piccolo - InstruCon

imagine making theimpossible possible

piccolo™Controllers

www.eurotherm.com/piccolo

Easy to commission easy to use… You have always been able to rely on the precision and accuracy of Invensys Eurothermtemperature and process controllers, but imagine process excellence made easy; a costeffective controller that works with you to help optimise yields and reduce energy usagewithout complication. Add to this, an absolute commitment to technological innovation,constant reinvestment in research and development, and a team of dedicated expertswho understand your problems and processes; we can and do imagine making theimpossible possible for our customers.

Designed around the needs of the 21st Century working environment to create a reliableand easy to apply unit, the piccolo™ controller works with you to help you achieve yourday to day objectives for yield and cost. Wherever in the world you or your process islocated, you can profit from the vast experience Invensys Eurotherm has gained overmore than 45 years as a world leading temperature and process control specialist.

• Reliable easy to use – the piccolo temperaturecontroller works to help achieve day-to-day objectivesfor yield and cost

• Improve quality – precise stable control means thatyour process stays within your quality limits

• Rapid set up with Quick Code configuration

• Customisation of lists and settings with PC basedWizard

• Standard panel cut outs in DIN sizes

• Comprehensive support by phone or email

• Recovery point simplifies support byensuring that any operator canquickly revert the controller to knownsettings

Easy to CommissionEasily Achieved Benefits


... easy to own

imagine processexcellence made easy

With an established track record ofreliability backed by a global servicenetwork, Invensys Eurotherm offers thepeace of mind provided by a qualityproduct.

• 3 year standard warranty

• Telephone and e-mail support

• Formal site service support andcalibration arrangements

• Full range of industry certificates,including CE, cUL, RoHS

Global availability and supportAs a global market leader, InvensysEurotherm offers its products via anextensive worldwide distribution network.If you need a controller fast, our globalsales and distribution network is bestpositioned to help you. Our commitmentto you for quality and reliability is backedby the support capability and the expertiseof a true specialist.

Easy to Own

6180A GRAPHIC RECORDER

INDUSTRYSTANDARD PLC

3508

MODBUS RTU

3504

P108 P104 P116SCADA AND CONTROL

In global businesses where manufacturing operations may take placeanywhere in the world, it is vital that instrument operators can quicklylearn to operate key process steps without risk of errors.

• Simple, customisable settings with security for different levels ofpersonnel

• Local and remote setpoint control and alarm acknowledgement

• High visibility 3 colour display with just the information you needto see

Aids continuous improvement against targetsAn increasingly competitive world means constant pressure on marginsand an ongoing need to improve the process efficiency. What oftenstands in the way of continuous improvement is the difficulty ofobtaining performance data from older control systems. With theInvensys Eurotherm piccolo controller you can easily access processmetrics, without the need to change your entire control system.

• Accurate measurements of process deviation from setpoint

• Energy usage estimates for electrical loads

• Measurements easily available over digital communications or onfront panel

Easy to Use

Easy to Integrate

Where spaceis at apremium, thecompact sizewith a depthof only 90mmprovidessignificantspace savings.

Selection guide

Features

Panel size (DIN)

IP Rating

piccolo controller

Display Type

Supply Voltage

Input Type

PV AccuracyControl Types

Timer Functions

Analogue IP/OP

Digital IP/OPDigital Comms

Alarm Types

P108

1/8

P104

1/4

P116

1/16

TC, RTD, mV, mA, CT

Main: 4 digits Lower: Secondary 4 digits, amber

Third : 4 digits, amber

<0.25%

24V ac/dc85-264V ac

On/Off. PID

Ramp/Soak, Delay, Soft Starter

In: 2 Out: 1

In: 2 Out: 4Modbus RTU – RS485

Hi, Lo, Dev, Sensor break, Event, Heater fail

Special Features Energy Monitoring, Recovery Point

IP65 IP65

TC, RTD, mV, mA, CT

Main: 4 digits Lower: Secondary 4 digits, amber

<0.25%

24V ac/dc85-264V ac

On/Off. PID

Ramp/Soak, Delay, Soft Starter

In: 2 Out: 1

In: 2 Out: 3Modbus RTU – RS485

Hi, Lo, Dev, Sensor break, Event, Heater failCE, cUL, RohS CE, cUL, RohSIndustry Certifications

PC Configuration Wizard/iToolsWizard/iTools

Energy Monitoring, Recovery Point

P116P116 P108 P104

The perfect fit for OEM applicationsInvensys Eurotherm works in partnership with many worldleading OEM customers, providing state-of-the art controlcapability in surprisingly affordable formats.

In crowded equipment markets your products must standout from your competitors – and the piccolo controllerprovides a hugely flexible platform to help you achieve this.From configurable HMI lists through branded front fasciasto fully customised firmware, Invensys Eurotherm can helpyou differentiate your products with a top quality controlcomponent.

We pride ourselves on exceptional on-time deliveryperformance. Our flexible and lean manufacturingoperations will ensure that we can supply the components

you need to feed your growth when you need them.Controllers can be supplied fully configured and to aidspeedy commissioning our product can be supplied pre-configured to your application needs.

With a growing range of global industry certifications andapprovals, we provide the peace of mind of a singlesupplier solution, wherever in the world you choose to dobusiness.

Where your own reputation rests on quality, reliability andperformance, Invensys Eurotherm should be your partnerof choice. Call us to discuss how we can provide anunbeatable package.


Wipedown fascias on ourpanel mounted instrumentsoffer a multitude ofpossibilities for designcustomisation. They alsoprovide the ideal solutionfor food and laboratoryapplications withenvironments requiring asolution that is easy to clean,hygienic and moisture tight.

Wipedown Front Fascia Space Saving


To order a piccolo controller with the most common configuration, including a logic SSR drive and two mains rated relays forcontrol or alarm as well as RS485 digital communications for setup and monitoring, specify:

Typical Order Codes

1/16 DIN Compact 48mm High x 48mm Wide x 90mm Deep panel formatP116/CC/VH/LRX/R/4CL

1/8 DIN Compact 96mm High x 48mm Wide x 90mm Deep panel formatP108/CC/VH/LRR/R/4CL

1/4 DIN Compact 96mm High x 96mm Wide x 90mm Deep panel formatP104/CC/VH/LRR/R/4CL

Comprehensive range of Input/Output optionsAs you would expect from an Invensys Eurothermcontroller, a full range of input and output optionsare supported. Full galvanic isolation is providedbetween the main measurement input and externalfunctions such as communications for safety andreliability.

• Input Type Thermocouple,resistance thermometer and mVinput. Current and voltagemeasurements available via externalshunt

• Outputs Relay, SSR logic drive, triacand 4-20mA DC outputs

• Digital Inputs Contact closure logicinputs to switch a wide range ofinstrument functions

• Current Transformer For currentmeasurement energy estimationcalculations, and heater healthdiagnostics

• Communications Industry standardRS485 Modbus RTU communications

• Supply Voltage Wide ranging ac/dcpower supply options

Rear Terminals

P108 and P104

P116


Plastic Processing Control (Extruders and Chillers)Eurotherm have vast experience in Plastic Processing control andhas helped improve the productivity of customers’ single-screw, twin-screw, co-extrusion, or blown film systems bytaking better control of the temperature. Using low cost On/Off temperature controllersor poor PID controllers can result in variation oftemperature in the feed throat, barrel and headwhich can ultimately lead to poor levels ofproductivity.

The precise PID control of the piccolo controller isused to ensure uniform heating of the material toavoid material degradation, undue strain on theextruder components, and improve process reliability.

Chillers are used in the plastics industry to protect valuableprocessing equipment – such as extrusion, injection moldingequipment and other applications. Another reason for their useis to increase production through constant and proper coolingtemperatures in the equipment. A chiller will reduce the number ofrejected parts while increasing the number of parts produced per hour.

A chiller is a compressor based cooling system that is similar to an airconditioner except it cools and controls the temperature of a liquidinstead of air.

The piccolo controller can be used to consolidate functions and replaceseveral interconnected devices to chillers, including an external timer. Thelevel of functionality, programmability and alarming gives the user a wayto create a local custom alarm strategy that can best achieve the operatingsafety of the machine, minimise downtime and improve quality.

Kilns, Ovens and Furnaces The piccolo controller is well adapted toovens, small furnaces and kilns. Formachines such as a small kiln forfiring ceramics or an oventreating complex smallparts, the timer functioncan gradually increasethe temperature to thedesired setpoint –preventing thermal shockor damage/distortion tothe work pieces beingheated.

The timer automatically maintainsthe temperature for the desireddwell period, before turning power off toallow the items to cool.

An over-temperature alarm may be used tocontrol an interlock on the door as a basic safeguard.

All of this may be controlled either using the piccolo controller fascia, or from anexternal switch wired to an input on the controller.

Photograph courtesy of Mokon

Photos displayed are purely to demonstrate applications that these controllers are suited to. Control systems on these specific units may differ from this product being offered

Photograph courtesy of Welex

Photograph courtesy of Wisconsin Oven

Time

Temperature

Setpoint

Dwelltime

Switch off

Ramp control

Batch OperationThe simple timer in the piccolo controller maybe used to control batch operations, e.g. foodovens, sterilisers, fryers. Ideal for anyapplication requiring a single dwell at the endof either a controlled ramp or natural approachto setpoint without the need for an additionaltiming device. This can also be used toautomatically bring the process up totemperature ready for production to start in themorning.

Real-world applicationsWhether it’s for excellence in control easy set up or easy straightforwardfunctionality the piccolo controllers can be used across a broad range ofapplications to solve problems.

Energy SavingEnergy saving in industrial processes is often as easy as increasing level s of thermal insulationaround furnaces, boilers or pipes. If a working environment feels hot when you walk into it,the chances are that simple measures such as these will save considerable energy. Howeverthis can lead to control problems, because a well insulated system can be slow to react tocooling commands from the controller. The piccolo controller range has been designed tocope with such challenges and provide excellent performance even when there is a wideimbalance between the effects of heating and cooling.

Energy can also be wasted in providing headroom for heating because of control instability. Ifa process must maintain a temperature of a given level for a given ‘soak’ period of time, it iscommon to add in a safety factor on the temperature so that oscillations during the soak timedon’t take the temperature below specification. By using precise and accurate control, thissafety factor may be reduced without risking expensive rework or scrap.


Practical functionality

L1

N/L2

TC

CT

OP

TC

OPOP

Heater Failure DetectionA current transformer input in the piccolo controllermeasures the current switched through the load. Themeasurement is filtered so that the on current and offcurrents can be separated. From this it is possible todiagnose several load faults including partial load failure,over current andan SSR fault.Typicalapplicationsinclude plasticextrusion,laboratory ovensand otherapplications whereearly indication offailure can helpyou to avoidproduct waste andallow you to planyour maintenanceschedule.

Time

Temperature

Setpoint

without cutbackwith cutback

Overshoot EliminationIt is interesting to compare process control with thefamiliar situation of driving a car at a given speed. Wetend intuitively to use full acceleration until weapproach the speed we want, and then progressivelyback off acceleration until the speed is reached andregulate the speed around that point.

PID control typically works by gradually reducingpower from a maximum over the full range ofoperation. This can cause a slower rise to setpoint, orcan create overshoot and oscillations if the PIDconstants are set to allow more aggressive heating.

Cutback is a unique feature of the Eurotherm control algorithm and allows aggressive application of poweroutside a defined approach region. Just like a driver trying to reach a particular speed as fast as possible,the algorithm applies full power when the measured temperature is outside the region, before using PIDcontrol to make adjustments to the power within the cutback region only. This provides rapid responsewithout overshoot or oscillations. This unique 'cutback' feature reduces process overshoot which in turnreduces startup time and hence allows processing to commence earlier.

The cutback function is automatically set up using the PID autotune facility in the piccolo controllers.

Undo FunctionYou wouldn’tuse a wordprocessorwithout anundo function sowhy settle for less whenworking on control systems?

The piccolo controller undofunction allows you to revertto a known instrumentsetting, either as suppliedfrom the factory or a trustedsetup. This enables you toexperiment with settings andfunctions without the worrythat you will lose the currentconfiguration and have torecommission from scratch.

Furnace

Output

Input

KiloWattHour Meter

OutpuOO

Energy EstimationThe aim of this function is to have an estimation of energy consumption ofthe controlled process. By setting the nominal power of your load with adedicated parameter the instrument is able to calculate the integral of theon time period of a selected output. Two counters are provided in operativemode to offer a partial and a total counting feature. The purpose of thisfeature is to provide visual feedback on theenergy being consumed. Any deviationobserved from the average value will alert youto possible problems in the process.

AUSTRALIA MelbourneInvensys Process SystemsAustralia Pty. Ltd.T (+61 0) 8562 9800F (+61 0) 8562 9801E [email protected]

AUSTRIA ViennaEurotherm GmbHT (+43 1) 7987601F (+43 1) 7987605E [email protected]

BELGIUM & LUXEMBOURGMohaEurotherm S.A./N.V.T (+32) 85 274080F (+32) 85 274081E [email protected]

BRAZIL Campinas-SPEurotherm Ltda.T (+5519) 3707 5333F (+5519) 3707 5345E [email protected]

CHINA Eurotherm ChinaT (+86 21) 61451188F (+86 21) 61452602E [email protected]

Beijing OfficeT (+86 10) 5909 5700F (+86 10) 5909 5709/10E [email protected]

FRANCE Lyon Eurotherm Automation SAT (+33 478) 664500F (+33 478) 352490E [email protected]

GERMANY LimburgInvensys Systems GmbH>EUROTHERM<T (+49 6431) 2980F (+49 6431) 298119E [email protected]

INDIA Mumbai Invensys India Pvt. Ltd.T (+91 22) 67579800F (+91 22) 67579999E [email protected]

IRELAND DublinEurotherm Ireland LimitedT (+353 1) 4691800F (+353 1) 4691300E [email protected]

ITALY ComoEurotherm S.r.lT (+39 031) 975111F (+39 031) 977512E [email protected]

KOREA Seoul Invensys Operations ManagementKorea T (+82 2) 2090 0900F (+82 2) 2090 0800E [email protected]

NETHERLANDS Alphen a/d RijnEurotherm B.V.T (+31 172) 411752F (+31 172) 417260E [email protected]

POLAND KatowiceInvensys Eurotherm Sp z o.o.T (+48 32) 7839500F (+48 32) 7843608/7843609E [email protected]

Warsaw Invensys Systems Sp z o.o.T (+48 22) 8556010F (+48 22) 8556011E [email protected]

SPAIN MadridEurotherm España SAT (+34 91) 6616001F (+34 91) 6619093E [email protected]

SWEDEN MalmoEurotherm ABT (+46 40) 384500F (+46 40) 384545E [email protected]

SWITZERLAND WollerauEurotherm Produkte (Schweiz) AGT (+41 44) 7871040F (+41 44) 7871044E [email protected]

UAE DubaiInvensys Middle East FZET (+971 4) 8074700F (+971 4) 8074777E [email protected]

UNITED KINGDOM WorthingEurotherm LimitedT (+44 1903) 268500F (+44 1903) 265982E [email protected]

U.S.A. Ashburn VAInvensys EurothermT (+1 703) 724 7300F (+1 703) 724 7301E [email protected]

ED68Contact details correct at time of print.

© Copyright Eurotherm Limited 2012

Invensys, Eurotherm, the Eurotherm logo, Chessell, EurothermSuite, Mini8, Eycon, Eyris, EPower, nanodac, piccolo, Foxboro and Wonderware aretrademarks of Invensys plc, its subsidiaries and affiliates. All other brands may be trademarks of their respective owners.

All rights are strictly reserved. No part of this document may be reproduced, modified, or transmitted in any form by any means, nor may it be storedin a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates, withoutthe prior written permission of Eurotherm Limited.

Eurotherm Limited pursues a policy of continuous development and product improvement. The specifications in thisdocument may therefore be changed without notice. The information in this document is given in good faith, but isintended for guidance only.

Eurotherm Limited will accept no responsibility for any losses arising from errors in this document.

Part No. HA031231 Issue 1 Printed in England on recycled paper 04.12

Represented by:

Eurotherm is also represented in thefollowing countries:Eurotherm:

International sales and service

www.eurotherm.com

AfghanistanAlbaniaAlgeriaAngolaArgentinaArmeniaAzerbaijanBahrainBangladeshBarbadosBelarusBermudaBoliviaBosnia and

HerzegovinaBotswanaBrazilBrunei DarussalamBulgariaCambodiaCameroonCanadaCentral AfricanRepublicChadChileColombiaCongoCosta RicaCôte d’IvoireCroatiaCyprusCzech RepublicDenmarkDjiboutiEcuadorEgyptEl SalvadorEritreaEstoniaEthiopiaFijiFinlandGeorgiaGhanaGreeceGreenlandGuineaHungaryIcelandIndonesiaIraqIsraelJamaicaJapanJordanKazakhstanKenyaKuwaitKyrgyzstanLaos

LatviaLesothoLibyaLithuaniaMacedoniaMadagascarMalaysiaMaltaMicronesiaMoldovaMoroccoMozambiqueMyanmarNamibiaNicaraguaNigerNigeriaNorwayOmanPakistan Palestinian TerritoryPapua New GuineaParaguayPeruPhilippinesPolandQatarRomaniaRussiaRwandaSaudi ArabiaSenegalSerbia and

MontenegroSierra LeoneSingaporeSlovakiaSloveniaSomaliaSouth AfricaSri LankaSudanSwazilandSyriaTajikistanTanzaniaThailandThe GambiaTunisiaTurkey TurkmenistanUgandaUkraineUnited Arab EmiratesUruguayUzbekistanVenezuelaVietnamYemenZambiaZimbabwe

Documents

piccolo - InstruCon