Process Controller

About the controller

The C200/C200E or C300 Process Controller handles all possible control

requirements, whether for continuous processes, batch processes, discrete operations, or machine control needs.

ATTENTION

A C300 – 20mS CEE controller has been introduced for Honeywell Turbine Control Solutions.

For detailed information refer to the C300 Controller User’s Guide.

The C200/C200E Process Controller architecture supports one common set of multiple size chassis for both Control Processor and remote chassis I/O configurations. The power supplies are attached, but separate from the chassis and support both 115/230 Vac and 24 Vdc sources. A single ControlNet communications module, available in

both non-redundant and redundant media configuration, supports all controller-to-server and controller-to-I/O networking. The Control Processor (CPM) provides the plant-level control execution environment (CEE) for your control applications. The I/O system supports discrete, analog, and special function modules.

The C300 Process Controller architecture features an innovative vertical design for more efficient mounting and wiring. It includes integral connections for redundant FTE media and Series C I/O or Process Manager I/O modules. It supports redundant configuration through a dedicated connection and provides the control execution environment (CEE) for your control applications like the C200/C200E controller. The Control Firewall ensures data integrity and an integrated power subsystem distributes power efficiently within a cabinet. The discreet and analog Series C I/O are optionally redundant.

The PMD Controller architecture supports a single automation system to control a production plant’s continuous and batch processes, machines and drives. The PMD Controller can be utilized on all plant’s control levels for implementing advanced controls, fast machine controls and process controls. For more information about Experion PKS with PMD Integration, refer to Experion PKS with PMD Controller Overview Guide.

Chassis

Experion supports a common chassis backplane technology that may be used for either C200/C200E controller or remote chassis I/O. This minimizes the cost while

maximizing the flexibility of the system.

Five different size chassis assemblies provide you with scalability and flexibility in your control system layout. Each chassis, with cards installed, is 14 cm (5.5 in.) high and 17 cm (6.7 in.) deep. Length is dependent upon the number of slots the chassis provides. Chassis sizes, by number of slots, include:

4-Slot, 26 cm (10.4 in.) in length

The C200/C200E or C300 Control Processor is designed for integrated continuous loop, Boolean logic, motor, sequence and batch control functions.

The specific functions of I/O Processing (via IOMs), Modulating/Logic Control (via CMs), and Sequential Control (via SCMs) are selected and defined by configuration prior to process operation. I/O Processing, Modulating/Logic Control, and Sequence Control have access to a common database that includes current parameter values for

all IOMs, CMs, and SCMs controlled by all controllers on the supervisory network.

The operator also has access to these parameters through Station displays.

Figure 16 - C200 Control Processor

Figure 17 - C300 Control Processor Controller redundancy

Process control applications require that the controller recognize when its integrity has been compromised and it should fail over to a back up processor in a bumpless fashion.

Honeywell's previous fail over schemes from the Process Manager family of process controllers have been built into Experion's controller redundancy scheme. This patented technology deals with:

Fault detection

Guaranteed database synchronization

Bumpless failure. The C200/C200E Controller achieves redundancy through matching chassis configurations that include a Redundancy Module with a dedicated link. The Series C form factor components include redundant capability as an integral part of their design. The input/output termination assembly (IOTA)

for the C300 Controller includes a connector for a dedicated redundancy link to another C300 Controller. This makes installing and configuring a redundancy scheme in a C300 Controller domain more efficient.

Figure 18 - Redundancy Module For C200 Controller Redundancy 4 character display

Primary LED Comm LED OK LED

Front View

Figure 19 - Module redundancy for C200 Controller in redundant supervisory ControlNet networks

Controller

LAN (TCP/IP, Ethernet, etc.)

Redundant Supervisory ControlNet networks

A B

AB

Redundant I/O ControlNet networks

Server

Figure 20 - C300 Controller redundancy in supervisory Fault Tolerant Ethernet network

Bumpless failure

The redundancy aspects implemented in the Experion system are far superior to those available today by PC/PLC systems. The most critical failure task, switching the controller in a bumpless fashion, has been fully implemented in the Experion system.

Chassis I/O

The Experion chassis I/O -Series A modules are an expanding family of traditional and special function input/output signal interface devices. The traditional models are available in a wide variety of densities, including 6, 8, 16 and 32 points, and they can interface to AC, DC or TTL voltage levels as well as common thermocouple and RTD sensors. The output modules are available with analog solid state AC, solid state DC or relay contact type output. The special function models include a Pulse Input Module (PIM) for counting dc pulses and a Serial Interface Module (SIM) for accepting asynchronous serial communications based on an EIA-232 (RS-232) or EIA-422/485 (RS-422/485) standard. The PIM provides up to eight input channels and two output channels and also provides channel-to-channel and terminal-to-backplane isolation.

All I/O modules, except the SIM, have a small form factor (5 inches by 5 inches) and feature deterministic I/O update rates and diagnostic capabilities. They can support local, front of module or remote terminations and software configuration. These I/O modules, except the SIM, share the same basic layout as illustrated in the following figure.

Figure 21 - Chassis I/O Module Basic Layout

DIGITAL INPUT

24 vdc 16 PT lsol O K ST ST

Chassis I/O terminal connectors

The chassis I/O has a uniquely designed termination connector that supports Removal and Insertion Under Power (RIUP) for field termination and backplane connectors.

Field wiring connectors allow RIUP to be accomplished without any detrimental effect on the I/O module operation. RIUP is accomplished on the field wiring connector by the length of the connecting pins. When removing the connector, the signal is broken first and when inserting the connector, the commons are connected first.

REFERENCE - INTERNAL

Review the Removal and Insertion Under Power (RIUP) Function Guidelines in the Control Hardware Installation Guide before you RIUP any module.

A jumper bar is shipped with each I/O module so that commons can be tied together very quickly, without the need for wiring. The front door of the housing opens and provides a handle for the removal of the connector from the I/O module. Labels are provided to attach to the inside of the connector door for identification of the field wire.

Series C I/O

The Series C I/O is an expanding family of Series C form factor I/O modules for handling a variety of analog and discreet I/O signals as wells as HART protocol interfaces. The Series C I/O module mounts directly on its mating I/O termination assembly (IOTA) for efficient mounting and wiring. All Series C I/O is optionally redundant by simply adding a second matching Series C I/O module to its I/O

termination assembly. The following illustration shows a typical non-redundant Series C I/O hardware configuration.

Figure 22 - Typical non-redundant Series C I/O configuration