Honeywell CC-MCAR01

¥999.00

HONEYWELL CC-MCAR01 is a high-performance Analog Input Redundant Module designed for Honeywell’s Experion PKS (Process Knowledge System) distributed control system, specializing in the precise acquisition of 4-20mA current and 0-10V voltage signals with built-in redundancy for mission-critical process monitoring applications. As a core component of Honeywell’s Experion PKS redundant I/O portfolio, HONEYWELL CC-MCAR01 delivers 16 channels of isolated analog inputs with fault-tolerant design, making it essential for refineries, chemical plants, nuclear power facilities, and LNG terminals operating Experion PKS systems. In a nuclear power plant’s coolant system monitoring, HONEYWELL CC-MCAR01 provides redundant temperature and pressure input acquisition to ensure continuous data collection; in a chemical plant’s reactor control system, HONEYWELL CC-MCAR01 processes redundant flow and level signals for safety-critical loops; in an LNG terminal’s storage tank monitoring system, HONEYWELL CC-MCAR01 acquires redundant pressure and level transmitter inputs to prevent system downtime. Additionally, HONEYWELL CC-MCAR01 features hot-swappable design, seamless integration with Experion PKS controllers, and advanced diagnostic tools, ensuring reliable performance in the most demanding industrial environments.

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Description

1. Product Overview

HONEYWELL CC-MCAR01 is a high-performance Analog Input Redundant Module designed for Honeywell’s Experion PKS (Process Knowledge System) distributed control system, specializing in the precise acquisition of 4-20mA current and 0-10V voltage signals with built-in redundancy for mission-critical process monitoring applications. As a core component of Honeywell’s Experion PKS redundant I/O portfolio, HONEYWELL CC-MCAR01 delivers 16 channels of isolated analog inputs with fault-tolerant design, making it essential for refineries, chemical plants, nuclear power facilities, and LNG terminals operating Experion PKS systems. In a nuclear power plant’s coolant system monitoring, HONEYWELL CC-MCAR01 provides redundant temperature and pressure input acquisition to ensure continuous data collection; in a chemical plant’s reactor control system, HONEYWELL CC-MCAR01 processes redundant flow and level signals for safety-critical loops; in an LNG terminal’s storage tank monitoring system, HONEYWELL CC-MCAR01 acquires redundant pressure and level transmitter inputs to prevent system downtime. Additionally, HONEYWELL CC-MCAR01 features hot-swappable design, seamless integration with Experion PKS controllers, and advanced diagnostic tools, ensuring reliable performance in the most demanding industrial environments.

2. Product Parameters

2.1 Core Input Specifications

  • Input Channels: 16 isolated analog input channels (independently configurable per channel)
  • Supported Signals:
    • Current: 4-20mA DC (loop-powered/sourcing), 0-20mA DC
    • Voltage: 0-5V DC, 0-10V DC
  • Resolution: 16-bit (analog-to-digital conversion)
  • Accuracy: ±0.05% of full scale (calibrated over -40°C to +70°C)
  • Isolation Rating: 2500V AC channel-to-channel, 3000V AC channel-to-ground
  • Sampling Rate: 100 samples per second (per channel)
  • Redundancy Architecture: 1:1 hot standby (automatic failover <50ms)

2.2 Electrical & System Parameters

  • Power Supply: 24V DC (redundant inputs, supplied by Experion PKS I/O rack), power consumption ≤15W per module
  • Backplane Interface: Honeywell FTE (Fault-Tolerant Ethernet) I/O bus, compatible with Experion PKS C300/C200 redundant controllers
  • Diagnostic Features: Open-loop detection, short-circuit protection, module health monitoring, LED status indicators (power, redundancy active, channel fault, communication)
  • Configuration: Software-configurable via Experion PKS Configuration Studio (signal type, range, redundancy settings, alarm thresholds)
  • Compatibility: Honeywell Experion PKS C300/C200 redundant controllers, 4-20mA/0-10V transmitters from major manufacturers (Siemens, Emerson, Rosemount)

2.3 Environmental & Mechanical Parameters

  • Operating Temperature: -40°C to +70°C (extended industrial range)
  • Storage Temperature: -40°C to +85°C
  • Relative Humidity: 5% to 95% (non-condensing), IP20 protection (rack-mounted)
  • Vibration Resistance: 5-2000Hz, 2g (IEC 60068-2-6, X/Y/Z axes)
  • Shock Resistance: 30g (11ms half-sine wave, IEC 60068-2-27)
  • Mounting: Experion PKS redundant I/O rack-mounted (standard 19-inch rack), hot-swappable (plug-in module)
  • Dimensions: 120mm (W) × 150mm (H) × 30mm (D), Experion PKS rack-compatible form factor

2.4 Certifications & Compliance

  • Industry Certifications: CE, UL/cUL Class 1 Div 2, ATEX Zone 2 (Ex nA IIC T4), IEC 61508 (SIL 3 certified for safety applications)
  • Compatibility: Honeywell Experion PKS systems (Release R400+), redundant I/O subsystems
  • MTBF: ≥1,500,000 hours (per Telcordia SR-332 standards for redundant modules)

3. Advantages & Features

  1. 1:1 Redundant Design: HONEYWELL CC-MCAR01 supports hot standby redundancy with automatic failover (<50ms), ensuring uninterrupted analog input acquisition in safety-critical applications like nuclear power plant coolant monitoring or chemical reactor control.
  2. High Precision & Reliability: 16-bit resolution, ±0.05% accuracy, and extended temperature operation make HONEYWELL CC-MCAR01 ideal for harsh industrial environments where precise and consistent data collection is non-negotiable.
  3. Comprehensive Diagnostics: Module health monitoring, channel-level fault detection, and real-time redundancy status reporting simplify troubleshooting, allowing maintenance teams to identify issues before they impact process control.
  4. Hot-Swappable & Easy Maintenance: HONEYWELL CC-MCAR01 can be replaced in live Experion PKS systems without interrupting process control, reducing maintenance downtime and eliminating the need for system shutdowns.
  5. SIL 3 Certification: Compliant with IEC 61508 SIL 3 standards, HONEYWELL CC-MCAR01 meets the highest safety requirements for critical infrastructure applications such as nuclear power, oil & gas, and chemical processing.

4. Application Fields & Cases

4.1 Application Fields

  • Nuclear Power: Coolant system temperature/pressure monitoring, reactor level control input, safety relief valve status acquisition
  • Oil & Gas: Refinery crude distillation unit redundant pressure/flow monitoring, LNG terminal storage tank level/pressure input, pipeline leak detection system
  • Chemical Manufacturing: Reactor temperature/level redundant input, batch process pressure monitoring, hazardous material storage tank safety systems
  • Power Generation: Fossil fuel power plant boiler steam pressure/temperature redundant input, turbine vibration monitoring, emissions control system data acquisition

4.2 Typical Cases

  1. Nuclear Power Plant Coolant Monitoring: A European nuclear power plant deployed HONEYWELL CC-MCAR01 modules in redundant configuration for its coolant system temperature and pressure monitoring. During a primary module failure, the standby unit automatically took over (<50ms failover), ensuring continuous data collection and compliance with nuclear safety regulations.
  2. Refinery Crude Distillation Unit Control: A major Middle Eastern refinery used HONEYWELL CC-MCAR01 to acquire redundant 4-20mA pressure and flow signals from 32 transmitters across 2 crude distillation units. The module’s SIL 3 certification enabled compliance with IEC 61511 standards, and the hot-swappable design allowed maintenance without process interruptions, improving plant uptime by 2%.
  3. Chemical Plant Reactor Safety System: A U.S. chemical manufacturer integrated HONEYWELL CC-MCAR01 into its Experion PKS reactor safety system to monitor redundant level and temperature inputs. The module’s high accuracy (±0.05%) ensured precise reactor control, reducing batch rejection rates by 10% and improving product quality consistency.

5. Competitive Comparison

Parameter HONEYWELL CC-MCAR01 Competitor A (Non-Redundant Experion PKS AIM) Competitor B (Generic Redundant Analog Input Module)
Redundancy Support 1:1 hot standby (<50ms failover) None 1:1 cold standby (>1000ms failover)
SIL Certification SIL 3 SIL 1 SIL 2
Accuracy ±0.05% full scale ±0.1% full scale ±0.1% full scale
Operating Temperature -40°C to +70°C 0°C to +60°C -20°C to +65°C
MTBF ≥1,500,000 hours ≥800,000 hours ≥1,000,000 hours

6. Selection Suggestions & Precautions

6.1 Selection Suggestions

  1. Redundancy Requirements: Choose HONEYWELL CC-MCAR01 for safety-critical applications requiring uninterrupted analog input acquisition (e.g., nuclear power, chemical reactors); non-redundant modules are unsuitable for these environments.
  2. System Compatibility: Opt for HONEYWELL CC-MCAR01 for Honeywell Experion PKS C300/C200 redundant controllers (Release R400+); generic redundant modules may lack native integration and SIL certification.
  3. Accuracy Needs: Select HONEYWELL CC-MCAR01 for applications requiring ±0.05% accuracy (e.g., precision reactor control); lower-accuracy modules may compromise process stability.

6.2 Precautions

  1. Installation Guidelines:
    • Install HONEYWELL CC-MCAR01 in Experion PKS redundant I/O racks only; ensure both primary and standby modules are connected to separate power supplies and FTE networks to maximize fault tolerance.
    • Use shielded twisted-pair cables for 4-20mA/0-10V signals (maximum distance 1000m for current, 500m for voltage) and ground the cable shield at the module end to minimize noise.
  2. Configuration Notes:
    • Configure redundancy settings (failover thresholds, health check intervals) via Experion PKS Configuration Studio before commissioning; mismatch between primary and standby modules may cause failover errors.
    • Enable channel-level fault detection and alarm notifications to track open-loop/short-circuit conditions for predictive maintenance.
  3. Troubleshooting:
    • For redundancy failures: Verify firmware compatibility between primary and standby modules, check FTE communication links, and inspect power supply stability for both units.
    • For inaccurate readings: Calibrate modules via Configuration Studio, verify transmitter calibration, and check for wiring issues (e.g., open loops for current inputs).
  4. Maintenance:
    • Inspect module connectors annually for corrosion or damage; clean with compressed air to remove dust and debris (avoid contact with backplane pins).
    • Recalibrate HONEYWELL CC-MCAR01 every 2 years (or per site maintenance protocols) to maintain SIL 3 certification and accuracy.
    • Stock spare HONEYWELL CC-MCAR01 modules—lead times for redundant I/O components may exceed 12 weeks for custom configurations.

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