Honeywell TDC3000X APM Advanced Process Manager

Honeywell TDC3000X APM Advanced Process Manager

Overall Introduction

Positioning: APM is a high-performance on-site controller for TDC3000X UCN network, with a memory increase of 4 times compared to the old PM; Add SOE event sequence records, device control points, array points, string/time variables, and external serial device interfaces.

network architecture

UCN universal control network: 5Mbps token bus, redundant coaxial cable, up to 32 redundant devices; APM, PM, and Logic Manager communicate peer-to-peer on UCN.

NIM network interface module: serves as a gateway between the LCN local control network and UCN; Complete protocol conversion, time synchronization, upload alarms to LCN, download database to APM, NIM can be redundant.

APM works together through UCN, Universal Station operation station, and Application Module application module.

APM internal multiprocessor parallel architecture

APMM Advanced Process Manager Module: Includes three independent processors

I/O subsystem: redundant I/O Link links; Up to 40 I/O processors IOP; IOP independently completes engineering unit conversion and alarm detection without occupying APMM control processor resources.

IOP connects FTA on-site terminal components; Support fiber optic remote I/O expansion.

Advanced communication processor: UCN network, peer-to-peer communication, high-precision timestamp;

Advanced I/O Link Interface Processor: connects I/O subsystems;

Advanced control processor: executes tuning, logic, sequence, CL/APM control language programs.

Control functions and various control points

APM allocates resources through "Slot slots (Point points)", with each point assigned a label name. The operation station provides standard details and group screens. The processing capacity unit is PU processing unit, with a maximum speed of 160 PU/second for the whole machine, supporting different execution cycles of 1/4s, 1/2s, and 1s.

Control point type

Regulatory PV (process variable point) completes PV calculation compensation; Built in traffic compensation, total accumulation, variable lag lead, high-low selection, linearization, calculator algorithm; Support PV high low, high high/low low, rate of change alarm, and signal filtering.

Regulatory Control includes algorithms such as PID, feedforward PID, external integral feedback, position ratio, ratio control, slope insulation Ramp Soak, and override selector; Support manual/automatic/cascade mode, anti integral saturation, set value ramp, and fault mode degradation.

Digital Composite is used for discrete devices such as motors and valves; Built in permissible conditions and override interlock; Up to 2 inputs and 3 outputs; Automatically generate interlocking traceability alarms (abnormal, inconsistent instructions, unexpected action alarms).

Logic points are equivalent to relay ladder logic on pages 1-2; AND/OR/NOT/delay, pulse, watchdog, comparison operation; Supports three optional configurations for input and output quantity.

Device Control integrates logic and digital composite functions for device control points, managing motors and regulating valves with a single label; Integrated simulation feedback facilitates fault tracing and reduces configuration workload.

Process Module (CL/APM) runs Honeywell CL/APM control language and is designed for batch process Phase Step architecture; Can handle abnormal Hold, shutdown, and emergency shutdown; A single APM can execute approximately 10000-20000 statements; Read and write all APM databases, supporting strings and time variables; The program can be modified online without interfering with the operation of the regulating circuit.

Array point storage formula and intermediate calculation variables; Can store Boolean, numerical, time, and string data; Used for CL programs and serial interface data caching.

Flag flag, Numerical value, Timer timer, String string, Time global variable library for logic and CL program calls.

Performance limit (single APM)

160 Regulatory Control circuits

80 Regulatory PVs

80 Logic Points

512 Digital Composite

160 Device Controls

80-160 Process Module CL programs (depending on program size)

I/O subsystem (IOP+FTA)

IOP is the processing board, FTA is the on-site terminal assembly unit; The two are connected by a cable, with a maximum length of 50 meters; FTA provides fuses, surge protection, and isolation; The same IOP can be paired with different FTAs to adapt to different on-site voltage levels. The maximum number of IOP for the whole machine is 40; HLAI high-level analog input, STI intelligent transmitter interface, AO analog output support one-to-one redundancy, while other IOPs do not support hardware redundancy.

IOP Processor Inventory

IOP model, channel number, purpose

MU-PAIH03 HLAI high-level analog input 16 4-20mA, 1-5V and other standard analog signals

MU-PAIL02 LLAI low-level analog input with 8 thermocouples and RTD resistors, isolated

MU-PLAM02 LLAI multiplex low-level input 32 channels TC/RTD, high point acquisition

MU-PSTX03 STI intelligent transmitter interface 16 Honeywell DE protocol ST3000 intelligent multivariable transmitter

MU-PAOX03 AO analog output 8 4-20mA output, supports redundancy

MU-PDIX02 DI digital input 32 switch input, 24Vdc/120Vac/240Vac

MU-PDISI11 DISOE event sequence DI 32 SOE event sequence, timestamp resolution 1ms

MU-PDOX02 DO Digital Output 16 Solid State, Relay Output Multiple FTA Options

MU-PRIX02 PI pulse input 8-pulse flowmeter, up to 20kHz

MU-PSDX02 SDI serial device interface with a maximum of 16 points per IOP. Specialized devices include Toledo weighing and UDC6000 regulator

MU-PISM11 SI Universal Serial Interface Up to 16 array points per IOP Modbus RTU, Allen Bradley DF1 protocol

Serial interface capability

SDI dedicated serial interface: Toledo weighing instrument, UDC6000 single loop regulator, manual automatic station MAS.

SI Universal Serial Interface

Modbus RTU（EIA‑232/485）；

Allen‑Bradley DF1（EIA‑232）；

Map third-party registers to APM internal array points, CL、 The control point directly uses third-party data for bidirectional reading and writing.

Simulation Options I/O Simulator

No need for real IOP/FTA, simulate all I/O on the computer; The database can be directly downloaded to real APM; Used for configuration debugging and operator training.

Alarm and safety redundancy features

Alarm system

AI: high, high high, low, low low, rate of change, deviation alarm; Support alarm dead zone;

DI/DO: Unexpected changes, inconsistent instructions, interlock alarms;

Level 5 alarm priority: Emergency, High, Low, Journal log, No Action, no action; Support Contact Cutout conditional suppression of alarms.

Multi level redundancy option (optional configuration, not mandatory full redundancy)

APMM controller redundancy: primary/backup APMM; Automatic fault switching; The typical switching time is 1.5 seconds, with a maximum of 3 seconds, and the database is synchronized in real-time.

I/O Link: Factory standard redundancy.

IOP one-to-one hardware redundancy: limited to HLAI, STI, AO only; Replacing the board does not interrupt control.

UCN network media redundancy.

Power redundancy: dual AC inputs, dual power modules.

Two types of power systems

Standard power supply system: built-in gel battery, power loss can maintain full load of the whole machine for ≥ 20 minutes; CMOS memory backup battery stores database for 50 hours; 20A DC output.

AC Only AC power supply: without built-in battery, relying on external UPS; 8A/16A version; Use alkaline batteries to store memory for 50 hours.

Standby Manual: AO/DO output FTA can be connected to an external manual operator to maintain on-site output when replacing the IOP board.

Remote I/O (fiber optic)

1km short distance I/O Link extender;

8km long-distance fiber optic extension;

Up to 6 remote I/O cabinets; Redundant fiber optic link, resistant to ground potential difference and EMI interference; Significantly saving on-site cables.

Intrinsic safety option: FTA with galvanic isolation, meeting FM Class I Div.2 and Zone0 intrinsic safety explosion-proof requirements.

Physics, Environment, Certification

Cabinet card box Card File: Up to 40 IOPs (single APMM) for a single cabinet; Redundant APMM with up to 35 IOPs; Up to 8 card boxes can be expanded.

environmental conditions

Operating temperature: 0-50 ℃; Storage -40~+80 ℃; Humidity 10-90% non condensing; Vibration and impact meet industrial standards.

Certification: FM, CSA universal occasions; FM certified Class I Div.2 hazardous area installation.

Hardware model

APMM controller: single-mode MU-AMS01, redundant MU-AMR01, PM upgrade APM kit;

All IOP processor card models;

FTA on-site terminal components (compression terminal/screw terminal two series, AI/AO/DI/DO/pulse/serial, intrinsic safety isolation FTA);

I/O-Link fiber optic extender MU-IOLM02 (local), MU-IOLX02 remote; Long distance MU-ILDX02;

Various types of connecting cables (FTA cable, UCN coaxial cable, serial shielded cable);

Complete material list for cabinets, fan components, power modules, backup manual units, and battery accessories.