HONEYWELL CC-PCNT02 – High-Speed Redundant Process Control Module

Technical Specifications

• Processor & Memory:
  • 32-bit Intel Processor: Provides real-time control execution with floating-point arithmetic support for complex algorithms .
  • Memory:
    • 256 MB RAM: Stores runtime data and user programs with battery-backed retention .
    • 512 MB Flash Memory: Preserves firmware, configurations, and historical data without external power .
• Power Requirements:
  • Input Voltage: 24 VDC (±15%) with reverse polarity protection .
  • Power Consumption: ≤8 W at full load .
• Communication Interfaces:
  • Ethernet: 10/100 Mbps ports supporting TCP/IP, Modbus TCP, and Ethernet/IP for seamless integration with enterprise systems .
  • Serial Ports: RS-232/RS-485 for legacy device connectivity, supporting Modbus RTU and Honeywell’s Serial Network Protocol (SNP) .
  • Protocol Support: MODBUS TCP/RTU, DNP3, and OPC UA for IIoT analytics .
• Physical Attributes:
  • Dimensions: 19.1 cm (H) × 18.8 cm (W) × 6.5 cm (D) (7.5″ × 7.4″ × 2.6″) with compact DIN rail mountable design .
  • Weight: 0.6 kg (1.32 lb) .
  • Environmental Ratings:
    • Temperature: -40°C to +70°C (-40°F to +158°F) for extended industrial environments .
    • Humidity: 5–95% non-condensing (IEC 60068-2-30) .
    • Shock/Vibration: Compliant with IEC 60068-2-6 (5–500 Hz, 0.5 g) for rugged stability .
  • Certifications: CE, UL, FCC Class A, and RoHS compliance for global deployments .

Functional Features

1. Programming & Logic Control:
   • IEC 61131-3 Compliance: Supports ladder logic, structured text, and function block diagram programming for flexible application development .
   • Deterministic Execution: Boolean logic cycle times <1 ms per 1,000 instructions with sub-millisecond synchronization .
   • Symbolic Tag Management: Simplifies complex system integration with auto-located variables and intuitive configuration .
2. Advanced Diagnostics:
   • Self-Monitoring: Continuous CPU, memory, and communication health checks with LED status indicators .
   • Event Logging: Stores 1,024 timestamped events (1 ms resolution) for root-cause analysis .
   • Web-Based Interface: Built-in HTTPS server enables remote firmware updates, data trending, and diagnostics .
3. Scalability & Redundancy:
   • Modular Architecture: Supports up to 32 I/O modules per chassis with hot-swap capability for maintenance-free operation .
   • Dual Controller Redundancy: Automatic failover (≤50 ms) via dedicated Ethernet port for critical processes .
   • Power Redundancy: Dual 24 VDC inputs with seamless transition during power interruptions .
4. Industrial Communication:
   • Ethernet Features:
     • Media Redundancy Protocol (MRP): <20 ms recovery in ring topologies .
     • OPC UA Server: Enables secure data exchange with enterprise-level analytics platforms .
   • Serial Flexibility: Configurable baud rates (1200–115200 bps) for legacy SCADA systems .
5. Safety & Security:
   • Cybersecurity: TLS-encrypted communication and role-based access control (RBAC) .
   • Fail-Safe Design: Hardwired emergency stop (ESTOP) interface for safety-critical applications .
   • Password Protection: Restricts unauthorized access to configuration settings .

Application Scenarios

1. Oil & Gas:
   • Refineries: Monitors distillation columns, pump stations, and safety interlocks with predictive maintenance analytics .
   • Offshore Platforms: Controls subsea wellheads and topside processing systems in harsh marine conditions .
2. Power Generation:
   • Thermal Power Plants: Optimizes boiler combustion and steam turbine auxiliary systems .
   • Renewable Energy: Supervises wind turbine pitch control and solar inverter synchronization .
3. Manufacturing & Process Automation:
   • Pharmaceuticals: Ensures batch recipe accuracy and regulatory compliance in sterile environments .
   • Food & Beverage: Manages filling, capping, and labeling machines with hygienic design compatibility .
4. Water/Wastewater:
   • Treatment Plants: Controls pump scheduling, chemical dosing, and SCADA integration .
   • Desalination: Maintains stable reverse osmosis (RO) membrane operation in high-salinity environments .
5. Mining & Metals:
   • Material Handling: Synchronizes conveyor belts, crushers, and slurry pumps in mineral processing .
   • Smelting: Regulates furnace temperature and electrode positioning in aluminum production .

Typical System Integration

• Hardware:
  • C300 Chassis: Supports modular I/O expansion with Control Firewall (CF9) for network aggregation .
  • I/O Modules: Digital (e.g., CC-PDIO01), analog (e.g., CC-PAIO01), and specialty modules (e.g., HART-enabled) .
• Software:
  • Experion PKS: Comprehensive engineering suite for programming, simulation, and HMI visualization .
  • Profit Controller Integration: Exclusive to CC-PCNT02 for real-time economic optimization of production processes .
• Network Design:
  • Ethernet Ring: MRP-enabled switches (e.g., Honeywell IC698CHS001) for redundant data transfer .
  • Serial Backbone: RS-485 networks for connecting legacy RTUs and field instruments .

Safety & Compliance

• Functional Safety:
  • IEC 61508: Optional SIL 2-rated firmware for safety-critical applications .
  • Fail-Safe Mechanisms: Automatically reverts to pre-fault state in case of communication failure .
• Environmental Sustainability:
  • RoHS-Compliant: Lead-free design reduces ecological impact .
  • Energy Efficiency: <1 W standby power consumption during low-activity periods .