Post on 13-Jun-2020
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
or 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
over 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 or
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