temperature controllers - honeywelludc controller closer look it is a single loop controller with :...

Selection ProcessTEMPERATURE CONTROLLERSAbhijeet Joshi

June 19, 2017

Honeywell Internal

© 2017 by Honeywell International Inc. All rights reserved.

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Selection Process


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Honeywell Controllers and Programmers


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• Automatic control of a thermal or process application

• Support single setpoint changes to providing sophisticated profilers (multiple setpoint

changes over a defined time period)

• Accepts an input from any type of sensor (thermocouple, RTD, transducer, voltage, current)

• Inputs easily scaled to desired operating and display range

• Single or dual loop control

• Adjusts the heating power, pressure or flow rate to the process via output relays, linear

voltage or current outputs, solid state switches, logic outputs

• Front of panel product with an integral display

• Ability for machine operator to set-up the controller using the display for setpoint

or program changes


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What is “Process Control” ?

• Measurement of a variable

• Comparison to a desired value

• Cause a change in the process to adjust the variable

to the desired value


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Functional Example

Alarm Relay Output

ControlValve

Exhaust

RecirculatingFan

Fuel In

T/C

Flame

SafetyControl

Control Relay Output

Digital Input

Work

Chamber PV

High Alarm

Input

Alarm

Acknowledge


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Honeywell Product Value

• Precise control

• Clear and informative operator interfaces

• Easy to set-up and operate

• Single-button tuning

• Fuzzy logic overshoot suppression

• Product quality and reliability

• PC Software tool


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Needs and Product Selection

What are you wanting to do - the application . . .

What is the needed accuracy?

What is the control output driving?

Where is the Set Point coming from (local or remote)?

Will the controller be networked to a SCADA or PLC?

Any local data history/viewing needs?

Need for outputs to drive alarms, other switches?

Need for digital inputs to change set points, tuning parameters, A/M mode?

Need for ramp/soak profiles or timers?

Need a limit controller?

What is the available budget?


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Controller Selection

PANEL SIZE INPUTS ACCURACYREMOTE

SETPOINT

INPUT

OUTPUTS NETWORKING


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Size:

1/32 DIN

(49 x 25 mm)

Size:

1/16 DIN

(48 x 48 mm)

Product Inputs Accuracy RSP

Input

Control

Outputs

Alarm

Outputs

Networking

DC1000

(DC101)

1

(T/C,

RTD,

linear)

0.2% 1

2

Relay (3A),

SSR Driver,

Linear

2(qty.1 if 2 control

outputs used)

Relay (3A)

RS-232 or 485

Modbus RTU

or ASCII

UDC1200

1

(T/C,

RTD,

linear)

0.1% 0

3

Relay (2A),

SSR Driver,

Linear

2(substitute for

control out puts

#2 & #3)

Relay (3A),

SSR Driver

RS- 485

ASCII or

Modbus RTU

EDC201

1

(T/C,

RTD)

0.5% 0

1

Relay (5A),

SSR Driver

1

Relay (3A) None


Input

Control

Outputs

Alarm

Outputs

Networking

UDC700

1

(T/C,

RTD,

linear)

0.1% 0

1

Relay (2A),

SSR Driver

2

Relay (2A),

SSR Driver

RS-485

Modbus


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Size:

1/8 DIN

(48 x 96 mm)


Input

Control

Outputs

Alarm

Outputs

Networking

DC1000

(DC102)

1

(T/C,

RTD,

linear)

0.2% 1

2

Relay (3A),

SSR Driver,

Linear

3(qty.1 if 2 control

outputs used)

Relay (3A)

RS-232 or 485

Modbus RTU

or ASCII

UDC1700

1

(T/C,

RTD,

linear)

0.1% 1

3

Relay (2A),

SSR Driver,

Linear

2(substitute for

control out puts

#2 & #3)

Relay (3A),

SSR Driver

RS- 485

ASCII or

Modbus RTU

EDC202

1

(T/C,

RTD)

0.5% 0

1

Relay (5A),

SSR Driver

2

Relay (3A) None


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Size:

1/4 DIN

(96 x 96 mm)


Input

Control

Outputs

Alarm

Outputs

Networking

DC1000

(DC104)

1

(T/C,

RTD,

linear)

0.2% 1

2

Relay (2A),

SSR Driver,

Linear

3

Relay (3A),

SSR Driver

RS-232 or 485,

Modbus RTU

or ASCII

UDC2500

1

(T/C,

RTD,

linear)

0.25% 1

2

Relay (5A),

SS Relay,

Open Collector,

Linear

2

Relay (5A),

SSRelay

RS- 485,

Modbus RTU,

Ethernet TCP/IP

DC3200

2

(T/C,

RTD,

linear)

0.2% 1

2

Relay (5A),

SS Relay,

OC, Linear

3

Relay (5A),

SSRelay

RS- 485,

Modbus RTU,

Ethernet TCP/IP

UDC3500

5

(T/C,

RTD,

linear)

0.1% 0

3

Relay (5A),

SS Relay,

OC, Linear

4

Relay (5A),

SSRelay

RS- 485,

Modbus RTU,

Ethernet TCP/IP

EDC203

1

(T/C,

RTD)

0.5% 0

1

Relay (5A),

SSR Driver

2

Relay (3A)None


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Additionally, check the specification for product . . .

1. Digital Inputs

2. Digital Outputs

3. Transmitter Outputs (Aux Out)

4. Transmitter Power

5. Timers

6. Internal Algorithms and Math computations

7. Set Point Programming

8. Indicator only versions (i.e. DC703, UDI1700, UDC2500)

9. Limit controller versions

10. Self-tuning capabilities

11. Display capabilities

12. Approvals

13. Environmental protection (NEMA/IP ratings)


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EDC200 Controller Closer Look

96 x 96 mm

1/4 DIN

48 x 96 mm

1/8 DIN

48 x 48 mm

1/16 DIN


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• Single Analog input supports thermocouples or RTD

• Single Digital input (Sense voltages: ON–13 VDC, OFF–5VDC)

• Single Control output supporting relay (5 Amp) or SSR (24 VDC) driver

• Single Alarm relay (5 Amp) output for EDC201, two Alarm relays for EDC202

and EDC203

• Accutune auto tuning and three control modes (ON-OFF, PID, Motor Control)

ON/OFF Control ActionAuto Tuning Action


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Input Burnout and

Control Output Failsafe

SSR

Sensor

Break

Input Burnout Configuration on Input Failure

UP - input to full scale value

DOWN - input to lower range value

Failsafe - configured failsafe output value

applied on input failure

NoFailsafe - configured failsafe output

value not applied, input at last

valid value

Thermocouple Failure Warning

Alarm Output for TC Warning or Failure

TC Warning - diagnostic that the thermocouple is

starting to burnout or resistance of

wires connecting TC to the controller

is above 100 ohms

TC Failure - diagnostic that the thermocouple will

soon fail or resistance of wires

connecting TC to the controller is

above 180 ohms

Thermocouple

Temperature Input

TC Connecting

Head

TC Extension

Wire

TC Reference

Junction

Alarm Relay Output


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DC1000 Controller Closer Look

• Autotune (PID & Fuzzy)

• Large range of inputs, outputs, algorithms

DC 1010

DC 1020

DC 1040

DC 1030

• 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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DC1000 Controller Closer Look

• 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:

Programmers:

• programs / 8 segments each


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UDC Controller Closer Look

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

1/4 DIN (96x96 mm)

UDC2500


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UDC3200

It is a single loop controller with :

0.2% accuracy

up to 2 analog inputs (universal)




Nema 4X/IP66

front panel IR communication port

Ethernet communication

enhanced display

universal input/output model

1/4 DIN (96x96 mm)


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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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UDC3500

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




Ethernet communications

real time clock

enhanced display

1/4 DIN (96x96 mm)


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Controller Programmer Selection

PANEL SIZE INPUTS PROGRAMS

SEGMENTS

OUTPUTSDIGITAL

INPUTS


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Controller Programmer Selection

Product Panel SizeAnalog

Inputs

Programs

SegmentsOutputs

Digital

Inputs

DCP50 1/16 DIN

1

0.25%

accuracy

4 programs, 16

segments each 3 1

DCP250 ¼ DIN

2

0.1% accuracy

256 segments

for 64 profiles 9 9

DCP300 ¼ DIN

2

0.1% and

0.2% accuracy

19 programs,

30 segments

each

5 12

DCP551 ½ DIN(144x144 mm)

2

0.1% accuracy

99 programs,

99 segments

each

16 16

DCP552 ½ DIN(144x144 mm)

2

0.1% accuracy

2 channels with

49 programs per

channel,

99 segments

each

16 16


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Controller Programmer Closer Look

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


• 256 shared segments

• 2 universal inputs


• data recording option










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DCP50 Programmer Closer Look

• 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)


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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

23 4

56

7

X 15Loop

Segment

Loop Back

Target

Segment

8

9

1

23

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


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EfficiencyReliabilitySafety

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, reliability and efficiency for industrial applications.

temperature controllers - honeywelludc controller closer look it is a single loop controller with :...

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