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UDC3500
Honeywell UDC3500 User Manual
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Troubleshooting/Serv
ice
3/07
UDC3500 Universal Digital Controller Product Manual
315
Low
er
Display
Reason for Failure
How
to Correct the Problem
ALRM3SP2
Alarm 3 Setpoint 2 is ac
tive.
Same as ALRM1SP1.
ALRM4SP1
Alarm 4 Setpoint 1 is ac
tive.
Same as ALRM1SP1.
ALRM4SP2
Alarm 4 Setpoint 2 is ac
tive.
Same as ALRM1SP1.
330
332
Table of Contents
Default Chapter
5
Table of Contents
5
1 Introduction
17
Overview
17
Operator Interface
22
Figure 1-1 UDC3500 Operator Interface
22
Function of Displays and Keys
23
Process Instrument Explorer Software
24
Figure 1-2 Screen Capture of Process Instrument Explorer Running on a Pocket PC
24
Figure 1-3 Depiction of Infrared Communications
25
CE Conformity (Europe)
26
2 Installation
27
Overview
27
Figure 2-4 Composite Wiring Diagram
27
Figure 2-5 Mains Power Supply
27
Figure 2-6 Input 1 Connections
27
Figure 2-7 Input 2 Connections
27
Figure 2-8 Input 3 Connections
27
Figure 2-11 Optional Analog Input Jumper Positions
27
Figure 2-12 First Current Output
27
Figure 2-13 Second Current Output
27
Condensed Specifications
29
Table 2-1 Condensed Specifications
29
Model Number Interpretation
33
Figure 2-1 Model Number Interpretation
34
Control and Alarm Relay Contact Information
35
Table 2-2 Control Relay Contact Information
35
Table 2-3 Alarm Relay Contact Information
35
Mounting
36
Figure 2-2 Mounting Dimensions (Not to Scale)
36
Table 2-4 Mounting Procedure
37
Figure 2-3 Mounting Methods
37
Wiring
38
Electrical Considerations
38
Table 2-5 Permissible Wiring Bundling
39
Wiring Diagrams
40
Table 2-6 Single or Cascade Loop Controller - Loop 1 Output Functionality and Restrictions
41
Table 2-7 Dual Loop Controller - Loop 2 Output Functionality and Restrictions
42
Figure 2-9 HLAI Inputs 2 and 4 Connections
48
Figure 2-10 HLAI Inputs 3 and 5 Connections
49
Figure 2-14 Output #2 - Electromechanical Relay Output
51
Figure 2-15 Output #2 - Solid State Relay Output
51
Figure 2-16 Output #2 - Open Collector Output- Third
52
Figure 2-17 Output #2 - Third Current Output
52
Figure 2-18 Output #2 - Dual Relay Output for Time Duplex
53
Figure 2-19 Output #2 - Dual Relay Output for Position Proportional or Three Position Step Control
53
Figure 2-20 RS-422/485 Communications Option Connections
54
Figure 2-21 Ethernet Communications Option with Adaptor Board
54
Figure 2-22 Ethernet Communications Option Without Adaptor Board
55
Table 2-8 Terminals for Connecting a UDC to a MDI Compliant Hub or Switch Utilizing a Cross-Over Cable
56
Table 2-9 Terminals for Connecting a UDC Directly to a PC Utilizing a Straight-Through Cable
57
Figure 2-23 Digital Inputs
57
Figure 2-24 Optional Electromechanical Relay Outputs
58
Figure 2-25 Transmitter Power for 4-20 Ma - 2 Wire Transmitter Using Open Collector Output
58
Figure 2-26 Transmitter Power for 4-20 Ma - 2 Wire Transmitter Using Second Current Output
59
3 Configuration
60
Overview
60
Table 3-1 Configuration Topics
60
Configuration Prompt Hierarchy
62
Table 3-2 Configuration Prompt Hierarchy
62
Configuration Procedure
66
Table 3-3 Configuration Procedure
66
Loop 1 Tuning Set up Group
67
Table 3-4 TUNING Group Function Prompts
67
Loop 2 Tuning Set up Group
71
Table 3-5 TUNING 2 Group Function Prompts
71
SP Ramp Set up Group
74
Table 3-6 SPRAMP Group Function Prompts
75
SP Program 2 Set up Group
80
Table 3-7 SP PROG2 Group Function Prompts
80
SP Program 3 Set up Group
83
Table 3-8 SP PROG3 Group Function Prompts
83
SP Program 4 Set up Group
86
Table 3-9 SP PROG4 Group Function Prompts
86
Accutune Set up Group
89
Table 3-10 ACCUTUNE Group Function Prompts
90
Algorithm Set up Group
94
Table 3-11 ALGORTHM Group Function Prompts
94
Figure 3-1 Mass Flow Example
107
Math Set up Group
109
Table 3-12 MATH Group Function Prompts
109
Figure 3-2 Example of Eight Segment Characterizer
114
Logic Gates Set up Group
115
Table 3-13 LOGIC Group Function Prompts
115
Output Set up Group
122
Table 3-14 OUTPUT Group Function Prompts
122
Input 1 Set up Group
133
Table 3-15 INPUT 1 Group Function Prompts
133
Input 2 Set up Group
137
Table 3-16 INPUT 2 Group Function Prompts
137
Input 3 Set up Group
140
Table 3-17 INPUT 3 Group Function Prompts
140
Input 4 Set up Group
143
Table 3-18 INPUT 4 Group Function Prompts
143
Input 5 Set up Group
146
Table 3-19 INPUT 5 Group Function Prompts
146
Control Set up Group
149
Table 3-20 CONTROL Group Function Prompts
149
Control 2 Set up Group
158
Table 3-21 CONTROL2 Group Function Prompts
158
Options Set up Group
165
Table 3-22 OPTION Group Function Prompts
165
Communications Set up Group
177
Table 3-23 Communications Group Function Prompts
177
Alarms Set up Group
181
Table 3-24 ALARMS Group Function Prompts
182
Real Time Clock Set up Group
189
Table 3-25 CLOCK Group Function Prompts
189
Maintenance Set up Group
190
Table 3-26 MAINTENANCE Group Function Prompts
190
Display Set up Group
193
Table 3-27 DISPLAY Group Function Prompts
193
Read Maintenance Set up Group
195
Table 3-28 READ MAINTENANCE Group Function Prompts
195
Time Events Set up Group
196
Table 3-29 TIME EVT Group Function Prompts
196
Tool Ethernet and Email Configuration Screens
198
Figure 3-3 Ethernet Configuration Screen
198
Figure 3-4 Email Configuration Screen
199
Configuration Record Sheet
201
Table 3-30 Configuration Record Sheet
201
4 Monitoring and Operating the Controller
209
Overview
209
Operator Interface
210
Entering a Security Code
210
Figure 4-1 Operator Interface
210
Lockout Feature
211
Table 4-1 Procedure to Enter a Security Code
211
Monitoring Your Controller
213
Annunciators
213
Table 4-2 Annunciators
213
Viewing the Operating Parameters
214
Table 4-3 Lower Display Key Parameter Prompts
214
Diagnostic Messages
215
Start up Procedure for Operation
216
Table 4-4 Procedure for Starting up the Controller
216
Control Modes
217
Mode Definitions
217
Table 4-5 Control Mode Definitions
217
What Happens When You Change Modes
218
Setpoints
218
Table 4-6 Changing Control Modes
218
Table 4-7 Procedure for Changing the Local Setpoints
219
Table 4-8 Procedure for Switching between Setpoints
219
Timer
220
Accutune III
221
Tune for Simplex Outputs
223
Table 4-9 Procedure for Starting "TUNE
223
Tune for Duplex (Heat/Cool)
224
Using AUTOMATIC TUNE at Start-Up for Duplex (Heat/Cool)
225
Table 4-10 Procedure for Using AUTOMATIC TUNE at Start-Up for Duplex Control
225
Using BLENDED TUNE at Start-Up for Duplex (Heat/Cool)
226
Table 4-11 Procedure for Using BLENDED TUNE at Start-Up for Duplex Control
226
Using MANUAL TUNE at Start-Up for Duplex (Heat/Cool)
227
Table 4-12 Procedure for Using MANUAL TUNE for Heat Side of Duplex Control
227
Table 4-13 Procedure for Using MANUAL TUNE for Cool Side of Duplex Control
227
ACCUTUNE Error Codes
228
Table 4-14 Procedure for Accessing Accutune Error Codes
228
Table 4-15 Accutune Error Codes
228
Fuzzy Overshoot Suppression
229
Using Two Sets of Tuning Constants
230
Table 4-16 Set up Procedure
230
Table 4-17 Procedure for Switching PID SETS from the Keyboard
231
Input Math Algorithms
232
Logic Gate Operation
234
Table 4-18 Logic Gates Constraints and Dynamic Operation Status
236
Digital Input Option (Remote Switching)
237
Table 4-19 Digital Input Option Action on Contact Closure
237
Table 4-20 Digital Input Combinations "DIG IN1" or "DIG IN2
240
Table 4-21 Digital Inputs 1 and 2 Combination
241
Auto/Manual Station
242
Figure 4-2 Auto/Manual Station for Loop 1 (Loop 2 Similar)
242
Table 4-22 Auto/Manual Station Mode Configuration Procedure
243
Two Loops of Control
246
Figure 4-3 Functional Overview Block Diagram of a Single Loop (Loop #1) or Dual Loop Controller (Loop #1 and Loop #2)
247
Figure 4-4 Functional Overview Block Diagram of Internal Cascade Controller
248
Configuring Two Loops of Control
249
Table 4-23 Procedure for Selecting Two Loop Algorithm
249
Figure 4-5 Hi/Lo Override Selector
249
Monitoring Two Loops of Control
250
Table 4-24 Digital Display Indication-Two Loops
250
Operating Two Loops of Control
251
Alarm Setpoints
252
Table 4-25 Procedure for Displaying Alarm Setpoints
252
Three Position Step Control Algorithm
254
Table 4-26 Procedure for Displaying TPSC Motor Position
254
Setting a Failsafe Output Value for Restart after a Power Loss
255
Table 4-27 Procedure for Setting a Failsafe Value
255
Setting Failsafe Mode
256
Carbon Potential, Oxygen and Dewpoint Algorithms
256
Table 4-28 Procedure for Setting a Failsafe Mode
256
Figure 4-6 Carbon Potential Control
258
Healthwatch
259
Setpoint Rate/Ramp/Program Overview
259
Setpoint Rate
260
Setpoint Ramp
260
Table 4-29 Running a Setpoint Ramp
261
Setpoint Ramp/Soak Programming
262
Table 4-30 Program Contents
263
Table 4-31 Ramp/Soak Profile Example (Using 12 Segments)
266
Figure 4-7 Ramp/Soak Profile Example
266
Table 4-32 Program #1 Record Sheets
267
Figure 4-8 SP Program #1 Record Sheets
267
Table 4-33 Program #2 Record Sheets
269
Figure 4-9 SP Program #2 Record Sheets
269
Table 4-34 Program #3 Record Sheets
271
Figure 4-10 SP Program #3 Record Sheets
271
Table 4-35 Program #4 Record Sheets
273
Figure 4-11 SP Program #4 Record Sheets
273
Table 4-36 Run/Monitor Functions
275
Tool Maintenance Screens
277
Figure 4-12 Loop Data Maintenance Screen
277
Figure 4-13 Alarm Details Maintenance Screen
278
Figure 4-14 Digital Inputs Details Maintenance Screen
279
Figure 4-15 Status Data Maintenance Screen
280
Figure 4-16 Diagnostic History Maintenance Screen
281
Figure 4-17 Ethernet Status Maintenance Screen
282
Figure 4-18 Healthwatch Data Maintenance Screen
283
Figure 4-19 Healthwatch Data Reset Screen
284
Figure 4-20 Totalizer Maintenance Screen
285
Figure 4-21 Real Time Clock Maintenance Screen
286
Configuring Your Ethernet Connection
287
Figure 4-22 IR Communications Address
287
Figure 4-23 Configuration Upload in Progress
288
Figure 4-24 Ethernet Communications Address
290
Figure 4-25 Configuration Upload in Progress
291
5 Input Calibration
293
Overview
293
Minimum and Maximum Range Values
294
Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input Range Values
294
Preliminary Information
296
Table 5-2 Equipment Needed
296
Figure 5-1 Input Wiring Terminals
296
Input Set up Wiring
298
Thermocouple Inputs Using an Ice Bath
298
Table 5-3 Set up Wiring Procedure for Thermocouple Inputs Using an Ice Bath
298
Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath
298
Thermocouple Inputs Using a Thermocouple Source
299
Table 5-4 Set up Wiring Procedure for Thermocouple Inputs Using a Thermocouple Source
299
Figure 5-3 Wiring Connections for Thermocouple Inputs Using a Thermocouple Source
299
RTD Inputs
300
Table 5-5 Set up Wiring Procedure for RTD Inputs
300
Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device)
300
Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential Inputs
301
Table 5-6 Set up Wiring Procedure for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential Inputs (Except 0-10 Volts and -1 to 1 Volts)
301
Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts, Carbon, Oxygen or
301
Table 5-7 Procedure to Determine Calibration Voltages for Thermocouple Differential Input Types Other than the Factory Setting
302
To 10 Volts or -1 to 1 Volts
303
Table 5-8 Set up Wiring Procedure for 0 to 10 Volts or -1 to 1 Volts
303
Figure 5-6 Wiring Connections for 0 to 10 Volts or -1 to 1 Volts
303
Milliamperes
304
Table 5-9 Set up Wiring Procedure for Milliampere Inputs
304
Figure 5-7 Wiring Connections for Milliampere Inputs
304
Dual High Level Voltage Inputs
305
Table 5-10 Set up Wiring Procedure for Dual High Level Voltage Inputs
305
Figure 5-8 Wiring Connections for Dual High Level Voltage Inputs
305
Dual High Level Milliamperes Inputs
306
Table 5-11 Set up Wiring Procedure for Dual High Level Milliampere Inputs
306
Figure 5-9 Wiring Connections for Dual High Level Milliampere Inputs
306
Input Calibration Procedure
307
Table 5-12 Input Calibration Procedure
307
Restore Input Factory Calibration
309
Table 5-13 Restore Factory Calibration
309
6 Output Calibration
311
Overview
311
First Current Output Calibration
312
Table 6-1 Set up Wiring Procedure for the First Current Output
312
Figure 6-1 Wiring Connections for Calibrating the First Current Output
312
Table 6-2 First Current Output Calibration Procedure
313
Second Current Output Calibration
314
Table 6-3 Set up Wiring Procedure for the Second Current Output
314
Figure 6-2 Wiring Connections for Calibrating the Second Current Output
314
Table 6-4 Second Current Output Calibration Procedure
315
Third Current Output Calibration
316
Table 6-5 Set up Wiring Procedure for the Third Current Output
316
Figure 6-3 Wiring Connections for Calibrating Third Current Output
316
Table 6-6 Third Current Output Calibration Procedure
317
Position Proportional and Three Position Step Output Calibration
318
Table 6-7 Position Proportional and Three Position Step Output Calibration Procedure
319
Restore Factory Output Calibration
321
Table 6-8 Restore Factory Calibration
321
7 Troubleshooting/Service
323
Overview
323
Troubleshooting Aids
324
Table 7-1 Procedure for Identifying the Software Version
325
Power-Up Tests
326
Status Tests
326
Table 7-2 Procedure for Displaying the Status Test Results
326
Background Tests and Diagnostic Messages
327
Table 7-3 Background Tests
327
Controller Failure Symptoms
332
Table 7-4 Controller Failure Symptoms
332
Troubleshooting Procedures
333
Procedure #1 - Power
334
Procedure #2 - Current Outputs
334
Table 7-5 Troubleshooting Power Failure Symptoms
334
Table 7-6 Troubleshooting Current Output Failure
334
Procedure #3 - Position Proportional
336
Table 7-7 Troubleshooting Position Proportional Output Failure
336
Procedure #4 - Time Proportional
339
Table 7-8 Troubleshooting Time Proportional Output Failure
339
Procedure #5 - Current/Time or Time Current/Proportional
340
Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure
340
Procedure #6 - Alarm Relays
341
Table 7-10 Troubleshooting Alarm Relay Output Failure
341
Procedure #7 - Keyboard
342
Table 7-11 Troubleshooting a Keyboard Failure
342
Procedure #8 - Analog Input
343
Table 7-12 Troubleshooting an Analog Input Failure
343
Procedure #9 - RS-485
344
Table 7-13 Troubleshooting a RS-485 Communications Failure
344
Procedure #10 - Ethernet
346
Table 7-14 Troubleshooting an Ethernet Communications Failure
346
Procedure #11 - Email
347
Table 7-15 Troubleshooting an Email Failure
347
Restoring Factory Configuration
348
Table 7-16 Restoring Factory Configuration
348
Software Upgrades
349
Table 7-17 Software Upgrades
349
8 Parts List
351
Exploded View
351
Figure 8-1 UDC3500 Exploded View
351
Table 8-1 Parts Identification
352
Table 8-2 Parts Not Shown
352
Removing the Chassis
353
Table 8-3 Software Upgrades (See Section 7.9)
353
9 Modbus Rtu Function Codes
354
Overview
354
General Information
354
Table 9-1 Integer Parameter Type
355
Table 9-2 Floating Point Parameter Type
355
Function Code 20 (14H) - Read Configuration Reference Data
356
Table 9-3 Register Parameter ID Address Format for Function Code 20
357
Read Configuration Examples
358
Function Code 21 (15H) - Write Configuration Reference Data
360
Table 9-4 Register Parameter ID Address Format for Function Code 21
361
Write Configuration Examples
362
10 Modbus Read, Write and Override Parameters Plus Exception Codes
363
Overview
363
Reading Control Data
366
Table 10-1 Control Data Parameters
366
Read Software Options Status
367
Table 10-2 Option Status
367
Figure 10-1 Software Option Status Information
367
Miscellaneous Read Onlys
368
Register Addresses for Read Onlys
368
Setpoint Program Read Only Information
368
Table 10-3 Miscellaneous Read Onlys
368
Table 10-4 Setpoint Program Read Only Information
368
Setpoints
369
Table 10-5 Setpoint Code Selections
369
Table 10-6 Setpoint Associated Parameters
370
Using a Computer Setpoint (Overriding Controller Setpoint)
371
Table 10-7 Computer Setpoint Selection
371
Table 10-8 Computer Setpoint Associated Parameters for Loop 1
372
Table 10-9 Computer Setpoint Associated Parameters for Loop2
373
Configuration Parameters
374
Tuning Loop 1
374
Table 10-10 Set-Up Group - Tuning Loop 1
374
Tuning Loop2
376
Table 10-11 Set-Up Group - Tuning Loop 2
376
SP Ramp/Rate/Program #1
377
Table 10-12 Set-Up Group - Setpoint Ramp/Rate/Program #1
377
Setpoint Program #2
383
Table 10-13 Set-Up Group - Setpoint Program #2
383
Setpoint Program #3
389
Table 10-14 Set-Up Group - Setpoint Program #3
389
Setpoint Program #4
395
Table 10-15 Set-Up Group - Setpoint Program #4
395
Accutune
401
Table 10-16 Set-Up Group - Adaptive Tune
401
Algorithm
403
Table 10-17 Set-Up Group - Algorithm
403
Math
408
Table 10-18 Set-Up Group - Math
408
Logic
411
Table 10-19 Set-Up Group - Logic
411
Output Algorithms
415
Table 10-20 Set-Up Group - Output Algorithms
415
Input 1
417
Table 10-21 Set-Up Group - Input 1
417
Input 2
419
Table 10-22 Set-Up Group - Input 2
419
Input 3
421
Table 10-23 Set-Up Group - Input 3
421
Input 4
423
Table 10-24 Set-Up Group - Input 4
423
Input 5
425
Table 10-25 Set-Up Group - Input 5
425
Control
427
Table 10-26 Set-Up Group - Control
427
Control Loop 2
430
Table 10-27 Set-Up Group - Control2
430
Options
433
Table 10-28 Set-Up Group - Options
433
Communications
437
Table 10-29 Set-Up Group - Communications
437
Alarms
439
Table 10-30 Set-Up Group - Alarms
439
Maintenance
443
Table 10-31 Set-Up Group - Maintenance
443
Time Event
446
Table 10-32 Set-Up Group - Time Event
446
Display
448
Table 10-33 Set-Up Group - Display
448
Clock
449
Table 10-34 Set-Up Group - Clock
449
Modbus RTU Exception Codes
450
Table 10-35 Modbus RTU Data Layer Status Exception Codes
451
11 Further Information
452
Modbus RTU Serial Communications
452
Modbus Messaging on Ethernet TCP/IP
452
How to Apply Digital Instrumentation in Severe Electrical Noise Environments
452
12 Index
453
13 Sales and Service
458
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Honeywell UDC3500 Specifications
General
Brand
Honeywell
Model
UDC3500
Category
Controller
Language
English
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