Product Short Description

Product Overview

TC-PRS021 is the primary redundant central processing unit for Honeywell Experion PKS C300 distributed control system (DCS), responsible for executing continuous process control logic, PID regulatory control, sequence batch control, safety interlock logic and cross-system communication coordination. It supports 1:1 hot standby redundant pairing to deliver bumpless switchover upon primary processor failure, and integrates seamlessly with Honeywell Safety Manager SIL 3 safety systems for unified process & safety control architecture.
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Honeywell TC-PRS021
Honeywell TC-PRS021 - Image 2
Honeywell TC-PRS021 - Image 3

Description

Core Technical Specifications

  • Processing Hardware: Dual-core industrial real-time CPU, 1.2GHz clock frequency
  • Memory Configuration: 2GB DDR4 RAM + 4GB industrial SLC Flash non-volatile storage
  • Maximum Supported I/O Points: 256 physical I/O tags per processor module
  • Redundancy Mode: 1:1 hot standby, automatic bumpless switchover ≤50ms failure transition time
  • Communication Ports: 2 × FTE Fault Tolerant Ethernet 10/100Mbps RJ45 ports, 2 × RS485 serial communication ports
  • Supported Protocols: FTE, Modbus TCP/RTU, HART IP, Profibus DP, OPC UA client/server
  • Control Execution Cycle: Configurable 10ms–1000ms real-time logic scan cycle
  • Operating Power Supply: 24VDC, 320mA typical module current draw
  • Operating Temperature Range: -20°C to +60°C operational; -40°C to +85°C storage
  • Humidity: 5%–95% RH non-condensing
  • Vibration Compliance: IEC 61580-2-6 industrial rack vibration standard
  • Physical Dimensions: 130(H) × 140(W) × 35(D) mm
  • Net Weight: 510g

Key Functional Features

  1. Dual-core real-time processing architecture separates control logic execution and communication task scheduling for deterministic scan cycle performance
  2. 1:1 hot standby redundant pairing; complete mirroring of control logic, setpoints and historical trend data between primary and backup processor
  3. Integrated FTE fault tolerant Ethernet dual redundant network to eliminate single network point of failure
  4. Native HART protocol processing for smart field transmitter parameter configuration and diagnostic data collection
  5. Built-in PID, feedforward, ratio, cascade, dead-time and batch sequence control function blocks
  6. Comprehensive system diagnostic coverage: backplane bus, I/O module health, communication link, internal memory, power rail monitoring
  7. Non-volatile storage for 12 months of process historical trend data and fault event audit logs
  8. Seamless integration with Honeywell Safety Manager SIL 3 safety instrumented systems for combined DCS/SIS plant control

Working Principle

24VDC rack power energizes the dual-core CPU and internal memory subsystems. The primary TC-PRS021 module executes user-defined control logic downloaded via Experion PKS Station engineering software, scans connected I/O modules via redundant C300 backplane bus at user-configured cycle intervals. Analog and discrete process variable data is processed through regulatory control algorithms, output setpoint values transmitted back to field I/O modules. The paired standby TC-PRS021 continuously synchronizes all memory data, control logic state and historical trend information with the primary module via dedicated redundant inter-module communication channel. Upon primary processor hardware or communication failure, the standby unit takes full control within 50ms without process control interruption. FTE dual Ethernet ports transmit real-time process data, alarm events and production parameters to upper-level Experion server and operator workstations over redundant plant control network.

Material Composition & Structural Characteristics

  • Module Housing: UL94-V0 flame retardant black polycarbonate alloy, anti-static coating for industrial cabinet EMC protection
  • Main Control PCB: Multi-layer high-speed FR-4 fiberglass substrate with gold-plated backplane edge connectors, low-loss signal traces for high-speed data transmission
  • Memory Components: Industrial-grade SLC flash memory chips with wide temperature operating range, high-reliability DDR4 RAM modules
  • Communication Interface: Isolated Ethernet PHY chips with surge protection, ESD protected RS485 transceivers
  • Indicator Panel: Multi-color LED status array (power, run, standby, fault, network link) with scratch-resistant polycarbonate window
  • Internal Hardware: Dual-core real-time industrial processor, precision voltage reference regulators, surface-mount tantalum energy storage capacitors

Installation Requirements

  1. Mount on Honeywell C300 series redundant control rack backplane slots; primary and standby processors occupy adjacent paired rack slots
  2. Maintain minimum 20mm vertical ventilation gap between adjacent rack modules to prevent CPU overheating
  3. FTE Ethernet wiring must use category 5e shielded twisted pair cables with single-ended cabinet grounding
  4. Rack protective earth grounding resistance ≤4Ω to eliminate EMC network communication interference
  5. Avoid mounting control rack adjacent to high-power variable frequency drives, transformers or welding equipment
  6. Cabinet cooling airflow ≥0.6m/s across module front panel; ambient temperature must not exceed 60°C continuously
  7. Front LED indicator panel must remain unobstructed for daily system health inspection

Typical Application Scenarios

  • Refinery & petrochemical plant main DCS control racks
  • Natural gas processing plant distributed process control systems
  • Power plant thermal unit boiler & turbine regulatory control
  • Chemical batch reactor continuous and sequence control systems
  • Pulp & paper mill pulp process distributed control architecture
  • Water treatment plant municipal wastewater DCS monitoring & control

Operation & Maintenance Precautions

  1. Execute processor hot swap only during low-risk process operating conditions; avoid replacement during critical batch cycle phases
  2. Backup control logic and historical trend data to Experion server storage monthly to prevent data loss during module failure
  3. Clean rack cabinet air intake filters every 3 months to maintain cooling airflow and prevent dust accumulation on PCB circuits
  4. Spare TC-PRS021 modules must be stored in ESD anti-static packaging at stable 10–30°C ambient temperature
  5. Unauthorized disassembly of module housing voids Honeywell factory warranty and DCS system calibration certification
  6. After processor replacement, verify full redundancy switchover test to confirm bumpless failover performance before resuming full process operation
  7. Separate control network Ethernet wiring from high-voltage AC power cables by minimum 30cm distance to avoid network packet loss interference

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