Process Instruments Controllers and Programmers Controllers and - PowerPoint PPT Presentation

Process Instruments Controllers and Programmers

Controllers and Programmers 2

Sampling of Served Industries 3

End User Products Thermal Processing Equipment Requiring Controls and Instrumentation Batch Furnace Batch Oven Box Furnace Asphalt Drum Mixer Incinerator Burner Controls 4

Thermal Processing Facility 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 5

Food and Beverage 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 6

Controllers and Programmers 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. 7

Accuracy, Efficiency and Compliance 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 8

Application Example Problem – Must maintain uniform temperature for compliance Recorder Temperature Controllers Solution - Use controllers to establish Actuator 3 zones of control Furnace Zone 1 Zone 2 Zone 3 - Control both temperature and Pressure fuel/air ratio in each zone TC TC TC - UDC controllers meet AMS2750 requirements (accuracy, security, passwords) Zone 1 Zone 2 Zone 3 - Alarms, email Alarm to alert Burner Burner Burner personnel of abnormal conditions - T/C Health monitoring - Accutune III automatically and Actuator Fuel continuously retunes the process Combustion Air Benefit – creating zones and linking the controllers together ensures uniform temperature and compliance 9

Controllers UDC3500 Price UDC3200 UDC2500 UDC1700/1200 UDC700 DC1000 Function 10

Controller Product Portfolio • 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 11

Controller Value • Clear and informative operator interface • Easy to set up and operate • Single-button tuning for precise control • Fuzzy logic overshoot suppression • PC Software Tools 12

UDC700 Controller and Indicator Compact Size High Degree of Functionality Low Price 1/32 DIN (49x25 mm) 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) 13

UDC1000 Controllers DC1010 48x48mm DC1030 1/16 th DIN 72x72mm DC1020 DC1040 3/16 th DIN 48x96mm 96x96mm 1/8 th DIN 1/4 DIN 14

UDC1000 Controllers • Large range of inputs, outputs, algorithms • Accuracy:  0.2% • Large range of input types: DC 1040 - 13 ranges of thermocouples - 3 ranges of RTDs - linear inputs DC 1030 • Remote Setpoint input • Autotune (PID & Fuzzy) • Two 4 digit, 7 segment LED displays • Bar-graph to display % output (N/A on 1010 model) DC 1020 • RS232/485 Modbus RTU or ASCII network • Retransmission output DC 1010 15

UDC1000 Controllers Large range of output types: • Relay (3 Amp) • SSR DC 1040 • Current (4-20mA) • Volts (0~5V, 0~10V, 1~5V, 2~10V) • Motor Control (TPSC) DC 1030 Large selection of algorithms: • ON/OFF & PID • Heat/Cool with dual PID sets • TPSC algorithm (N/A on 1010 model) DC 1020 Programmers: • programs / 8 segments each DC 1010 16

UDC1000 Controllers 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 17

UDC1200 and UDC1700 Controllers 1/16 DIN 1/8 DIN 18

UDC1200 and UDC1700 Controllers  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 19

UDC1200 and UDC1700 Controllers  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 2 nd input for remote setpoint  Setpoint ramp function  Limit controller with FM approval for UDC1200 20

UDC1200 and UDC1700 Controllers Option Boards - easy upgrade, jumper free Slot 1 modules : Slot 2&3 • Relay • Triac • 10V DC SSR Driver • Linear (mA/V DC) Slot 2&3 module : • Relay • 10V DC SSR Driver • Triac (Slot 2 only) • Linear (mA/V DC) • Dual Relay (Slot 2 only) Slot 1 • 24V Transmitter PSU (Slot 3 only) Slot A 21 Slot A : • RS485 Communications • Digital Input 21

Controller Differences UDC1200 DC1010 • Flexibility • Fixed hardware configuration • 0.1% accuracy • 0.2% Accuracy • 4 times/sec. sample rate • 2 times/sec. sample rate • TPSC • No TPSC • Digital input available • No digital input available • Limit model • No limit model • Not a SP Programmer • Basic SP Programmer • Modbus & ASCII Comm • ASCII Comm • Nema 3/IP64 protection • Not rated • CE, UL & FM • CE & UL 22

Controller Differences UDC1700 DC1020 • Flexibility • Fixed hardware configuration • 0.25% Accuracy • 0.2% accuracy • 4 times/sec. sample rate • 2 times/sec. sample rate • Digital input available • No digital input available • Not a SP Programmer • Basic SP Programmer • No bargraph available • Bargraph available • Modbus & ASCII Comm • ASCII Comm • Nema 3/IP64 protection • Not rated • CE, UL & FM • CE & UL 23

UDC2500 Controller Available as an FM Approved High/Low Limit controller plus additional features ... 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 1/4 DIN (96x96 mm)  up to 2 digital inputs  Nema 4X/IP66  front panel IR communication port  Ethernet communication 24

UDC3200 Controller 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 1/4 DIN (96x96 mm)  universal input/output model 25

UDC3200 vs. UDC2500 Sometimes the application requires more power than a UDC2500 can handle... 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 26