Calling all experts in AB and EPKS! Our Experion PKS DCS system, running on aging C200 hardware, is in need of an upgrade. Spare processors are available, but obtaining more from Honeywell is not an option. Time is of the essence to modernize our system. While Honeywell manages one process section in our large plant, the rest is predominantly AB, with PLC-5 IO still present in the Experion PKS system. Considering that the C200 hardware is essentially controllogix, it would be ideal to switch to rockwell hardware. However, the cost of converting a specialty batch program from a Honeywell ACE controller to AB Structured Text is a concern. Is the Honeywell Controledge UOC controller the solution we need? It appears to support EPKS and AB DLR rings and I/O, enabling us to utilize controllogix I/O while retaining our current controls and HMI. Any insights on the UOC controllers compared to the C200 and C300 models would be greatly valued. Thank you for your assistance.
It is a known fact that Honeywell UOC controller, HC900 Controller, and ControlEdge PLC all utilize the same rack, power supply, and I/O cards designed and produced by Honeywell. Despite my 15 years of experience with the Honeywell HC900, I have never come across information suggesting that the Honeywell Rack and I/O are interchangeable with ControlLogix I/O. It is possible that the Honeywell C200 was specifically designed to be compatible with CLX hardware. Honeywell Systems, the DCS division of Honeywell, allows distribution to sell the UOC and PLC but maintains a distance in terms of support. As a retiree, I have heard about the UOC being positioned to replace the C200, but I have not come across a comprehensive explanation of the framework for this transition. It seems that the DCS Systems group is leveraging distribution channels to generate leads for potential sales and service takeovers. If you are unable to go through one of the two distributors with internal expertise on Experion LS/UOC group (such as Loy in Indiana or the California distributor), you may need to engage directly with Honeywell's Systems team for assistance. It appears that they may steer the conversation towards staying within the Honeywell PKS world (C300) based on the information they provide about the capabilities of the UOC.
The University of Cincinnati should cater to your specific needs when it comes to upgrading your control systems. A few years back, we upgraded from a C200 to a C300 controller, maintaining the C200 (also known as series A I/O by Honeywell). Since the C300 controller was in place, we opted for the Honeywell FTEB card instead of DLR, as it wasn't compatible with the C300. The migration process was seamless, requiring no changes to the software. While we have the flexibility to switch to Rockwell cards for I/O if necessary, we have not encountered the need to do so yet. Honeywell provides a list of Rockwell cards that are compatible with their systems. Although the physical cards may appear identical, earlier versions of Honeywell's Rockwell cards had distinct firmware. In most cases, it is more cost-effective to pay for a migration rather than converting software, especially when transitioning between different vendors' systems.
The Honeywell C200 series is fully compatible with ControlLogix, sharing the same hardware components. We have successfully utilized AB DHRIO cards in our C200 racks, demonstrating seamless integration. If you are considering an upgrade path for your Honeywell C200 system, helpful articles like the one found on https://theautomationblog.com/honeywell-c200-upgrade-paths/ and diagrams from official Honeywell documentation can provide valuable insights. However, it seems that only the Experion LS (LX?) distributors may offer significant support for the UOC, while the DCS team may view it primarily as a marketing tool. Have you encountered any challenges in converting processors to C300, Remrun? It may be a viable option, although concerns about the longevity of FTEB card support for Series A I/O cards should be taken into account.
When looking at potential migration plans, Honeywell UOC offers swing arm conversion options that are cost-effective and space-efficient compared to Series C I/O. Despite its advantages, there have been some challenges with setting up the I/O modules in UOC that can cause complications if not configured correctly. It seems that there are still some kinks to work out with UOC, particularly in managing processor loads and communication issues between standalone PLCs. Despite these obstacles, UOC remains our preferred choice for future migrations.
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Answer: - The upgrade options for the Experion PKS DCS system running on aging C200 hardware include considering the Honeywell Controledge UOC controller, which supports EPKS and AB DLR rings and I/O, enabling the utilization of controllogix I/O while retaining current controls and HMI.
Answer: - Yes, converting a specialty batch program from a Honeywell ACE controller to AB Structured Text can be costly, which is a concern for upgrading the Experion PKS DCS system.
Answer: - Insights on how the Honeywell Controledge UOC controllers compare to the C200 and C300 models would be greatly valued in terms of upgrading the Experion PKS DCS system.
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