Process Instruments Controllers and Programmers Controllers and - - PowerPoint PPT Presentation

Process Instruments Controllers and Programmers

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Controllers and Programmers

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Sampling of Served Industries

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Thermal Processing Equipment Requiring Controls and Instrumentation

Batch Furnace Batch Oven Box Furnace Asphalt Drum Mixer Incinerator Burner Controls

End User Products

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Customer Challenges

• Obtaining tighter control of the

process to improve product quality and reduce scrap

• Online Accutune ensures optimum

tuning of the process to improve quality

• Having a High Limit Model that

provides safety shut-off in an over temp condition

• Must meet all agency approvals
• Compliance to AMS2750 or other

quality assessment programs

• Quick and easy start-up using PC

Configuration Software

Thermal Processing Facility

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Customer Challenges

• NEMA-4X Front Face for wash-

down operations

• Math functions including

sequencing, logic gates and totalization

• Large easy to read displays
• Must meet all agency approvals
• Quick and easy start-up using PC

Configuration Software

• Online Accutune ensures optimum

tuning of the process to improve quality

Food and Beverage

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Field proven control algorithms provide precise and repeatable control of customer processes, resulting in manufacture of high quality end products. Controller and programmer product reliability and performance are beyond specification limits. Easy Operation with one-touch auto tuning, bright and vivid displays, keypad or touch screen display for easy access to change setpoints, modes of operation, acknowledge alarms, initiate ramps/soaks and modify configuration parameters. Reduced Operational Costs with quick enterprise access to information and PC supported software applications for status diagnostics, device data access, configuration changes and faceplate views.

Controllers and Programmers

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More accurate process control - ensures product quality and compliance

• Easy-to-read displays and intuitive operation enhance efficiency and decision making
• Single button tuning ensures proper tuning constants eliminating errors
• Accutune III continuously retunes the process insuring precise control
• Fuzzy logic with overshoot suppression insures against process disturbances
• Efficient process alarming and notifications provide quick response to process upsets

Intuitive methods and tools - make for better decisions, more efficient employees

• Process Explorer Software (PIE) makse configuration of the controller quick and easy
• Easy to read displays allow operators to easily interrupt alarm and other abnormal

conditions

• Ethernet connection allows alarm data to be sent directly to your cell phone so you

don’t have to be in the area to be alerted to an abnormal situation

Compliance to most approval agencies - as required by many industries

• Meets ASM2750 as required by the Aerospace Industries
• Meets FM Approval as a high limit as required in the heat treat industry
• Meets NEMA4X wash down as required in many food & beverage applications

Accuracy, Efficiency and Compliance

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Application Example

Solution

• Use controllers to establish

3 zones of control

• Control both temperature and

fuel/air ratio in each zone

• UDC controllers meet AMS2750

requirements (accuracy, security, passwords)

• Alarms, email Alarm to alert

personnel of abnormal conditions

• T/C Health monitoring
• Accutune III automatically and

continuously retunes the process

Problem – Must maintain uniform temperature for compliance

Benefit – creating zones and linking the controllers together ensures uniform temperature and compliance

Burner Burner Burner

Zone 1 Zone 2 Zone 3

TC

Zone 2 Zone 3

Temperature Controllers

Combustion Air Fuel Furnace Pressure

Actuator

Actuator

TC TC

Zone 1

Recorder

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Price Function

UDC700 UDC2500 UDC3200 UDC3500 UDC1700/1200 DC1000

Controllers

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• Complete line of controllers/programmers/indicators
• Best Price/Performance ratio compared to competition
• Engineered to provide “Targeted Functionality”
• solutions tailored to specific requirements
• purchase only what you need

Controller Product Portfolio

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• Clear and informative operator interface
• Easy to set up and operate
• Single-button tuning for precise control
• Fuzzy logic overshoot suppression
• PC Software Tools

Controller Value

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UDC700 Controller and Indicator

1/32 DIN (49x25 mm)

Compact Size High Degree of Functionality Low Price

Power Input (universal)

90 to 264 Vac, 24 Vac/dc option

Signal Input (universal)

Thermocouple, RTD, Linear DC

Input Accuracy

0.1% of span

Control Output

2 Amp relay or SSR driver

Alarm Output

up to 2 Alarm outputs

Networking

RS485 / Modbus

Approvals

UL and CE Mark - Nema4/IP66 (front face)

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DC1010 48x48mm 1/16th DIN DC1020 48x96mm 1/8th DIN DC1030 72x72mm 3/16th DIN DC1040 96x96mm 1/4 DIN

UDC1000 Controllers

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• Autotune (PID & Fuzzy)
• Large range of inputs, outputs, algorithms

DC 1010 DC 1020 DC 1040 DC 1030

UDC1000 Controllers

• Accuracy:  0.2%
• 13 ranges of thermocouples
• 3 ranges of RTDs
• linear inputs
• Large range of input types:
• Two 4 digit, 7 segment LED displays
• Bar-graph to display % output (N/A on 1010 model)
• RS232/485 Modbus RTU or ASCII network
• Retransmission output
• Remote Setpoint input

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• ON/OFF & PID
• Heat/Cool with dual PID sets
• TPSC algorithm (N/A on 1010 model)

Large selection of algorithms:

• Relay (3 Amp)
• SSR
• Current (4-20mA)
• Volts (0~5V, 0~10V, 1~5V, 2~10V)
• Motor Control (TPSC)

Large range of output types:

UDC1000 Controllers

DC 1010 DC 1020 DC 1040 DC 1030

Programmers:

• programs / 8 segments each

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ALARM Features

• 3 ALARMS max can be selected
• 17 types of ALARM modes are available:
• deviation high, low, high/low alarms
• high & low alarms
• segment end alarm
• program run alarm
• Each ALARM has an associated timer:
• make the alarm stay active continuously
• make the alarm disappear after a certain amount of time

UDC1000 Controllers

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UDC1200 and UDC1700 Controllers

1/8 DIN 1/16 DIN

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• Universal controllers for temperature, pressure and level control
• 1/16 DIN (UDC1200) and 1/8 DIN (UDC1700) panel mount sizes
• Dual 4 digit LED displays
• Single universal input
• 0.1% accuracy
• Input sampling of 4 times per sec.
• RS485 ASCII or Modbus RTU communications interface
• Nema 3 / IP66 front panel sealing
• CE, UL, FM approvals

UDC1200 and UDC1700 Controllers

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• Universal power supply 90 VAC to 264 VAC (24/48 Vac/dc option)
• Pre-tuning for PID parameter optimization
• Two soft ALARMS for PV, deviation
• Special loop alarm (continuously analyzes PV response to control output)
• Up to 3 output types available (relay, SSR driver, linear)
• Dual Setpoints
• UDC1700 supports 2nd input for remote setpoint
• Setpoint ramp function
• Limit controller with FM approval for UDC1200

UDC1200 and UDC1700 Controllers

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Slot 1 modules :

• Relay
• 10V DC SSR Driver

Option Boards - easy upgrade, jumper free

Slot 2&3 module :

• Relay
• 10V DC SSR Driver
• Triac (Slot 2 only)
• Linear (mA/V DC)
• Dual Relay (Slot 2 only)
• 24V Transmitter PSU (Slot 3 only)

Slot A :

• RS485 Communications
• Digital Input

Slot 2&3 Slot A Slot 1

• Triac
• Linear (mA/V DC)

UDC1200 and UDC1700 Controllers

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UDC1200

• Flexibility
• 0.1% accuracy
• 4 times/sec. sample rate
• TPSC
• Digital input available
• Limit model
• Not a SP Programmer
• Modbus & ASCII Comm
• Nema 3/IP64 protection
• CE, UL & FM
• Fixed hardware configuration
• 0.2% Accuracy
• 2 times/sec. sample rate
• No TPSC
• No digital input available
• No limit model
• Basic SP Programmer
• ASCII Comm
• Not rated
• CE & UL

DC1010

Controller Differences

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UDC1700

• Flexibility
• 0.25% Accuracy
• 4 times/sec. sample rate
• Digital input available
• Not a SP Programmer
• No bargraph available
• Modbus & ASCII Comm
• Nema 3/IP64 protection
• CE, UL & FM
• Fixed hardware configuration
• 0.2% accuracy
• 2 times/sec. sample rate
• No digital input available
• Basic SP Programmer
• Bargraph available
• ASCII Comm
• Not rated
• CE & UL

DC1020

Controller Differences

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It is a single loop controller with :

• 0.25% accuracy
• up to 2 analog inputs
• 1 universal input + 1 high level input
• up to 2 analog outputs
• up to 4 digital outputs
• up to 2 digital inputs

Available as an FM Approved High/Low Limit controller plus additional features ...

• Nema 4X/IP66
• front panel IR communication port
• Ethernet communication

UDC2500 Controller

1/4 DIN (96x96 mm)

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It is a single loop controller with :

• 0.2% accuracy
• up to 2 analog inputs (universal)
• up to 2 analog outputs
• up to 4 digital outputs
• up to 2 digital inputs
• Nema 4X/IP66
• front panel IR communication port
• Ethernet communication
• enhanced display
• universal input/output model

UDC3200 Controller

1/4 DIN (96x96 mm)

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Use a UDC3200 when you need:

• two low level inputs (such as 2 T/C’s or RTD’s)
• position proportional control (with a feedback

slidewire)

• math functions
• weighted average
• multiplier/divider
• adder/subtracter
• input high/low select
• feedforward summer
• feedforward multiplier

Sometimes the application requires more power than a UDC2500 can handle...

UDC3200 vs. UDC2500

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Use a UDC3200 when you need:

• improved accuracy (0.2% vs. 0.25%)
• enhanced display (7 characters vs. 6)
• 3 local setpoints
• improved output resolution (14 bits vs. 12 bits

for 4 to 20 mA)

• 2 low level inputs for
• carbon control
• oxygen control
• dewpoint control

UDC3200 vs. UDC2500

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It is a dual loop controller with :

• up to 5 analog inputs
• 3 universal inputs
• or 2 univ + 2 high level inputs
• or 1 univ + 4 high level inputs
• up to 3 analog outputs
• up to 5 digital outputs
• up to 4 digital inputs
• Ethernet communications
• real time clock
• enhanced display

UDC3500 Controller

1/4 DIN (96x96 mm)

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Use a UDC3500 when you need:

• 4 local setpoints
• 5 logic gates
• 8 segment characterizer
• totalizer
• 4 sets of tuning constants
• real time clock (start/stop process)
• enhanced I/O
• 5 analog inputs
• 3 analog outputs
• 5 digital outputs
• 4 digital inputs

Sometimes the application requires more power than a UDC3200 can handle...

UDC3500 vs. UDC3200

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14-segment display Top: 7-characters Bottom: 8-characters Discrete Annunciators Active SP Indicator Lens Legends Lens Legends

UDC3200 and UDC3500 Display

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To ensure a NEMA 4/IP66 rating:

• use 4 screws
• use 4 mounting clips

Note: NEMA 3R (rain) rating without screws

UDC2500, UDC3200 and UDC3500 Controllers

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To remove the instrument from the case:

UDC2500, UDC3200 and UDC3500 Controllers

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Power Supply Auxiliary Output + Digital Input + RS-422/485 communications

• r Ethernet

MCU/Input PWA

Flexibility - boards can be easily changed

UDC2500, UDC3200 and UDC3500 Controllers

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Thermocouple health monitoring Jumper free configuration 1 page quick start guide

T/C inputs are monitored for deterioration:

• 4 Levels of Alarms

1) good 2) failing (TCW) 3) failure imminent (TCF) 4) failed (Burn-Out)

• Replace the T/C before it fails

Jumper free configuration:

• No need to open the case
• All set-up & configuration is done

from the keyboard or comm link Manuals on CD:

• Quick-Start guide included
• Paper copy of manual available

UDC2500, UDC3200 and UDC3500 Controllers

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The controllers can send email ! Email on Alarm

(Ref. App Note for details)

UDC2500, UDC3200 and UDC3500 Controllers

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Process Instrument Explorer (PIE)

• Runs on a desktop, laptop or pocket PC
• Non-intrusive I/R connection
• saves time
• maintains NEMA 4X integrity
• no need to go behind the panel
• Easy to use
• no need to specify speed or parity
• built-in security
• Runs on RS 485 Modbus port
• Runs over Ethernet
• Online or Offline configurations.
• Store multiple instrument configurations
• Transfer stored configurations to a PC
• Maintenance information can be reviewed
• ver the IR connection

Infrared PC & Pocket PC configuration

PC Tools

Configuration Software

UDC2500, UDC3200 and UDC3500 Controllers

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Configuration Software

Process Instrument Explorer (PIE)

Select

• Setup Comm
• Upload
• Configure off line
• Download
• Configure online
• Maintenance Data

Store as many Configurations as you need (give each file a name) Same menu you see on the UDC Controller (when you press the Function key) Current Value Click and change value Save new configuration Same menu you see on the UDC Controller (when you press the Set-up key) Range of allowable values

UDC2500, UDC3200 and UDC3500 Controllers

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Price Function

DCP300 DCP551/552 DCP50 DCP250

Controller Programmers

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Controller Programmers

DCP50

1/4 DIN (96x96 mm) 1/16 DIN (48x48 mm)

DCP250

1/4 DIN (96x96 mm)

DCP300

1/2 DIN (144x144 mm)

DCP551/552

• 4 program profiles
• 16 segments / profile
• single universal input
• 0.25% input accuracy
• 64 program profiles
• 256 shared segments
• 2 universal inputs
• 0.1% input accuracy
• data recording option
• 19 program profiles
• 30 segments / profile
• 2 universal inputs
• 0.1% input accuracy
• 99 program profiles
• 99 segments / profile
• 2 universal inputs
• 0.1% input accuracy

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DCP50 Controller Programmer

• Single universal input with ±0.25% accuracy
• Automatic tuning with pre-tune and self-tune
• 4 program profiles and 16 segments per profile
• Digital input for remotely selecting programs or

program run/hold enabling

• Large and vivid dual 4-digit LED display
• Up to 3 output types (relay, voltage/current, SSR driver, triac)
• Event alarm outputs (up to 2 relays or SSR outputs on outputs 2 and 3)
• Retransmission voltage/current output (output 3)
• RS485 Modbus networking interface
• Compact size saves panel space
• UL and CE Mark approvals

1/16 DIN (48x48 mm)

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• One or two control loops
• Universal inputs with ±0.1% accuracy
• 64 program profiles sharing 256 segments
• Data logging with real time clock
• LCD display supports text and graphics
• USB port for configuration and logged data access
• Remote setpoint input option
• Up to 9 outputs, 9 digital inputs
• 24V DC transmitter power option
• Ethernet (Modbus TCP) or RS485 (Modbus RTU) networking interface
• UL and CE Mark approvals

1/4 DIN (96x96 mm)

DCP250 Controller Programmer

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Timer

• r

Delay Start Trigger Starting Setpoint Ramp (Time/Rate) Target Setpoint Dwell Continue Trigger Hold Segment (pre-programmed Hold) 1 2 3 4 5 6 7 X 15 Loop Segment Loop Back Target Segment 8 9 1 2 3 10 Join Segment Profile 1 to Profile 9

Profile 1 Profile 9

Step Segment 5 4 6 Dwell End Ramp (Time/Rate)

• 255 Segment 64 Profiles
• Profiles can be joined
• Cycle Profiles 1 to 9999 times
• Loop segments 1 to 9999 times
• Can use more than 1 loop segment
• Runs single profile at a time
• Supports Guaranteed Soak/Ramps
• Can manually Hold profile
• Power/signal lost recovery actions
• Set Profile End action

Profiles and Segments

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A single product that provides a powerful level of functions for managing an industrial control process resulting in:

• fewer components for managing the process
• reduced wiring
• reduced panel space
• easy and familiar access to User operations
• Advanced Process Control
• 2 Control Loops
• Set Point Profiling
• Data Logging
• Real-Time Clock
• High Visibility Alarms

A cost effective controller programmer solution !

DCP250 Controller Programmer

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DCP300 Controller Programmer

1/4 DIN (96x96 mm)

• One or two control loops with universal inputs
• Input 1 accuracy ±0.1%, input 2 accuracy ±0.2%
• Relative humidity control model
• 19 program profiles and 30 segments per profile
• Up to 3 output types (relay, voltage, current)
• 3 event outputs (relay)
• 5 time event outputs (open-collector)
• Up to 12 external switch inputs
• Expansive display panel with vivid 7 segment LED displays,

profile display (orange segment LEDs) and status displays (24 round LEDs)

• CE Mark approvals

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DCP551 / DCP552 Controller Programmer

1/2 DIN (144x144 mm)

DCP551 DCP552

Channels 1 2 Programs/Profiles 99

(99 segments

per profile) 49 per channel (99 segments per profile) Memory Card

(programs storage)

No Yes

• 2 universal inputs with ± 0.1% accuracy
• 16 event outputs (open-collector)
• 16 external switch inputs
• Various vivid displays for PV, program, segment, messages, status
• RS485 or RS232-C networking
• CE Mark approvals

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Efficiency Reliability Safety

Dedicated, FM approved “High Limit” model safely shuts down the process on an over temperature condition Thermocouple Health Diagnostics determines if the T/C is in danger of failing allowing replacement before it fails Accutune III accurately tunes the process, increasing fuel efficiency, speeding-up and simplifying start-up and lowering cost.

“Controllers and Programmers from Honeywell – unmatched safety, efficiency and reliability for industrial applications”

Improving Business Performance