HC900 Control Station

Model Numbers 900CS10-00 and 900CS15-00

Installation

Document Number: 51-52-33-157 Revision 8

Effective: 03/3/13

Supersedes: Revision 7, 09/8/11

Summary

These instructions explain how to install your Control Station. Once installed, the unit must be configured.

Configuration is a detailed process described in other documents.

The overall steps for getting your Control Station up and running are as follows.

Step Action

1

Install the unit per this instruction sheet.

Refer to other documentation for details on the following steps.

2

After completing installation, configure the HC900 controller for your application using Hybrid

Control Designer software and save the .cde file.

3

Using Station Designer software, create data tags from your .cde file, create your operator interface configuration and save the .sds file.

4

Download the .sds file to the 900 Control Station and verify operation.

Note: Configuration of the 900 Control Station may be performed prior to mounting if found to be more

convenient when using the USB port since once loaded the configuration is maintained in non-volatile memory, but doing so requires the station to be connected to a 24Vdc power supply.

Note: USB 3.0 support is only available on the 900CS10

Contents of package

Check that you received the following items.

• Control Station

• Panel Gasket

• Template for panel cutout

• Hardware packet for mounting unit into panel

• Power connector (3 terminals)

• Documentation CD

Supplied separately

• Flash Memory Module (optional) Note: The Flash Memory Module must be a UL approved component

Smart Modular Technologies model SG9CF (UL Listed Directory Category NWGQ) to maintain UL station approval when installed.

51-52-33-157 Rev. 8 Page 1 of 15

Safety Summary

WARNING - EXPLOSION HAZARD

DO NOT DISCONNECT EQUIPMENT WHILE THE CIRCUIT IS LIVE OR UNLESS

THE AREA IS KNOWN TO BE FREE OF IGNITABLE CONCENTRATIONS

WARNING - EXPLOSION HAZARD

SUBSTITUTION OF ANY COMPONENT MAY IMPAIR SUITABILITY FOR CLASS

I, DIVISION 2

WARNING - EXPLOSION HAZARD

BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE

NON-HAZARDOUS.

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.

WARNING - EXPLOSION HAZARD

DO NOT CONNECT OR DISCONNECT CABLES WHILE POWER IS APPLIED

UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS. USB PORT IS FOR

SYSTEM SET-UP AND DIAGNOSTICS AND IS NOT INTENDED FOR

PERMANENT CONNECTION

ATTENTION

Approvals

UL Listed

CSA Certified

FM Approved

WARNING - EXPLOSION HAZARD

THE AREA MUST BE KNOWN TO BE NON-HAZARDOUS BEFORE SERVICING /

REPLACING THE UNIT AND BEFORE INSTALLING OR REMOVING I/O WIRING.

Failure to follow these installation instructions could result in diminished performance and/or invalidate the UL approvals. for use in Hazardous (Classified) locations – Class I, Division 2,

Groups A, B, C and D

Page 2 of 15 51-52-33-157 Rev. 8

Installation procedure overview

Refer to the pages shown for details on each step.

Step

1. INSTALL FLASH MEMORY MODULE (IF PURCHASED SEPARATELY)

2. MOUNT THE CONTROL STATION

3. CONNECT TO EARTH GROUND

4. MOUNT AND CONNECT POWER SUPPLY

5. CONNECT COMMUNICATIONS

See page

3

4

6

6

7

1. Install Flash Memory Module (if purchased separately)

Step Action

1

With the 900 Control Station positioned face forward, and with connectors on the bottom, locate the

Flash Memory Module receptacle through the access hole on the right side of the case.

Rear Face

2

Note

Control Station supports a minimum of 4MB and a maximum of 2GB Compact Flash memory card.

Note

The Flash Memory Module should not be installed or removed while the Control Station has power applied.

Insert the Flash Memory Module into the connector, being sure the card is fully engaged in its receptacle. Note the card is keyed to assure proper orientation.

51-52-33-157 Rev. 8 Page 3 of 15

2. Mount the Control Station

Model 900CS10-00

Step Action

1

ATTENTION

If the 900 Control Station is replacing an existing product, contact your local Honeywell representative for instructions.

Using the drawing below, cut panel hole. You can use the cardboard template as a rough guide but be sure to measure against the drawing below before cutting. Drill holes using a 3/16 inch (4.76mm) size drill bit. Remove any loose material from the mounting cut-out to prevent that material from falling into the Control Station during installation.

2

Mount the gasket by placing its 14 holes over the Control Station’s 14 mounting bolts. Push gasket all the way on to the mounting bolts. Insert Control Station into panel cutout.

3

Install the 14 kep nuts provided with the Control Station. Tighten evenly for uniform gasket compression. Do not tighten the kep nuts beyond a maximum of 17 inch-pounds (1.92 N-m) or you may cause damage to the Control Station’s front panel.

Page 4 of 15 51-52-33-157 Rev. 8

Model 900CS15-00

Step Action

1

Using the drawing below, cut panel hole. You can use the cardboard template as a rough guide but be sure to measure against the drawing below before cutting. Drill holes using a 3/16 inch (4.76mm) size drill bit. Remove any loose material from the mounting cut-out to prevent that material from falling into the Control Station during installation.

2

Mount the gasket by placing its 22 holes over the Control Station’s 22 mounting bolts. Push gasket all the way on to the mounting bolts. Insert Control Station into panel cutout.

3

Install the 22 kep nuts provided with the Control Station. Tighten evenly for uniform gasket compression. Do not tighten the kep nuts beyond a maximum of 17 inch-pounds (1.92 N-m) or you may cause damage to the Control Station’s front panel.

51-52-33-157 Rev. 8 Page 5 of 15

General wiring considerations

• Use only Class I, Division 2 wiring methods as specified in the National Electrical Code NFPA70 and the Canadian Electrical Code C22.1.

• The Control Station cables contain low voltages. Keep cables away from high voltage wires that can cause interference.

• CE testing was performed with shielded, twisted pair cables. For noise reduction tips, see

Honeywell document 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical

Noise Environments.

ATTENTION

The emission limits of EN 55011 (CISPR11) 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.

3. Connect to earth ground

The back of the unit has a chassis ground terminal identified with the symbol . Connect this terminal to earth ground (protective earth).

The chassis ground is not connected to signal common of the unit electronics. Maintaining isolation between earth ground and signal common is not required to operate the unit, but when connecting the HC900 controller to the unit using the recommended shielded CAT5 Ethernet cable, a path to earth ground is created via the Ethernet shield of the controller. Other equipment connected to the unit may require isolation between signal common and earth ground. To maintain isolation, care must be taken when connections are made to the unit. For example, a power supply with isolation between its signal common and earth ground must be used.

Connecting a device via a USB cable may also connect signal common and earth ground. The shield of the

USB’s connector at the host may be connected to earth ground. A USB’s shield may also be connected to signal common.

4. Mount and connect power supply

The Control Station requires a 24 VDC power supply rated at 29 W or more. Your unit may draw considerably less than rated power depending upon the options being used. As additional features are used your unit will draw increasing amounts of power. Items that could cause increases in current are additional communications, Flash Memory Module, and other features programmed using Station Designer software.

It is important that the power supply is mounted and wired correctly if the unit is to operate reliably. Please take care to observe the following points.

• A 10” model requires a minimum of 29 Watts of power supply and a 15” model requires a minimum of 46

Watts of power supply.

• The power supply should be mounted close to the unit. Recommended not more than 6 feet (1.8 m) of cable between the supply and the Control Station. Ideally, the shortest length possible should be used.

• A power supply with isolation between its signal common and earth ground must be used.

• The wire used to connect the power supply to the Control Station should be at least 22-gage wire. If a longer cable run is used, a heavier gage wire should be used.

• The routing of the cable should be kept away from large contactors, inverters, and other devices which may generate significant electrical noise.

Page 6 of 15 51-52-33-157 Rev. 8

• A power supply with a Class 2 or SELV rating should be used. A Class 2 or SELV power supply provides isolation to accessible circuits from hazardous voltage levels generated by a mains power supply due to single faults. SELV is an acronym for “safety extra-low voltage.” Safety extra-low voltage circuits shall exhibit voltages safe to touch both under normal operating conditions and after a single fault, such as a breakdown of a layer of basic insulation or after the failure of a single component has occurred.

• If the power supply will be mounted in a hazardous location, it must be rated for Class I, Div. 2 by an

OSHA recognized NRTL, such as UL or FM.

• Using the terminal block provided, connect the power supply’s +24Vdc lead to terminal 2 and the Common lead to terminal 1. See figure below. Plug the terminal block into the connector located on the bottom of the interface.

5. Connect communications

Overview

Connections and ports used depend on the architecture of your installation.

See architecture examples starting on page 8.

For cabling and connections, see page 11.

For details on connections to devices other than the Control Station, see HC900 Hybrid Controller

Installation and User Guide, document number 51-52-25-107.

When your connections are finished, installation is complete and your unit is ready to be configured. Refer to the appropriate manuals for details.

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.

51-52-33-157 Rev. 8 Page 7 of 15

Example #1

900 Control Station

HC900

Controller

C30, C50, C70 CPU

10/100Base-T

100m max.

Use shielded CAT5 cable with RJ45 connectors. Connect to HC900 Ethernet port. (On models C70 and

C70R with two ports E1 and E2; either port can be used.)

Example #2

Experion LS, SpecView or 3 rd

Party Software

900 Control Station

Ethernet

Switch

Ethernet

10/100Base-T

100m each

HC900

Controller

C30, C50, C70 CPU

Use shielded CAT5 cable with RJ45 connectors. Connect to HC900 Ethernet port. (On models C70 and

C70R with two ports E1 and E2; either port can be used.)

Page 8 of 15 51-52-33-157 Rev. 8

Example #3

Experion LS, SpecView or 3 rd

Party Software

900 Control Station

Ethernet

10/100Base-T

100m each

HC900

Controller

C70 CPU (with 2 Ethernet ports)

Use shielded CAT5 cable with RJ45 connectors. Connect to HC 900 to E2 of the C70 CPU and connect the host PC to E1.

Example #4

900 Control Station

HC900

Controller

C30, C50, C70 CPU

RS 485

2000 ft. max.

Connect to HC900 RS485 port with unterminated switch settings. S2 port is RS485 terminated by default;

S1 port can be configured as RS485.

RS-232 RS-485 unterminated RS-485 terminated

(last link in network)

RS-485 with external bias, unterminated

51-52-33-157 Rev. 8 Page 9 of 15

See manual 51-52-25-107 for full details.

Note: Ethernet connections will provide faster performance than RS-485.

Example #5

Experion LS, SpecView or 3 rd

Party Software

Ethernet

Switch

900 Control Station

10/100 base-T

Dual

Ethernet support

Ethernet or

RS-485

(Non-redundant)

A

100 base-T

Up to 100m

B

HC900 Redundant Controller

C70R CPU

Connect to C70R using either RS-485 or Ethernet. Communication redundancy is not supported using both

RS 485 and Ethernet. Communications to the Lead CPU is maintained following a CPU failover event.

Page 10 of 15 51-52-33-157 Rev. 8

Example #6

Connect to C70R using dual Ethernet cables.

Example #7

900 Control Station 2

900 Control Station 3

900 Control Station 1

Ethernet

Switch

Ethernet

10/100Base-T

100m each

HC900

Controller

C30, C50, C70 CPU

Up to 3 Control Stations may be connected to a HC900 controller using Ethernet. Multiple stations via RS

485 are not supported.

Cables

Ethernet

51-52-33-157 Rev. 8 Page 11 of 15

Ethernet communications are recommended for best performance.

Use shielded CAT5 cable (Honeywell part no. 514514032). Cable length must be less than 100 meters. For longer distances use Ethernet switches between cables. The use of Ethernet cables in excess of 100 meters may cause transmission delays that could have adverse affects on performance.

RS485

For RS485 between Control Station and HC900, construct a cable as follows.

1. Cut off one connector of the shielded CAT5 cable.

2. Connect the wires indicated to the 3-plug connector that was supplied with the HC900 CPU module.

See table below.

Shielded CAT5 cable 3-plug connector

1

2

3

Signal Pin

Shield (aluminumpolyester foil tape with 26

AWG stranded drain wire)

Terminal

1

RXA 3

RXB 4

TXEN 5

Common 6

3. Cut off any unused wires in the cable and insulate with heat shrink tubing or other appropriate insulating material.

This connector plugs into the HC900’s RS485 port; the RJ45 connector plugs into the Control Station’s

RS485 port.

Page 12 of 15 51-52-33-157 Rev. 8

RS232 Communications

If using RS232 communications to have the station communicate with other Honeywell or Modbuscompatible equipment, create a communications cable as follows.

RJ12 connector Connector of slave device

6

1

9

8

7

6

5

4

3

2

1

Terminal no. Signal Terminal no.

1 CTS

Signal

7 RTS

2 RX 3 TXD

3 Ground 5 Ground

4 Ground 1 DCD

5 TX 2 RXD

6 RTS 8 CTS

51-52-33-157 Rev. 8 Page 13 of 15

Specifications – apply to all models unless specified.

Environmental

Operating Temperature Range: 0 to 50 °C (32 to 122 F)

Storage Temperature Range: -20 to 70 °C (-4 to 158 °F)

Safety

Electromagnetic

Compatibility

Operating and Storage Humidity: 80% maximum relative humidity (non-condensing) from

0 to 50°C.

Vibration According to IEC 68-2-6: 5 to 150 Hz, in X, Y, Z direction for 1.5 hours, 2 g.

Shock According to IEC 68-2-27: Operational 35 g, 9 msec in 3 directions.

Type 4X Indoor use only Enclosure rating (face only), UL50.

IP66 Enclosure rating (face only), IEC529.

Altitude: Up to 2000 meters.

EN 61010-1 – 2001. CE Mark requirements for General Purpose (Ordinary Location)

Safety.

ANSI/UL 61010-1 – 2005, Second Edition. General Purpose (Ordinary Location) Safety.

UL evaluated to CSA C22.2 No. 61010-1-2004- Second Edition. General Purpose

(Ordinary Location) Safety.

UL, CSA and FM Class I, Div 2 Groups A,B,C and D

IEC61326 - 2005 CE Mark EMC requirements for electrical equipment for measurement, control and laboratory use.

Immunity to Industrial Locations:

ESD IEC 61000-4-2

EM field

Electrical Fast

Transient/Burst

Surge

Conducted RF

Magnetic field

IEC 61000-4-3

IEC 61000-4-4

IEC 61000-4-5

IEC 61000-4-6

IEC 61000-4-8

Criterion A

4kV contact discharge

8kV air discharge

Criterion A

10 V/m (80 MHz to 1 GHz)

3 V/m (1.4 GHz to 2 GHz)

1 V/m (2.0 GHz to 2.7 GHz)

Criterion A

2kV power

1kV I/O signal/control, including functional earth lines

Criterion B

1kV L-L, 2kV L-Gnd power

1kV I/O signal/control, including functional earth lines

Criterion A

3Vrms Power and all I/O

Criterion A

30A/m

Emissions:

(CISPR11)

Page 14 of 15 51-52-33-157 Rev. 8

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

51-52-33-157 Rev. 8 Page 15 of 15