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- Model: TC-PRS021
- Brand: Honeywell
- Series: Experion PKS C200
- Core Function: C200 process control and user program execution
- Type: Control Processor Module (CPM)
- Key Specs: 4 MB user memory; +5 VDC and +3.3 VDC supply rails; 0 to +60°C operating range
- Configuration: Supports non-redundant and redundant C200 controller configurations
Product Introduction
Honeywell TC-PRS021 is the C200 Control Processor Module (CPM) used in Experion PKS controller chassis. It provides the processing core for a C200 controller and is designed for chassis-based control architectures with plug-in communication, I/O, redundancy, and interface modules.
The module provides 4 MB of user memory and can be deployed in both non-redundant and redundant controller configurations. Published Honeywell specifications list an operating ambient range of 0 to +60°C and module power requirements of approximately +5 VDC at 1.5 A and +3.3 VDC at 1.0 A.
Key Technical Specifications
| Parameter | Specification |
|---|---|
| Manufacturer | Honeywell |
| Model | TC-PRS021 |
| Controller | Experion PKS C200 |
| Product Type | Control Processor Module |
| Function | C200 controller processing |
| User Memory | 4 MB |
| Operating Temperature | 0 to +60°C |
| Relative Humidity | 5 to 95%, non-condensing |
| Power Requirement | +5 VDC ±5% @ 1.5 A |
| Additional Supply | +3.3 VDC ±5% @ 1.0 A |
| Battery Backup | Standard lithium battery |
| Standard Battery Backup Time | Up to 144 hours |
| Redundant Configuration | Supported |
| Hot Insertion | Not permitted |
The published Honeywell documentation specifies that removal or insertion under power is not permitted. The standard lithium battery provides up to 144 hours of backup; a Battery Extension Module (BEM) provides approximately 120 hours under the documented configuration.
Honeywell C200 TC-PRS021
Installation & Configuration Guide
Stage 1 — Pre-Installation
Estimated time: 10 minutes
⚠️ Power must be removed before installing or removing the CPM.
- Notify the control-room/operator team of the planned maintenance window.
- Place the process in the approved safe operating state.
- Isolate controller power according to the site’s LOTO procedure.
- Confirm that no power remains on the chassis.
- Wear an ESD wrist strap and use an antistatic work surface.
- Photograph the existing controller position and adjacent modules.
- Record the existing TC-PRS021 hardware/firmware revision.
- Verify that the replacement is the correct C200 CPM.
Honeywell’s installation documentation specifically requires the chassis to be unpowered before installing or removing the C200 processor.
Stage 2 — Remove the Existing CPM
Estimated time: 5 minutes
- Confirm the controller chassis location.
- Check that the power supply is isolated.
- Open or remove the applicable module cover according to the chassis procedure.
- Identify the CPM retaining mechanism.
- Release the module carefully.
- Withdraw the processor straight from its chassis position.
- Inspect the backplane and connector contacts.
⚠️ Do not force the module sideways. The backplane connector is a precision interface.
Stage 3 — Install the Replacement
Estimated time: 5–10 minutes
- Verify the exact model before insertion.
- Check the module housing and connector for mechanical damage.
- Align the CPM with the designated chassis position.
- Insert the module carefully and fully seat it.
- Confirm that the retaining mechanism is engaged.
- Check that the module sits flush with neighboring modules.
- Reinstall any applicable cover or mechanical retainer.
For a redundant C200 controller, Honeywell documentation identifies the Control Processor Module as occupying the designated CPM position and notes that the TC-PRS021 supports redundant controller configurations.
Stage 4 — Power-On and Verification
Estimated time: 10–15 minutes
- Recheck the chassis installation.
- Restore power following the approved startup sequence.
- Observe the processor status indicators.
- Confirm that the controller starts without hardware alarms.
- Open the Experion engineering environment.
- Verify controller communication.
- Check the loaded configuration and controller status.
- Confirm I/O and network communications.
- For redundant systems, verify controller synchronization and redundancy status.
- Monitor the system for at least 30 minutes.
Do not start making configuration changes immediately after power-up. First establish that the replacement controller is recognized and operating normally.
Common Replacement Risks
1. Firmware Revision Mismatch
A physically identical processor may have a different firmware revision.
Check: Record the old revision before replacement and confirm compatibility with the installed Experion PKS release.
2. Incorrect Chassis Position
The C200 CPM has a defined chassis position within the controller architecture.
Check: Photograph the original layout before removal. Honeywell documentation identifies the CPM in the dedicated controller slot arrangement.
3. Power Removal Error
This is not a hot-swappable module.
Warning: Honeywell documentation states that CPM removal and insertion under power are not permitted.
4. Battery Condition
The processor uses battery-backed memory.
Check: Inspect the battery condition during maintenance. Do not assume an old spare has the same remaining battery life as a newly supplied module.
5. Redundant Controller Compatibility
In a redundant C200 system, the processor must be evaluated as part of the complete controller configuration.
Check: Verify the companion processor, redundancy module, CNI configuration, and software release before swapping only one processor.
FAQ
1. What is Honeywell TC-PRS021 used for?
It is the C200 Control Processor Module, providing the processing function for a Honeywell Experion PKS C200 controller.
2. How much user memory does the C200 processor provide?
The documented TC-PRS021 C200 CPM provides 4 MB of user memory. The later C200E controller uses the Tx-PRS022 and increases user memory to 16 MB.
3. Can TC-PRS021 be used in a redundant C200 controller?
Yes. Honeywell documentation states that the TC-PRS021 can be used in both non-redundant and redundant controller configurations.
4. Can I replace this module while the controller is powered?
No. Published C200 documentation states that removal/insertion under power is not permitted. The controller chassis must be powered down before replacement.
5. What temperature range is specified?
The documented operating ambient range is 0 to +60°C. The transport/storage specifications are different, so do not use the transportation range as the normal operating limit.
6. What power does the processor require?
Honeywell documentation lists approximately +5 VDC ±5% at 1.5 A and +3.3 VDC ±5% at 1.0 A for the module.
7. Is TC-PRS021 the same as the coated TK-PRS021?
Not exactly. Honeywell documentation identifies TC-PRS021 as the uncoated C200 CPM and TK-PRS021 as the coated variant for more demanding environmental conditions. Select the revision/coating that matches the installed system requirements.
Inventory note: For critical C200 controller spares, keeping 1 tested spare processor on-site is a reasonable buffer-stock position. Before stocking, record the controller firmware revision and battery condition; those details can matter more than the housing looks.
