Honeywell CC-TAON01 51306519-175 Replacement for Experion PKS

Product Overview

Honeywell CC-TAON01 51306519-175 Replacement for Experion PKS: Seamless Migration & Upgrade Solution

The Honeywell CC-TAON01 (part number 51306519-175) is a high-density analog output module designed for the Experion PKS distributed control system platform. As legacy DCS installations age and original spare parts become increasingly scarce, plant engineers and procurement teams face mounting pressure to source reliable, drop-in replacements that preserve existing wiring infrastructure, control logic, and cabinet layouts without triggering costly system-wide revalidation. TOPNLMS supplies the CC-TAON01 51306519-175 as a fully tested, ready-to-ship replacement module backed by a 12-month warranty, enabling facilities to execute controlled migrations with minimal unplanned downtime.

The CC-TAON01 delivers 16 channels of 4–20 mA analog output, interfacing directly with the C300 Controller and the IOTA termination assembly via the standard Experion PKS Series C I/O bus. Each channel is individually configurable through Control Builder, and the module supports HART pass-through communication, allowing field instruments such as control valves, positioners, and variable-speed drives to retain their HART diagnostic capability without rewiring. When replacing a failed or end-of-life CC-TAON01, the field wiring connected to the companion CC-TAON01 IOTA (input/output termination assembly) remains completely undisturbed — the module simply slides out of the I/O chassis and the replacement unit clicks into place, dramatically reducing the risk of wiring errors during a live-plant swap.

For sites migrating from older TDC 3000 or PlantScape systems to Experion PKS, the CC-TAON01 is a core building block of the Series C I/O architecture. During such migrations, the analog output channels previously handled by PM I/O or HPM I/O cards are re-mapped to CC-TAON01 modules mounted in the Series C I/O Link chassis. The migration typically involves updating the Control Builder database to reassign tag addresses, verifying loop power budgets, and confirming that the existing marshalling cabinet wiring is compatible with the IOTA terminal layout. In most cases, existing 24 VDC field loop power supplies and shielded twisted-pair cabling can be reused without modification, significantly reducing retrofit cost and schedule risk.

Power for the CC-TAON01 is supplied through the I/O chassis backplane, which is fed by a dedicated 24 VDC power supply module — typically the CC-PWR01 or CC-PWR02 — mounted in the same chassis. When planning a replacement or expansion, it is important to verify that the chassis power budget accommodates the additional load of the new module, particularly in high-density configurations where multiple analog output modules share a single chassis. The CC-TAON01 draws approximately 1.5 W from the backplane, and each active 4–20 mA output channel sources loop power from the field supply rather than the module itself, keeping the backplane load predictable.

Communication between the CC-TAON01 and the C300 Controller traverses the Experion I/O Link, a proprietary high-speed serial bus that supports hot-swap module replacement without interrupting other I/O points on the same link. This architecture is a key advantage during live-plant maintenance windows: a technician can remove the faulty CC-TAON01, insert the replacement unit, and allow the C300 to automatically re-download the module configuration — all without placing the controller in a degraded operating mode. Sites that have implemented redundant C300 controllers can perform the swap while the standby controller maintains process control, achieving a zero-impact replacement.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful CC-TAON01 migration rarely involves a single module in isolation. In practice, the analog output replacement is one element of a broader I/O refresh that may also address analog input capacity, digital I/O, and controller redundancy. The CC-TAIX01 analog input module shares the same Series C chassis and IOTA architecture as the CC-TAON01, making it a natural companion when upgrading both input and output channels in the same cabinet. Similarly, the CC-TDIL01 digital input module and CC-TDOB01 digital output module are commonly refreshed in the same maintenance window to standardize the I/O chassis population and simplify spare-parts inventory.

Controller-side upgrades often accompany I/O module replacements. The C300 Controller — the primary process controller in the Experion PKS architecture — may itself be approaching end-of-support, and sites frequently use an analog output module replacement project as the trigger to evaluate a C300 firmware upgrade or a full controller swap. The CC-PCF901 fault-tolerant controller pair is a common upgrade target for high-availability loops previously managed by older single C300 units.

On the termination side, the CC-TAON01 IOTA is the dedicated wiring interface for this module. If the existing IOTA shows signs of terminal wear or corrosion — common in humid or chemically aggressive environments — replacing the IOTA alongside the module eliminates a latent failure point. The Series C I/O chassis itself, available in 4-slot and 8-slot configurations, may also be upgraded when expanding output channel count beyond what the existing chassis can accommodate.

For sites that require signal conditioning or galvanic isolation between the DCS output and field devices, the CC-TAON01 can be paired with DIN-rail-mounted signal isolators or loop-powered barriers installed in the marshalling cabinet. This is particularly relevant when interfacing with legacy pneumatic positioners or when field cable runs exceed 500 meters, where loop resistance budgets become critical. In such configurations, the HART signal integrity should be verified after inserting any passive or active isolator in the loop.

Finally, for sites that are simultaneously upgrading their operator interface, the Experion PKS platform supports integration with Honeywell’s HMI Station and the Experion Orion Console, both of which consume the analog output data published by the CC-TAON01 through the standard Experion data highway. Upgrading the HMI in parallel with the I/O refresh ensures that new trend displays and alarm configurations accurately reflect the re-mapped tag addresses in the updated Control Builder database.

Retrofit Guidance FAQ

Q: Can I replace a failed CC-TAON01 without shutting down the C300 Controller?
A: Yes. The Experion I/O Link supports hot-swap replacement. Remove the faulty module, insert the replacement CC-TAON01 51306519-175, and the C300 will automatically re-download the module configuration. Outputs will return to their last commanded values within seconds of the module coming online. Confirm with your site safety procedures before performing a live swap on critical control loops.

Q: Do I need to rewire the field terminals when replacing the CC-TAON01?
A: No, if the IOTA termination assembly is retained. All field wiring connects to the IOTA, not to the module itself. The CC-TAON01 plugs into the IOTA via the backplane connector, so a module swap requires no field wiring changes.

Q: Is the CC-TAON01 51306519-175 compatible with HART field devices?
A: Yes. The module supports HART pass-through on each channel, allowing HART-capable field instruments to communicate with the Experion HART Multiplexer or directly through the I/O Link. Verify that HART is enabled in the Control Builder channel configuration.

Q: What is the physical installation space requirement?
A: The CC-TAON01 occupies one standard slot in a Series C I/O chassis. No additional panel space is required beyond the existing chassis slot. Ensure the chassis power budget (CC-PWR01 or CC-PWR02) has sufficient headroom before installing additional modules.

Q: Can this module replace analog output cards from TDC 3000 or PlantScape HPM systems?
A: Not as a direct drop-in. Migration from TDC 3000 or PlantScape to Experion PKS requires remapping tag addresses in Control Builder, installing Series C I/O chassis and IOTAs, and re-terminating field wiring to the new IOTA terminals. TOPNLMS can provide technical documentation to support your migration planning.

Q: What communication protocol does the CC-TAON01 use?
A: The module communicates over the Honeywell Experion I/O Link, a proprietary high-speed serial bus. It does not natively support Modbus, PROFIBUS, or EtherNet/IP — those protocols are handled at the controller or gateway level within the Experion PKS architecture.

Warranty Assurance

Every CC-TAON01 51306519-175 shipped by TOPNLMS is covered by a 12-month warranty from the date of delivery. Prior to shipment, each unit undergoes functional verification including power-on self-test, channel output accuracy check across the 4–20 mA range, and HART communication validation. Units that do not meet specification are quarantined and not shipped.

In the event of a warranty claim, TOPNLMS will arrange a replacement unit shipment within 3 business days of claim confirmation, minimizing the impact on your plant operations. Our after-sales team is reachable by email and phone to support installation questions, compatibility verification, and return merchandise authorization (RMA) processing.

For time-critical plant shutdowns or emergency maintenance windows, expedited shipping from our Xiamen warehouse is available to most destinations in Asia, Europe, and the Americas. Stock availability is confirmed at the time of order, and a certificate of conformance is provided with each shipment upon request.

TOPNLMS maintains a dedicated inventory of Honeywell Experion PKS Series C I/O modules to support both planned maintenance programs and emergency replacement requirements. Bulk procurement pricing is available for MRO contracts and system integrators managing multi-site DCS upgrade programs.