Process Controllers

The 800lb Gorillas of Process Controllers

PCMs

The Most Points, Programs and Power

Each D/3® Process Control Module (PCM) has the horsepower to control over 25 unit operations, 2000 tags, 4500 I/O points, 100 simultaneous SABL programs, and 100 Active Batches easily making the D/3 PCMs the most powerful process controllers in the industry.

The D/3 PCM is a real-time, microprocessor-based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM provides autonomous control over a portion of the process plant after the PCM’s databases and programs are downloaded over the network. The PCM performs all continuous, sequential, and batch control functions and communicates with other D/3 nodes to support alarm, trending, and display functionality.

Features

Continuous Control

Database function blocks are defined and then chained through easy to use utilities to create loops. Graphically developed Master Devices simplify the development and maintenance of simple to complex device logic used for the control of valves, pumps, motors and other devices. For each instance of a device (i.e. a motor), the user  inputs only the items that are different, such as the I/O terminations. A change to the Master Device logic will change every device using that logic, providing an incredible engineering savings over ladder logic and other PLC configuration software.

Sequence and Batch Capability

The D/3 Sequence and Batch Language (SABL) is a very powerful and versatile structured text programming language specific to process control. It is used to develop sophisticated interlocks, batch sequencing, FlexBatch phases, and enhances the operator interface. The PCM 4200 can store hundreds of SABL programs in its memory.

Redundancy

Redundancy is automatic with the addition of the redundant hardware and license. A redundant PCM can be added to the rack mount chassis while the primary is online. All the same databases and control programs run in both PCMs, staying in lock step with each other over a dedicated high speed Ethernet connection between the redundant PCMs.

Chassis

PCM rack mount chassis fits in a standard 19-inch rack and can contain 2 independent PCMa or a redundant pair, each with 8-slot backplanes with room for up to 5 I/O communication cards. Each PCM is electrically isolated and protected and cooled by four separate fans. This allows one controller to be powered down and serviced while the other is powered up. In the unlikely event of a PCM failure, just slide out the card cage with the backplane and replace the failed component in minutes.

I/O Support

NovaTech 8000 Series I/O includes a full range of remote I/O modules with a -40oC to +70oC temperature range and ISA’s stringent G3 corrosion resistance. HART® information passes through the modules without additional field wiring and intrinsically safe modules are available for hazardous locations. In addition to the redundant Ethernet communication modules, NovaTech 8000 I/O is available in a 1 to 6 I/O module redundant configuration. D/3 also directly supports I/O families from Schneider and Siemens and a wide variety of I/O protocols including Modbus/TCP, EtherNet/IP, Foundation Fieldbus, and DF-1.

Intelligent Utility Assembly

The PCM Intelligent Utility Assembly monitors the health of the PCM and switches control to the backup PCM in case of a failure. In a redundant configuration, if a failure were to occur on one Utility Assembly, a bumpless transfer would occur resulting in the backup PCM taking control. The failed PCM can then be slid out and components replaced while the backup PCM is online. The Intelligent Utility Assembly uses a powerful micro controller, ensuring reliability while executing more sophisticated watchdog and failover logic.

Micro Select Assembly

The Micro Select Assembly in the PCM chassis contains minimal hardware components — a selector switch and associated LEDs used to indicate the position of the selector switch and the selected PCM. The assembly is used to manually switch control from one PCM to the other or provide automatic failover in the unlikely event of a PCM failure. If the Micro Select Switch should fail, control is maintained with the selected PCM and the assembly can be replaced with both PCMs operational.

Ethernet

Peer to peer communications between PCMs and Display Control Modules (DCMs) utilizes two 10Base-T/100Base-TX Ethernet ports on the main CPU board, providing redundant communication with all D/3 nodes. A third Ethernet port is available on a daughter board for a 100 Mbit/s communication link (R-link) connecting redundant PCM controllers.

Power Supplies

Each PCM contains up to two 300W hot-swap redundant AC power supply modules for each PCM. Two power supplies provide load sharing and redundancy, a MTBF of 100,000 hours, over voltage and thermal protection. Optional 48 VDC and uninterruptible power supplies (UPS) also available.

PCM4100

PCM 4100 Process Controller

  • Provides distributed automation and control capabilities for continuous and batch process plant operations
  • Connect to over 10,000 I/O points from multiple vendors
  • Redundant Ethernet communications
  • 250ms scan rate
  • Autonomously perform all continuous, sequential and batch control functions
  • Available in 250, 500, 1000, 1500, and max tag license configurations
  • Up to three I/O communication cards
  • Facilitates online upgrades
  • 19″ rack mount chassis holds two slide-out PCM 4100s in either redundant or separate PCM configurations

PCM4200

PCM 4200 Process Controller

Same features as PCM 4100 plus:
  • MTBF of 100,000 hours
  • Two hot-swappable AC power supplies per PCM for load sharing and redundancy
  • Over voltage and thermal protection
  • Up to five I/O communications cards per PCM
  • PCM5 — D/3 Process Control Module 5 Series  

    The NovaTech D/3® Process Control Module 5 Series (PCM5) represents a leap forward in the development, virtualization, and Cyber Security capabilities of the D/3 PCM family. The upcoming PCM5™ will deliver even higher levels of agility and performance to the DCS with the longest life cycle support and lowest total cost-of-ownership in the industry: the D/3.

    June 7, 2016

  • D/3® PCM 4100 Datasheet  

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations…

    August 27, 2014

  • D/3® PCM 4200 Process Control Module Datasheet  

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    August 15, 2014

  • D/3® PCM 4200 Process Control Module Datasheet: A4  

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    December 10, 2010

  • PCM 4200 过程控制站 (Chinese)  

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    April 1, 2008

  • Additional Datasheets, Application Notes, Customer Success Stories and other documents in our documentation library

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