Azbil Corporation has started sales of the model C1A single loop controller, which features high accuracy and fast response and reduces the burden on personnel, from installation through to maintenance. Despite its compact 48x48mm front panel size, the C1A achieves a high accuracy of ±0.1% of the reading (for thermocouple or Pt100 RTD) and high-speed response with a sampling cycle of 25ms, and it is equipped with various labor-saving functions for manufacturing sites. Single loop controllers compare signals from sensors with set values, execute PID control*1 according to the deviation amount, and output control signals to actuators for keeping the control targets (temperature, pressure, flow rate, etc.) at correct levels.

Controllers are essential devices for efficient operation at factories and plants. Azbil provides single loop controllers with a variety of functions that are required for applications in the factory automation market. As typified by semiconductor manufacturing facilities, compact and high-performance equipment is needed for maximizing productivity in limited factory space.

For devices like single loop controllers, which are built into other equipment, demand is growing for smaller size and higher performance. Additionally, it is important while equipment is running to reduce downtime by maintaining a constant understanding of the state of processes to prevent problems. Also, to cope with problems like a decrease in skilled workers and labor shortages, the manufacturing industry has turned to more intuitive and simpler methods of PID adjustment rather than methods that rely on experienced workers. Despite its compact size, the C1A achieves high accuracy and high-speed response.

Its multi-status indicator allows onsite personnel to grasp the controlled process status at a glance. Also, communication with a programmable logic controller (PLC) can be set up easily without the need for special programs. This makes it easy to create a system for remote process monitoring, for example, using a host system, touch panels, and other external devices. A major application of controllers is controlling temperature using electric heaters, which are known to deteriorate and have a limited service life.

An effective method of diagnosing deterioration is to monitor the resistance of the heater. The C1A calculates the voltage, current, and resistance of the heater using voltage transformer (VT) and current transformer (CT) inputs. These values can be monitored on the C1A's front panel or be used to output alarms if the preset threshold is exceeded.

By monitoring the resistance and the controlled temperature, the condition of a heater can be easily understood and unexpected heater burnout can be prevented. Additionally, the C1A's Smart Loader Package includes a PID simulator based on proprietary Azbil simulation technology as a standard feature. The PID simulator uses operating data to create mathematical models that reproduce characteristics of the object of control, allowing users to simulate PID control on the PC and reduce adjustment time.