Industrial Measurement and Control

Hybrid Controller

EASIER BY DESIGN

HC900 Redundancy
Overview

Honeywell Process Solutions Slide 1

HC900 Redundancy

Secure
Redundant CPUs
Redundant Networks
Redundant Power

Cost Effective
Operational systems under $16K

Easy to Use
Automatic Reserve CPU setup
No special configuration
Existing file conversion

Honeywell Process Solutions Slide 2

HC900 Redundancy

• Provides “no single point of failure” for:

– Controller CPU

– Controller Power Supply

– Controller communications to a dual Plant Network

– Controller communications to its I/O

– I/O Power supply (Optional)

• Provides “bumpless transfer” between redundant controllers

• Maintains form / fit / function consistency with non-redundant

HC900 Controllers

• Provides ease of configuration

• Offers a competitive price

Honeywell Process Solutions Slide 3

HC900 Redundant Controller Rack

ƒ Compact CPUs, single rack design

ƒ Internal high speed CPU to CPU communications
ƒ Two network Ports per CPU (Simplex or Redundant)
ƒ Synchronized CPU operation
ƒ 1042, 559 or 3rd party Operator Interface support
ƒ Independent CPU Power
ƒ Distinct Lead/Reserve controller status indication
ƒ Secure key-lock mode access

Honeywell Process Solutions Slide 4

HC900 Redundant Controller Operation
Lead CPU Reserve CPU

Power for Power for

Lead CPU Reserve CPU

To I/O To I/O
Racks Racks
RSM

• All user and process interaction is with the Lead CPU.

Either CPU can be the Lead
Both CPUs receive Inputs
Both CPUs execute function blocks
Lead CPU writes outputs
• All communication is with the Lead CPU
• Lead CPU detects a Reserve CPU and automatically configures the Reserve
• Redundant Switch Module (RSM) identifies the Lead and Reserve CPUs
• RSM supports manual Fail-over of the Lead CPU
• Function Block execution resumes on start of next scan following a fail-over

Honeywell Process Solutions Slide 5

CPU Execution
Lead Controller Reserve Controller

Get Inputs Get Inputs

Diagnostic SYNC Diagnostic SYNC

Controller Cycle

Control SYNC Control SYNC

Execute Control Execute Control
Strategy Strategy

Write Outputs

Diagnostic Check Diagnostic Check

Communications

Honeywell Process Solutions Slide 6

HC900 Redundant Controller
ƒ C70R Controller CPU
- Based on proven HC900 C50 CPU design
- Standard 10/100BaseT Ethernet Communications
- Peer to Peer Communications
- Network and Serial PC Configuration Access
- 2 Serial Ports (RS232 or RS485, switch selectable)
- Modbus RTU Master or Slave Protocol

- 5000 Function Blocks

- Configuration backup in Flash Memory
- Dynamic data backup via Battery backed RAM
RIUP

Honeywell Process Solutions Slide 7

HC900 Redundant Controller
Redundancy Switch Module (RSM)
- Identifies Lead & Reserve CPUs
- Secure key switch to set:
o RUN Mode (no program changes)
o RUN / PROGRAM Mode (on-line changes)
o PROGRAM Mode (outputs off)
o Force manual fail-over (momentary)
RIUP
- Replace under power

Power Supplies
ƒ 28W

ƒ Same as I/O Rack Power

RIUP

Honeywell Process Solutions Slide 8

I/O Racks
• Remote mount up to 300M from CPUs

• 3 sizes, 4, 8 and 12 I/O Modules

• Up to 5 Remote Racks per CPU

- 2 or more racks require Industrial
(Ethernet) Hub

• Up to 960 total I/O, 256 analog Inputs

• Dual-Ported Scanner Module

• Optional Redundant I/O Power

- 8 & 12 Slot Racks

• Power Status Module

Honeywell Process Solutions Slide 9

Scanner

• One Scanner2 Module per I/O Rack

• Two ports – one for each C70R CPU
Status LED Indicator
• Maintains communications with Lead
and Reserve C70R CPU’s to facilitate
fail-over
• Reads inputs from modules & writes
outputs to modules in rack
Connection to C70R-A (I/O A)

Connection to C70R-B (I/O B)

RIUP

Honeywell Process Solutions Slide 10

Redundant I/O Power
• Provides backup power for Racks with I/O

• Maintains power to the rack if the Primary Power

Supply fails
• May be used with Redundant and Non-redundant
systems
RIUP RIUP RIUP
• Supports P01 (60W) and P02 (28W) Power Supplies
• Available for 8-Slot and 12-Slot I/O Racks

• Power Status Module (PSM) provides status of

power supplies

• Uses an extended rack to hold a 2nd (Reserve)

Power Supply and Power Status Module.

• Either Power Supply may be replaced while

maintaining power to the rack

• Also available as an field installation kit

Honeywell Process Solutions Slide 11
Small Redundant System
Redundant HC900 Controller with One I/O Rack
OPC Server
with Redundant
Network Driver
Redundant
1042 Networks
Operator Interface 10/100 baseT

Redundant
CPU
Assembly

A
B
100 baseT
Redundant Up to 100m
I/O Links
I/O Rack

Redundant
Power

Honeywell Process Solutions Slide 12

Large Redundant System
Redundant HC900 Controller with Five I/O Racks
OPC Server
to PC Software

Ethernet 10/100 baseT

Switch

Controller
Rack

Ethernet
A B Switch
100 baseT

Peer to Peer
Data Exchange

I/O
Rack

Honeywell Process Solutions Slide 13

Expanded Architecture
Two redundant Systems with PC Supervision

OPC Server
to PC Software
10/100 baseT
Ethernet
Switch
Peer to Peer
Data Exchange

Controller
A Rack
B Controller
Up to Rack
100 baseT Ethernet A
100m
Switch
B
100 baseT
I/O Rack

I/O Rack

I/O Rack

I/O Rack

Honeywell Process Solutions Slide 14

Expanded Architecture
Network with Redundant & Non-redundant Controllers

OPC Server with

Redundant Network Support

10 baseT

Peer to Peer
Data Exchange

Controller
Rack
A
B
100 baseT

I/O Rack Controller & I/O

Rack

I/O Rack

I/O Rack

Redundant HC900, Redundant Network Non-Redundant HC900

Honeywell Process Solutions Slide 15

Redundant Controller Operation

Lead Controller
Controls Operation of Outputs
Accepts Configuration and Edits
Programs and Updates Reserve
Communicates with Host
Communicates to Local OI
Accepts operator changes
Checks status of Reserve
Interchanges data with peers
Interchanges data with Modbus Slaves Redundant Configuration
No special requirements
Reserve Controller Function block for Reserve status
Accepts configuration from Lead Use C50 or C30 configurations
Accepts operator changes from Lead
Assumes Lead on Lead failure Fail-over
Outputs hold last position
Assigning Lead Detection & Fail-over in 4 scan cycles or less
On power up, first ready assumes lead Functions resume on next scan
On tie, CPU on left assumes lead.
Manual fail-over Failure Recovery Procedure
Power down failed CPU
Replace Module
Power up new CPU
New Reserve configured by Lead
(Backup restored)

Honeywell Process Solutions Slide 16

Benefits
• Cost Effective
Backup of critical assemblies
C70R CPU
Network Communications
Power (CPU and I/O)

• Easy to Implement
No complex configurations
No Reserve Controller Configuration
Operator Interface auto transfer, Lead to Reserve
Peer to Peer Comm. Auto transfer, Lead to Reserve

• Secure Operation
Key lock for Mode changes
Configure only Lead controller – guaranteed synchronization

• Performance to meet future needs

Ethernet 100 baseT Communications
5000 Controller function blocks

Honeywell Process Solutions Slide 17

End

HC900 Hybrid Controller

Now with Redundancy

Honeywell Process Solutions Slide 18