HONEYWELL TC-PRS021 Control Processor Module

I. Overview

• It supports 2 independent process control loops, and each loop can be flexibly configured into PID control, proportional control, or manual control mode. With a control accuracy of ±0.1% F.S., it can quickly respond to fluctuations in process parameters.

• It is compatible with all types of I/O modules in the HONEYWELL TDC 3000 series (such as the TC-ODK161 digital output module and TC-RTD081 analog input module), enabling seamless integration into existing control systems without complex adaptation.

• Meanwhile, it is designed with wide temperature adaptability (-20℃~+70℃), electromagnetic interference resistance, and oil/dust prevention, allowing continuous and stable operation in harsh industrial environments such as power, chemical, and petroleum industries.

II. Technical Specifications

(I) Core Control and Loop Parameters

(II) Electrical and Power Parameters

• Power Supply Requirements: Operating voltage is 24V DC (with a wide adaptation range of 20.4V DC~28.8V DC), powered by the backplane of the TDC 3000 system rack; operating current ≤250mA (without load output), full-load current ≤400mA (when 2 loops output control signals simultaneously); power consumption ≤9.6W (powered by 24V DC under full-load conditions); supports reverse power connection protection (no damage under reverse voltage ≤36V DC); built-in overcurrent protection (current limiting triggered when current exceeds 500mA).

• Electrical Isolation: Photoelectric isolation between control loops and power circuits (isolation voltage ≥2500Vrms for 1 minute); isolation between input signals and output signals (isolation voltage ≥1500Vrms for 1 minute), which prevents ground loop interference and signal crosstalk and protects the module's core control circuits.

• EMC Compatibility: Complies with the EN 61000-6-2 industrial immunity standard; Electrostatic Discharge (ESD) protection level of ±15kV (air discharge)/±8kV (contact discharge); RF radiation immunity level of 10V/m (80MHz~1GHz); Electrical Fast Transient (EFT) burst immunity level of 2kV (power terminal)/1kV (signal terminal); surge immunity level of 4kV (power terminal)/2kV (signal terminal), ensuring stable operation of control logic in complex electromagnetic environments.

(III) Physical and Installation Parameters

• Physical Dimensions: Adopts the standard rack-mounted design of the TDC 3000 series, with dimensions (length × width × height) of 160mm×80mm×140mm. It is compatible with TDC 3000 standard racks (e.g., TC-RACK01) and can be installed side by side with I/O modules and communication modules. One rack slot supports one module, ensuring high space utilization.

• Installation Method: Supports DIN rail mounting (compatible with DIN 35mm standard rails) or screw fixing. The installation torque ≤2N・m to avoid damaging the module housing due to over-tightening; the module weight ≤550g, featuring a lightweight design for easy installation and maintenance.

• Indicator Light Configuration: The panel is equipped with 8 LED indicators (power status, 2 loop operation statuses, 2 loop alarm statuses, 2 loop manual/auto statuses, fault status). The operating status of the module is intuitively displayed through the color and flashing mode of the lights (e.g., "steady red light of Loop 1 alarm indicator" indicates control deviation over-limit), facilitating quick troubleshooting.

(IV) Environmental and Reliability Parameters

• Operating Environment: Operating temperature range of -20℃~+70℃, supporting low-temperature startup (no preheating required at -20℃, startup time ≤30s); storage temperature range of -40℃~+85℃; humidity range of 5%~95% (non-condensing, complying with IEC 60068-2-3 standard); altitude ≤2000m (derating is required when exceeding this altitude, with the control cycle increasing by 10% for every 1000m increase in altitude).

• Vibration and Impact Resistance: Vibration resistance level of 5g (10Hz~500Hz, complying with IEC 60068-2-6); shock resistance level of 20g (11ms pulse, complying with IEC 60068-2-27), adapting to the vibration environment of equipment such as chemical reactors and power plant boilers (no attenuation of control accuracy when vibration frequency is 20Hz~300Hz).

• Reliability Indicators: Mean Time Between Failures (MTBF) ≥150,000 hours (per Telcordia SR-332 standard at 25℃); design life ≥10 years; the retention life of control algorithm parameters ≥100,000 hours (maintained by a built-in battery after power failure), ensuring no loss of parameters during long-term operation.

III. Functional Features

(I) Dual-Loop Precise Control to Adapt to Complex Process Requirements

• Independent Operation of Dual Loops: The 2 control loops can be connected to different process parameters respectively to meet multi-variable control needs. For example, in a chemical reactor control system, Loop 1 controls the reaction temperature (PV is a temperature signal of 4-20mA, SV set to 80℃) using the PID control algorithm, and stabilizes the temperature by adjusting the opening of the heating valve (MV output of 4-20mA); Loop 2 controls the reaction pressure (PV is a pressure signal of 4-20mA, SV set to 0.8MPa) using the proportional control algorithm, and stabilizes the pressure by adjusting the opening of the exhaust valve. The two loops operate independently with no mutual interference in data, achieving a temperature control error ≤±0.1℃ and a pressure control error ≤±0.005MPa.

• 
  

• PID Algorithm Optimization: Built-in integral separation and anti-integral windup functions to avoid overshoot and control lag. For example, in the feedwater control of a power plant boiler, when the water level deviation is large (e.g., dropping from 50% to 30%), the integral separation function automatically turns off the integral term, and only uses the proportional and derivative terms to quickly adjust the speed of the feedwater pump, preventing the water level from overshooting to 70%; when the water level is close to the setpoint (e.g., 48%~52%), the integral term is re-enabled to achieve non-static error control. The anti-integral windup function can prevent integral accumulation caused by long-term deviations, avoiding the valve from being fully open or fully closed and extending the service life of the equipment.

• 
  

• Flexible Control Mode Switching: Supports one-click switching between auto and manual modes to meet operation and maintenance needs. For example, during the maintenance of petroleum refining units, operators can switch the loop from auto mode to manual mode through the HMI and manually output control signals (e.g., fixing the valve opening at 50%). After maintenance is completed, switching back to auto mode is smooth with no impact (control signal fluctuation ≤±0.5%) and stable process parameters.

(II) Strong System Compatibility and Data Interaction to Simplify Integration Process

• Compatibility with Full-Series I/O Modules: Directly connects to TDC 3000 series I/O modules without additional adaptation. For example, the module communicates with the TC-RTD081 analog input module (collecting temperature RTD signals) and TC-ODK161 digital output module (outputting alarm signals) through the backplane bus, automatically identifying the module model and signal type without manual driver configuration. Only by setting "Loop 1 PV source = TC-RTD081 Channel 1" and "Loop 1 MV output to TC-ODK161 Channel 2" through the HMI, configuration can be completed within 10 minutes, increasing integration efficiency by 80%.

• 
  

• Real-Time Data Interaction: Achieves high-speed data synchronization with the system upper computer, supporting remote monitoring and parameter modification. For example, in the temperature control of petroleum storage tanks, operators can real-time view data such as "Loop 1 temperature PV=25℃", "SV=25℃", and "MV=12mA" through the central control room HMI, and remotely modify the SV value (e.g., adjusting from 25℃ to 28℃). The modified parameters are synchronized to the module within 100ms, and the control signal is adjusted accordingly without on-site operation.

• 
  

• Historical Data Storage: Built-in data storage function to record the change trend of key parameters. For example, the module can store PV, SV, and MV data of the past 72 hours (sampling cycle of 1s). Operation and maintenance personnel can view historical curves through the HMI to analyze the causes of process parameter fluctuations (e.g., whether temperature fluctuations during a certain period are caused by changes in raw material batches), providing data support for process optimization.