Connected Plant

CONTROLEDGE™ HC900
Process Control and Safety Made Easy

Process Measurement
and Control
Diverse Applications
Ranging from Process
PLCs to DCS
The Honeywell ControlEdge™ HC900 Process and Safety System is a
fully field-proven system for process control and safety applications, with
over 13,000 installations throughout the world. Its SIL-2 certification
means it can be used in a variety of safety application such as burner
management systems (BMS), emergency shutdown systems (ESD),
fire & gas monitoring, pipeline monitoring, spill prevention etc.

TUV Compliance
The ControlEdge HC900 is fully Its non-interfering software protection for configuration,
validated to perform its safety means that the ControlEdge alarm processing and data
tasks, and is certified by TUV for HC900 system is capable of acquisition for process
use in a SIL-2 environment. The hosting process control and applications thus adding to
system is ideal for a process/ safety applications, providing reliable data and information
safety environment. control, monitoring, password being stored and protected.
Typical Industries Customer Benefits Typical Applications
• Chemicals (including Proven & Reliable Safety
specialty and fine Maximizes uptime • Burner Management Systems
chemicals, plastics and (e.g. furnaces, boilers, ovens,
• Proven track record
rubber) pre-heaters, reactors, calciners,
• Redundancy dryers, thermal oxidizers, kilns,
• Pharmaceuticals and
• G3 conformal coating for melters, incinerators, process
Cosmetics
harsh environment heaters, vaporizers)
• Power (excluding
• RoHS compliant • Combustion Control
nuclear)
• Actionable information • Pipeline Monitoring
• Cement and Glass
• Spill Prevention
• Pulp and Paper
High Performance
• Metro/ Road Transportation-
• Mining and Metals Increases profitability Tunnel Safety, Ventilation
• Water and Waste Water • Tighter control • Waste Water Treatment
• Food and Beverage • Reduced scrap • Terminal Automation
• Heat Treatment • Higher throughput • Emergency Shutdown
• Buildings/
• Fire & Gas Monitoring
Infrastructure- Metro Easy to Use & Engineer
Rail, HVAC etc. Lowers operational costs • Pressure and Flow Control

• Easy engineering
Critical Control
• Faster startup • Electronics & SemiConductor
• Simple intuitive tools • Cement and Glass
• No additional • Textiles
maintenance fees
Certifications
Enhanced Safety • TUV SIL2
with SIL2 certification • CSA-Canada and USA (HazLoc) /
• Common hardware and FM CL1 / Div2
software for process and • ATEX
safety • ABS
• UL
• Improved plant safety
• CE
• RoHS
Multiple Systems,
Multiple I/O Racks
ControlEdge HC900 Hot Stand-by Architecture

CPU Capacity

Function Point per module Max. for C30 CPU Max. for C50 CPU Max. for C70 / C75 CPU

Universal: 8, Universal: 96, Universal: 1152, Universal: 1152,

Analog in
High Level: 16 High Level: 192 High Level: 2304 High Level: 2304

Analog out 4, 8, 16 40 480 480

Analog out
8, 16 192 2304 2304
(external Power)

Digital in 16 or 32 384 4608 4608

Digital out 8 AC or 16 DC, 32 384 4608 4608

Function blocks n/a 400 2000 15000

 Controller
• Function Blocks: C70, C75 CPU–15000,
C50 CPU–2000, C30 CPU–400
• Analog Inputs: Up to 1152 universal analog inputs,
2304 high level, A/D Resolution is ±15 Bits
• Accuracy: 0.1% of span
(field calibration to ±0.05% of span)
• Analog Outputs: Up to 480 with
internal power, 2304 with external power
0 to 20 mA maximum, 0.1% accuracy
• Universal SIL IO Module (UIO)- 16 channel, with
1ms SOE, Line Monitoring, Voting & Validation
• Digital Inputs / Outputs: Up to 4608, contact DI, 24
Vdc DI / DO, 120VacDI /DO, 240 Vac DI/DO
• Total I/O: Up to 4608
• I/O Racks per System: One controller and up to 11
remote I/O racks
• Control Loops: PID, on/off, cascade, ratio, %C,
ControlEdge HC900 three-position step
Designer Software • Control Output Types: Current, time -proportioning,
• Configuration: ControlEdge HC900 Controller – position-proportioning, three-position steps
offline with run-mode editing • New Input Voting (1oo2 and 2oo3) and output
• Operating environment: Windows 7 Pro (32 or validation function blocks (with feedback
64-Bit), Win 8 and Win 10 verification)
• PC: Pentium, 1.5 GHz with 1 GB RAM minimum, • Setpoint Programmers: 50 segments each, 16 event
SVGA or greater screen resolution outputs, multiple stored profiles
• English and Mandarin languages supported • Setpoint Scheduler: 50 segments, 8 ramp / soak
(switchable after installation) outputs, eight auxiliary outputs, 16 events, multiple
schedules
• Cable: RS 485 – three-wire, Ethernet 10/100
base T • Communications: Ethernet 10 / 100/ base T,
Modbus / TCP protocol, up to 10
• Modem support: Monitor, upload, download
Ethernet hosts on C50, C70, C75 up to 32
configuration
peer-to-peer controllers, Serial Modbus RTU,
• New input voting (1oo2 and 2oo3) and output
RS485, slave or master operation (up to 32 slaves)
validation function blocks (with feedback
• Operating Temp: Rated 32° to 140°F (0° to 60°C)
verification)
• Humidity: Rated 10% RH to 90% RH,
• New non-interfering process and safety
non-condensing
worksheets in
• Change management and Version Control built
into the software same configuration
Modular and Scalable
• Available in three rack sizes and three CPU • Scalable and expandable
performance levels • Easy to own, engineer, operate and maintain
• Handles a wide range of automation • Upto 12 racks and 4608 IO’s
requirements
• Analog and digital modules support up to
4608 I/O points
Function Blocks Separate Process Safety Worksheets
• Simplify execution of complex control strategies • Same type of controller can be used for process and
safety applications thus reducing total cost of ownership
• Over 125 different types of software function blocks
available • Provisions are provided within programming environment
to program using safety/process worksheets
• Each function block represents a unique algorithm for a
specific control function
• Available CPU options support up to 400, 2,000 or
15,000 function blocks
• Simply drag and drop, and soft-wire
• 1oo2 and 2oo3 Voting Function Blocks. DO-V and AO-V
(Digital Output and Analog Output Validation Function
blocks).

Universal Analog Inputs SIL Universal IO Module

• Accept both direct and indirect inputs from sensors • 16 channel user configurable to DI, DO, AI or AO
• Minimize the number of input cards and spare parts • High resolution SOE with 1 ms time stamp
required • Line Monitoring (Open Wire, Short Circuit Detection)
• Inputs may be mixed on a module and may include • In-built Voting & Validation
multiple thermocouple types, RTDs, ohms, voltage or
millivoltage types.
 Control Loops
• Provide tighter, more accurate • Increase throughput, reduce scrap, and
process control minimize energy costs
• Include applications ranging from single • Quantity of loops per controller is not limited
loop control to interactive cascade, ratio,
duplex, feed-forward, three-position-step, or
custom controlled strategies

Cascade control
• The Cascade Loop uses
2 PID block with the back
calculation pin of the
secondary (BCD) connected
to the primary loop (BCI). This
transfers values back to the
primary loop to adjust the PID
for changes in mode of the
secondary loop
• The RSP input for the
secondary loop can be
selected to be in engineering
units or %, eliminating the
need to scale the output of
the primary loop

Accutune III
• Standard auto tuning on
every control loop
• Reduces start-up time
• Ensures on-spec product
Fuzzy Overshoot
Suppression
• Fuzzy Overshoot Suppression
minimizes the Process Variable
(PV) overshoot following a
Setpoint (SP) change or a
process disturbance. This is
especially useful in processes
that experience load changes
or where even a small overshoot
beyond the setpoint may result in
damage or product loss.
• The Fuzzy Logic in the controller
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.

Carbon Potential
• The carbon potential of the
furnace atmosphere can be
controlled by monitoring the
furnace temperature and the
probe output because oxygen
potential directly relates to the
carbon potential. A combined
carbon probe, temperature
probe and PID algorithm
determine carbon potential of
furnace atmospheres based on a
zirconium probe input.
• Activates anti-sooting feature
that limits the working setpoint
of the carbon control loop to a
value that prevents sooting in the
furnace.
Free-format Logic
• Optimizes design by combining
multiple logic functions into one
• Simplifies operation and
troubleshooting

Sequencers
• Control the output states of
multiple digital parameters
• Control the sequence of process
operation based on time or
process events
• Each sequencer supports up to
16 digital outputs and may have
up to 50 process states
• Multiple sequences can be
selected on demand from the
operator interface or as part of
a recipe
Recipes
• Stored in the controller memory
• Ensure error-free product/
process changeovers
• Write values into analog and
digital variables
• Load via Control Station
• Load via RCP block
• Can be used to:
– Write a value to any variable
– Load setpoints
– Select setpoint programs
– Set alarm limits
– Activate control valves

Setpoint Programmer
• Automatically manipulates a
setpoint value for use by PID
loops
• Creates a time / value profile for
process batch control
• Multiple setpoint programmers,
with profiles of up to 50
segments each, may be
configured and stored
• Any programmer may run
any profile separately or
simultaneously
• Each also has an auxiliary soak
output and up to 16 event
outputs for integration with
sequence control functions
Dew Point Control
• Dew point analysis measures
the amount of water vapor
present which in turn helps
determine the carbon
potential of a furnace
atmosphere
• This application uses the
dew point function block to
calculate dew point based on
using a carbon probe where
the input is an O2 sensor
• A typical example is control of
an endothermic atmosphere
generator when the user
requires dew point for PV

Setpoint Scheduler
• Provides up to eight ramp/
soak setpoints that operate
on a common time base
• Supports up to 16 event
digital outputs 50 segments
per schedule; the number
of stored schedules is
configurable
• Auxiliary Scheduler provides
an additional 8 Soak
Setpoints
• Multiple independent
setpoint schedulers are
available in a configuration
Redundancy
• Maximize process availability
by providing backup
controllers, power supplies and
communications for seamless
failover under fault conditions
• Redundant Switch Module (RSM)
is located in the rack between
two CPUs and visually indicates
which CPU is the lead and which
is the reserve
• Key switch on the RSM allows
the user to change the operating
mode of the lead and reserve
CPUs
• Ethernet network ports are
continuously active on the lead
controller, each on a different
subnet
• Transfer of communications from
one port to another port on the
same CPU is handled by the host
application
• A secondary power supply
can also be added to each
ControlEdge 900 Platform I/O
rack for standby redundancy

AMS Compliance
• The ControlEdge HC900 meets
AMS 2750E, the key requirement
for controlling, monitoring and
recording instruments, which
is a calibrated accuracy (± 2°
F/1.1°C)
Flexible connectivity
suits your process
environment
Open Ethernet Serial Ethernet Connectivity and
Connectivity Connectivity Communications
• Enables ControlEdge • Allows two RS485 ports • Adapts to existing process-line
HC900 controllers to to be configured as infrastructure
communicate with their Modbus slaves, while one • Satisfies specific control
host interfaces and each of the ports is selected as requirements
other a Modbus master
• Accommodates specialty
• Open Modbus / • Wide variety of devices applications
TCP protocol allows (touch panel operator
interfacing to most interfaces, I/O devices,
popular HMI, data etc.) can be connected to
acquisition and OPC the controller
software • Provides greater
• Up to 10 device flexibility in system
connections are design
supported on the host
Ethernet port
• ControlEdge HC900
network of controllers
and operator interfaces
are partitioned into
segments on the
network to maximize
communication
performance
Peer-to-peer
Communications
• The improved ControlEdge
HC900 controllers provide
peer-to-peer interface between
a maximum of 32 units for
process/safety equipment
applications that require sharing
data between controllers.
• Up to 2,240 parameters per
controller may be exchanged
• Standard Ethernet
communication port
supports concurrent peer-
to-peer communications and
connectivity to supervisory
systems
• Peer-peer between safety
systems is done using the new
Safety-peer protocol that can
exchange safety critical data
between peers

Integration
with Experion
• ControlEdge HC900 controllers
can be integrated with the
Honeywell Experion DCS system
for supervisory control and data
acquisition
• Can be integrated with Experion
PKS, LX and HS systems
Configured using Quick Builder
application
• Uses Universal Modbus Driver for
communication
• Redundant controllers can also
be integrated with Experion
• History Backfill: If Experion
HS loses communication
with ControlEdge HC900 the
History backfill functionality
will backfill data to the HMI
once communication is
restored. This feature is very
important for food and beverage, ControlEdge HC900
pharmaceutical and other data OPC Server from
critical applications and is not MatrikonOPC
often provided by other general
purpose PLC’s • Provides secure and reliable
real-time data access between
• Paired with Experion HS, the ControlEdge HC900
ControlEdge HC900 Controller and any OPC-enabled
can meet FDA 21 CFR applications such as Historians,
part 11 requirements for HMIs, SCADA etc.
pharmaceuticals, food and
beverage industry that need • Enables 3rd party connectivity
a proven and reliable solution for successful phased migration
capable of change management, and integration
automated electronic record • Enables easy and cost-efficient
keeping, and advanced controller management of openly
security and protection methods connected systems
 Building-block
configuration simplifies
control implementation

ControlEdge HC900 • Ease of record-keeping, faster Printable Presentation

Designer Software access to functional areas during Formats
programming
• Enables system configuration with a • Simplify configuration
Windows 7 (32 or 64-bit), Win 8 and • Better support for user-specified documentation
Win 10 based PC process function identifications
• Include a summary of controller I/O,
• English and Mandarin languages the graphic configuration diagram,
supported (switchable after Configuration Debug Tools function block properties, recipe
installation) • Simplify troubleshooting Include groups, setpoint profile groups,
online monitoring of multiple operator display and point selection
• Uses drag-and-drop placement
function blocks on a single display,
techniques for graphic icons and
on/off identification of digital signal Run-mode
soft-wiring connections between
flow connections, and output forcing
function blocks Configuration Editing
capability for most block outputs
• Automatically calculates memory • Standard feature that can
• Selectable user-defined Watch significantly reduce start-up time
usage and processor scan time as
Windows and Signal Trace- and avoid costly process shutdowns
function blocks are configured
back provide a clear view of the
• User-friendly graphic development configuration operation and quick
allows partitioning of the control identification of potential errors
strategy into multiple worksheets
System configuration
and operation adapt
to your needs

Standard displays provided in The 900 Control Station

ControlEdge HC900 Control Station operator interface

Operator Interface features

• NEMA Type 4X operator interface screen • Alarm/Event logging with e-mail • Concurrent Batch Reports: Schedules
withstands harsh operating environments notification of impending problems multiple batch reports to run
tracks process upsets and validates concurrently
• Easy-to-operate 10”-display includes
performance
both a touch screen and dedicated • Bar Code/Keyboard Input: Use touch
buttons • Ethernet or serial connectivity enhance screen, remote keyboard or barcode
installation flexibility, includes Modbus reader to enter data
• Standard and custom graphic elements
and Modbus\TCP protocol support
can be assembled into specific displays, • GSM/GPRS, SMS Available: The GSM/
for fast and easy start-up • Embedded web server feature allows GPRS modem may be used via a Cellular
access to your application from anywhere Network Provider’s wireless network
• Custom graphics tools let you select from
4,000+ pre-built objects for animation • Multiple interfaces on each controller • Emulation: Launch the emulator to see
support, math, formulas, scripting enable process management from up to data as it would appear on the operator
three locations interface
• Function block widgets accelerate
configuration development • Multilingual: English, French, Italian,
German, Spanish. Other languages may
• Controller status displays verify system
be added by expanding its lexicon library
integrity, with no configuration required
• The software also supports accessing
• Recipe selection makes product/process
the translation libraries of Microsoft®
changeovers simple and accurate
and / or Google® for any untranslatable
• Trending and data logging is provided via text strings used in the product during
non-volatile flash card storage, with USB configuration
memory support and no artificial limits
• Setpoint Programmer Pre-Plot Display:
• Multi-level log-on security feature Pre-plot display is a Widget that gets
prevents unauthorized access bound to a Setpoint Programmer
function block
 Graphic symbols provided in Station Designer software to
Standard displays in station designer 4 - Widgets simplify configuration. Hundreds of icons available
including pumps, valves, and tanks icons shown.

Control Station Operator Interface 900 Station Designer Software

• The 900 Control Station is available with either a 10.4 inch (254 • Configuration: 900 control station CS interface – offline
mm) or 15 inch (381mm) display size
• Operating environment: Windows 7 (32, 64-bit), Windows 8,
• LCD Display: 10 inch 640 X 480 15 inch 1024 x 768 pixels, color Windows 10
active matrix thin film transistor (TFT), 32,000 colors
• PC: Pentium class processor and RAM as required by the chosen
• Touch Screen: Resistive analog operating system plus 50MB for software installation, 800 by
600 pixels minimum, 256 or more colors. RS-232 or USB port
• Backlight: 50,000 hr typical lifetime at room temperature (field
replaceable in non-hazardous locations) • Cable: USB Host, RS232 Serial, Ethernet 10/100 base T
• Distance from Controller: Ethernet-328 ft (100 m), RS485 -
2000ft (600 m) RS232 - 50ft (15.24 m)
• Power Supply 10 inch: 24 Vdc, 29 Watts maximum 15 inch 46
Watts maximum without options
• Operating Temperature: 32 to 122 °F, (0 to 50 °C)
• Humidity: Rated 10 to 80%, non-condensing from 32 to 122 °F,
(0 to 50 °C)
• Panel Rating: Type 4X
• Memory: 32 MB onboard non-volatile flash, optional memory card
(compact flash 2 GB)
• Communication Ports: 10 inch (254 mm) 1 x Ethernet RJ45
10/100 base T, 15 inch (381mm) 2 x Ethernet 10/100 base T, 1
x RS-485, 2 x RS232 Serial
• USB Ports: 2 x USB specification 2.0 host port, type A, 1 x USB
specification 2.0 device port type B
Easy engineering and
flexibility through user
friendly tools
Bulk Edit
• Reduces engineering hours

Configuration
Comparison
• Change management
• Save engineering hours in
finding previous changes
Version Control
• Easy tracking, de-bugging
• Revert to earlier versions
• Save dollars for a separate
version control offering

Paste Special
• Saves 15-20% of
engineering efforts

Change
Management
• Manage versions, track and
compare configurations
• Easier troubleshooting
thereby reducing
maintenance costs
Re-usable Custom
Libraries
• Save engineering time,
create logic once and avoid
errors

Password
protection
• Controllers are password
protected and thus prevents
any intrusion through the
network
• Any changes to the controller
are monitored and validated
with credentials
For more information
To learn more about Honeywell’s Control Edge HC900,
visit www.honeywellprocess.com
or contact your Honeywell account manager.

Honeywell Process Solutions

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