The OCR3000 is a modern DCS controller module used in the Ovation system for monitoring and controlling industrial processes. It is widely used in:

  • Power generation plants
  • Water and wastewater treatment systems
  • Large-scale industrial automation

The controller performs real-time control by processing field signals and executing control logic.

One of the key advancements of the OCR3000 is its integrated architecture.

The controller combines:

  • Processor
  • I/O Interface (IOIC)

into a single module, simplifying system design and improving performance.

The OCR3000 provides a highly scalable I/O structure:

  • Supports up to 16 I/O branches
  • Each branch supports up to 8 I/O modules

This results in a total capacity of:

16 × 8 = 128 I/O modules per controller

The controller scans all I/O branches in parallel, significantly improving response time compared to earlier models.

Evolution from OCR1100

The OCR3000 is the successor to the OCR1100 controller. While maintaining compatibility with existing Ovation I/O modules and applications, it introduces:

  • Higher processing performance
  • Improved system integration
  • Faster I/O scanning

Key Technical Features

Processor and Performance

  • System-on-Chip: Zynq UltraScale+ MPSoC
  • Quad-core ARM Cortex-A53 processor
  • Operating frequency: 1.2 GHz
  • Supports up to 64,000 process points
  • Up to 5 control tasks, each configurable

Control Execution

  • Loop execution time: 10 ms to 300 seconds

Memory and Storage

  • 1 GB LPDDR4 SDRAM with ECC
  • 32 MB QSPI Flash (expandable)
  • USB storage support

Communication and Networking

  • Ethernet ports:
    • 4 × RJ45 (copper) OR
    • 2 × RJ45 + 2 × SFP (fiber)
  • Supports 10/100/1000 Mbps

Network Terminals and Connectivity

The OCR3000 controller includes multiple network terminals used for different communication purposes:

  • N1 Terminal
    Used for communication with third-party systems (such as external SCADA, OPC, or other control systems)
  • N2 and N3 Terminals
    Used for communication within the Ovation control network
    These connect the controller to Ovation servers, workstations, and other system nodes
  • N4 Terminal
    Used for controller redundancy communication

Redundancy Example

In a redundant controller pair:

  • Controller 1 = Primary
  • Controller 51 = Secondary (Backup)

The N4 terminal connects Controller 1 to Controller 51, enabling:

  • High-speed synchronization
  • Automatic takeover in case of failure

This ensures continuous operation without interruption.

Redundancy and Reliability

The OCR3000 is designed for high-availability systems and supports:

  • Controller redundancy (primary and backup)
  • Network redundancy
  • Redundant 24V power supply

These features ensure reliable operation in critical industrial environments.

Cabinet and Installation Flexibility

Ovation systems provide flexible cabinet configurations:

  • Basic controller cabinet with local I/O branches
  • Expansion cabinets for additional I/O modules

Features include:

  • DIN rail mounting
  • Front and rear access
  • Flexible cable entry options

Typical Applications

The OCR3000 controller is used in:

  • Thermal and hydro power plants
  • Water and wastewater treatment plants
  • Industrial automation systems

It is designed for applications where continuous operation is essential.