous situation,

could result in serious injury or death

WARNING symbol on the equipment refers the user to the product manual for additional information

The symbol appears next to required information in the manual

WARNING,

Risk of electrical shock: Potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,

4 Vpeak,

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

Symbol Definitions

Definition ESD HAZARD: Danger of an electro-static discharge to which equipment may be sensitive

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

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

Contents 1

ABOUT THIS GUIDE

Introduction

Intended audience

C300 CONTROLLER PURPOSE

C300 Controller and C200 Controller comparison

Getting started

What task do you want to perform

C300 CONTROLLER PLANNING AND DESIGN

Review Experion system capabilities

Control Hardware Planning Guide

Series C control hardware

Series C form factor

Identify C300 Controller components

C300 Controller performance data

Control network considerations

C300 Interface to C200 Controllers and ControlNet using FTEB

C300 CONTROLLER INSTALLATION AND UPGRADES

Pre-installation considerations

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

Contents

Installation declarations

Series C Power System

Controller Memory Backup

C300 Controller installation

C300 Controller assembly

CF9 Control Firewall

Series C I/O modules installation

Series C FIM installation

Upgrading C300 Controller Firmware

Using the Controller Migration Wizard

C300 CONTROLLER CONFIGURATION

Configuration overview

Configuration Studio

Create C300 Controller and CEE function blocks

To configure a C300 Controller block

Configure CEEC300 block

To configure a CEEC300 function block

Configure a Secondary C300 Controller block

To configure a Secondary C300 Controller block

Convert a non-redundant C300 Controller to a redundant controller

To convert a non-redundant C300 Controller to a Redundant controller

Convert a redundant C300 Controller to a non-redundant controller

To convert a redundant C300 Controller to a non-redundant controller

Configure IOLINK function blocks

To configure IOLINK blocks

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

Contents

Import/export C300 Controller configuration

Reset Device Index and IP address of a controller

Create a Control Module

To create and save a Control Module

Assign Control Modules and IOMs to a CEEC300 block

To assign Control Modules and IOMs to a CEE

Copy Control Modules

To copy an existing Control Module

Assign I/O Modules to C300 IOLINK blocks

To assign Series C IO Modules and Process Manager IOMs to IOLINK blocks

Add an I/O Channel to a Control Module

To add IO Channel blocks to a Control Module chart

C300 CONFIGURATION FORM REFERENCE

C300 Controller Block

Main tab

Secondary C300 Block

Main Tab

CEEC300 Function Block

Main Tab

Experion PKS C300 Controller User's Guide Honeywell

Contents

Exchange Communications tab

IOLINK Block

Main Tab

LOAD C300 CONTROLLER CONFIGURATION

About load operations

Loaded versus project database versions

Initial load order guidelines

Component deletion considerations

Load components from Project

Loading C300 Controller

Load With Contents command

Reloading components from project

R410 March 2012

Contents

Upload to the Monitoring database

C300 CONTROLLER OPERATION

C300 Controller start up

C300 Controller states in boot mode

C300 faceplate indicators/displays

Power and Status LEDs

C300 faceplate display indications

Controller display during normal operation

Control Builder block icon descriptions

Activate C300 Controller's CEE

Initial activation order guidelines

Initiating C300 Controller Shutdown

Initiating Synchronization command

Prerequisites

Disable Synchronization command

Prerequisites

Initiating Become Primary command

Prerequisites

Initiating Switchover command

Prerequisites

Using Station displays

C300 Controller Point Detail displays

Viewing controller operation and status in Control Builder

Contents

C300 operating behaviors

Time management in the C300 Controller

C300 Controller processing overload behavior

Causes of controller overloading

C300 REDUNDANCY OPERATION

Description

Redundancy configuration restrictions

C300 Controller Device Index

Partner (controller) compatibility

Redundancy compatibility parameter

- RDNCMPT

Synchronization states

Standby state

Redundancy parameters

Enable Synchronization

Switchover

Initiate Switchover

243 xiv

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

Contents

Redundancy history

C300 Redundancy-related notifications

Redundancy Link Status

On-process Migration of C300 Controller

'Go-Back to Idle' option

Controller redundancy specifications

C300 CONTROLLER MAINTENANCE

Periodic Checks

Recommended Spare Parts

C300 Controller module and IOTA replacement

To replace a non-redundant controller module

C300 CONTROLLER TROUBLESHOOTING

Overview

What to do when faults occur

Initial checks

Checking Control Builder error code reference

Fixing common problems

Loss of power

-bp- or

Experion PKS C300 Controller User's Guide Honeywell

Contents

Isolated (lonely) Node

C300 Controller soft failures

IOLINK block soft failures

Additional status and fault messages

Redundancy-related notifications

Online diagnostics

Fault classifications

Hard/Severe Failures

Communications and system time faults during startup

Non-redundant C300 Controller with no Memory Retention

Gathering information for reporting problems to Honeywell

Getting further assistance

Other troubleshooting sources

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

Contents

Tables Table 1 Series C Hardware components

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

Contents

Figures Figure 1 Series C form factor example

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

About this guide 1

Introduction This guide provides information that will assist you in planning and designing activities,

and troubleshooting of C300 Process Controllers in an Experion system

Intended audience This guide is intended for the following users: •

Persons responsible for system planning,

initial hardware installation,

and control strategy configuration

Operators who help to maintain control system operations on a day-by-day basis

Service persons responsible for routine maintenance of control hardware and who also diagnose and repair faults

Prerequisite skills It is assumed that you should have some knowledge of Experion control systems and experience of working in a Microsoft Windows environment

Online documentation reference Knowledge Builder is the online documentation library for the Experion system

It is provided on a compact disc and can be installed on a suitable personal computer

If you are using a printed copy of the C300 Controller Guide,

we recommend that you install Knowledge Builder to take advantage of its online search and reference capabilities

Other resources and guides in Knowledge Builder provide this same information for other Experion control hardware,

Series C I/O,

See Locating related documentation for a partial listing of these documents

Locating related documentation Listed here are Knowledge Builder documents that contain general information for planning and implementing control hardware and network communications in your Experion system: Control Hardware Planning Guide

Control hardware includes C200 Controllers,

Series A Chassis I/O and FIMs,

It includes some supervisory network considerations for general reference

Series C I/O Module User's Guide

Module types include: AI,

SPM and SVPM

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

About this guide 1

Introduction

Series C Fieldbus Interface Module User's Guide

Control Firewall User's Guide

Fault Tolerant Ethernet Overview and Implementation Guide

Fault Tolerant Ethernet Installation and Service Guide

The guide includes troubleshooting and service information for an FTE node

Fault Tolerant Ethernet Bridge User Guide

It includes module installation,

Process Manager I/O Troubleshooting and Maintenance Guide

service procedures and parts lists for PMIO I/O control hardware

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

C300 Controller Purpose This section provides a quick comparison of C200 and C300 Controller features and reference to topics in this book for a given task related to using the C300 Controller with the Experion system

Click on the topic to view it

Topic C300 Controller and C200 Controller comparison Getting started task list

C300 Controller and C200 Controller comparison The C300 Controller provides design improvements and greater operational capabilities for process control over the chassis-based C200 controller

The following table is a listing that compares design features and operational improvements of the C300 Controller with the C200 controller

ATTENTION The C300 – 20mS CEE Controller has all the features as the C300 – 50ms Controller with exceptions related to the faster execution speed (20ms)

The C300 – 20mS CEE controller supports only the Series C I/O modules

Two new Series C I/O Modules (Speed Protection Module (SPM) and Servo Valve Positioner Module (SVPM)) are only supported by the C300 – 20mS CEE Controller

The C300 – 20mS CEE controller is only intended for Honeywell Turbine Control Solutions

Controller Feature Form Factor

Comparison C200

I/O Link Interface,

Redundancy,

FTE interface,

Fieldbus,

Control module functions include a Control processor,

Redundancy functions,

Memory (RAM)

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

C300 Controller Purpose 2

Getting started

Controller Feature

Comparison C200

Redundancy

A second C300 Controller and redundancy cable is all that is required for redundant controller operation

I/O Link Interface

Each I/O Link can connect with either PMIO I/O or Series C I/O modules

Note: C300 – 20mS CEE Controller supports only Series C I/O modules

Communications Interface to supervisory network

ControlNet Interface plug-in module is needed to connect with other ControlNet nodes

No ControlNet interface

Peer-to-Peer Connections

ControlNet Interface plug-in module is needed to connect with other ControlNet nodes

C300 connection to C200 controller is made through an FTE Bridge module installed in the C200 chassis

No ControlNet interface

Note: C300 – 20mS CEE Controller does not support peer-topeer connection with C200E

Function Blocks

C200 and C300

There are some exceptions

Note: C300 – 20mS CEE Controller supports only limited function blocks

For more information refer to Series C Control Hardware

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

C300 Controller Purpose 2

Getting started

Controller Feature

Comparison C200 and C300

The CTools engineering utility is used to upgrade C300 firmware and extract files containing diagnostic data when troubleshooting problems

Engineering Tools

Getting started The following table lists some of the tasks covered in this document that are related to implementing a C300 Controller in your Experion R300 system or later

If you are viewing this document online,

just click the reference to jump to the topic in this document

What task do you want to perform

Plan and design a C300 Controller installation

C300 Controller Planning and Design

Know more about C300 hardware

Series C Control Hardware Identify C300 Controller components

Know more about C300 Controller performance

C300 Controller performance data

Install and wire C300 Controller hardware

C300 Controller installation

Upgrade Controller firmware

Upgrading C300 Controller firmware

Create C300 Controller and CEE function blocks

C300 Controller Configuration

Configure CEE function blocks

Configure CEEC300 block

Configure IOLINK function blocks

Configure IOLINK function blocks

Configure a Secondary C300 Controller

Configure a Secondary C300 Controller block

Convert a Non-redundant C300 Controller to a redundant controller

Convert a non-redundant C300 Controller to a redundant controller

Convert a redundant C300 Controller to a Nonredundant controller

Convert a redundant C300 Controller to a Nonredundant controller

Reset Controller Device Index

Reset Device Index and IP address of a

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

C300 Controller Purpose 2

Getting started

If You Want to

View configuration parameter descriptions

C300 Configuration Form Reference

Load function blocks to C300 components

Load C300 Controller Configuration

Reload components from Project

Reloading components from Project

Review C300 Controller start up routines

C300 Controller start up

Review C300 Controller operating indications

C300 Faceplate indicators/displays

Shutdown a C300 Controller

C300 Controller shutdown

Activate the Controller's CEE

Activate C300 Controller's CEE

View Controller operations

Viewing controller operation and status Interacting through Station displays

Review C300 controller operating behaviors Time management,

Watchdog Timer

C300 operating behaviors

Controller processing overload behavior and recovery

C300 Controller processing overloads

Review C300 Controller redundancy functionality

C300 redundancy operation

Review C300 Controller maintenance and replacement procedures

C300 Controller Maintenance

Investigate a cause of a problem

C300 Controller Troubleshooting

Install and wire C300 Controller hardware

C300 Controller installation

Review C300 Controller redundancy functionality

C300 redundancy operation

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

C300 Controller Planning and Design This section includes information about system planning and design of the C300 Controller

The following topics are presented here

Click on the topic to view it

Topic Review Experion system capabilities Control Hardware Planning Guide Series C control hardware C300 Controller Identifying C300 Controller components C300 Controller performance data Control network considerations

Review Experion system capabilities Read the Overview document in Knowledge Builder so that you understand the basic concepts and terminology,

and appreciate the capabilities of Experion

Complement the information in this document with the data in the Server and Client Planning Guide to cover all aspects of an Experion installation

REFERENCE

see the Server and Client Planning Guide

Control Hardware Planning Guide Refer to the Control Hardware Planning Guide in Knowledge Builder for a general discussion of planning activities for Experion Control hardware that covers: •

Initial planning and design

Control network considerations

Control hardware configuration

Site selection and planning

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

C300 Controller Planning and Design 3

Series C control hardware

Control processing considerations

Application licensing considerations

Series C control hardware Series C control hardware consists of the following system components: ATTENTION The C300 – 20mS CEE controller is only intended for Honeywell Turbine Control Solutions

C300 Controller is a distributed process controller and I/O gateway for the Experion system

With only a few exceptions,

the C300 Controller fully supports configuration,

load and execution of the standard function blocks supported in previous Experion releases,

C300 – 20mS CEE Controller is a distributed process controller and I/O gateway for the Series C I/O modules including the two new modules

The C300 – 20mS CEE Controller fully supports the functions,

load and execution of control applications

Once loaded,

you cannot change the base execution speed and retain the application configuration

Note: To change the base execution period,

refer to the Control Hardware and I/O Modules Planning Guide

Series C Input/Output Modules that feature HART-capable AI and AO modules,

Digital input modules that support high voltage AC and 24V DC inputs,

and a Digital Output module that provides 24 VDC

Speed Protection (SP) modules that support speed control and voting logic algorithm,

and Servo Valve Positioner (SVP) modules that support LVDT/RVDT signals and PID execution

The Series C Fieldbus Interface Module,

(Series C FIM) which is designed to complement the C300 Controller and support Fault Tolerant Ethernet (FTE) communications within Experion R300 systems or later

A 9-port Control Firewall,

(CF9) provides eight FTE interface connections for C300 Controllers and Series C FIMs within a control cabinet and one uplink to the supervisory FTE communications network

ATTENTION The Speed Protection (SP) modules and Servo Valve Positioner (SVP) modules are only supported by the C300 – 20mS CEE Controller

These modules are supported for Turbine Control solutions

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

C300 Controller Planning and Design 3

Series C control hardware

Series C form factor All Series C control hardware is constructed using the same form factor

Series C I/O modules,

Control Firewall modules,

and Series C FIMs all mount on their associated Input Output Termination Assemblies (IOTAs),

which are installed on channel hardware specifically designed to support Series C hardware installation

The module's circuit board assemblies are housed in a plastic case with a round faceplate that identifies the module type and model number along with status LEDs and a four-character alphanumeric display

The IOTA contains connectors that accept the associated control module and the various I/O connectors for cables that connect to other Series C control hardware

Figure 1 shows an example of the design

Figure 1 Series C form factor example

R410 March 2012

Experion PKS C300 Controller User's Guide Honeywell

C300 Controller Planning and Design 3

Series C control hardware

Experion PKS C300 Controller User's Guide Honeywell

R410 March 2012

C300 Controller Planning and Design 3

Series C control hardware

REFERENCE

CF9 and FIM modules refer to the following documents in Knowledge Builder: •

Series C I/O User's Guide

Control Firewall User's Guide and

Series C Fieldbus Interface Module User's Guide

C300 Controller The C300 Controller is constructed using the Series C form factor that employs an Input Output Termination Assembly (IOTA) and an electronics module which mounts and connects to the IOTA

One C300 Controller contains all of the control functionality and most of the communications functions that previously required a C200 controller chassis filled with plug-in modules

This smaller controller footprint and ease of installation,

combined with enhanced functionality that is built upon C200 performance,

provides greater value for Experion users

The C300 Controller fully supports configuration,

load and execution of the standard function blocks supported in previous Experion releases,

Note that there are a few exceptions defined below

Exceptions The following function blocks are not supported by the C300 Controller: •

The LIOM function block set

CAB related function blocks other than the Custom Data