Honeywell UDC3500 Manuals

Table of Contents

• • 4

    Symbol Definitions
  • 5

    Table of Contents

• 15

  1 Introduction

  • 15

    Overview
  • 16

    Analog Inputs
  • 16

    Math Functions
  • 17

    Digital Inputs
  • 20

    Operator Interface
    • 20

      Figure 1-1 UDC3500 Operator Interface
    • 21

      Function of Displays and Keys
  • 22

    Process Instrument Explorer Software
  • 22

    Figure 1-2 Screen Capture of Process Instrument Explorer Running On a Pocket PC
  • 23

    Figure 1-3 Depiction of Infrared Communications
  • 24

    CE Conformity (Europe)

• 25

  Installation

  • 25

    Overview
  • 25

    Figure 2-4 Composite Wiring Diagram
  • 25

    Figure 2-5 Mains Power Supply
  • 25

    Figure 2-6 Input 1 Connections
  • 25

    Figure 2-7 Input 2 Connections
  • 27

    Condensed Specifications
  • 27

    Table 2-1 Condensed Specifications
  • 27

    Pre-Installation Information
  • 31

    Model Number Interpretation
  • 32

    Figure 2-1 Model Number Interpretation
  • 33

    Control and Alarm Relay Contact Information
    • 33

      Alarm Relays
    • 33

      Control Relays
    • 33

      Table 2-2 Control Relay Contact Information
    • 33

      Table 2-3 Alarm Relay Contact Information
  • 34

    Mounting
  • 34

    Figure 2-2 Mounting Dimensions (Not to Scale)
  • 34

    Physical Considerations
  • 35

    Table 2-4 Mounting Procedure
  • 35

    Figure 2-3 Mounting Methods
  • 36

    Wiring
    • 36

      Electrical Considerations
    • 37

      Table 2-5 Permissible Wiring Bundling
  • 38

    Wiring Diagrams
  • 39

    Table 2-6 Single or Cascade Loop Controller - Loop 1 Output Functionality and Restrictions
  • 40

    Table 2-7 Dual Loop Controller - Loop 2 Output Functionality and Restrictions
  • 41

    Wiring the Controller
  • 46

    Figure 2-9 HLAI Inputs 2 and 4 Connections
  • 47

    Figure 2-10 HLAI Inputs 3 and 5 Connections
  • 49

    Figure 2-14 Output #2 - Electromechanical Relay Output
  • 49

    Figure 2-15 Output #2 - Solid State Relay Output
  • 50

    Figure 2-16 Output #2 - Open Collector Output- Third
  • 50

    Figure 2-17 Output #2 - Third Current Output
  • 51

    Figure 2-18 Output #2 - Dual Relay Output for Time Duplex
  • 51

    Figure 2-19 Output #2 - Dual Relay Output for Position Proportional or Three Position Step Control
  • 52

    Figure 2-20 RS-422/485 Communications Option Connections
  • 52

    Figure 2-21 Ethernet Communications Option with Adaptor Board
  • 53

    Table 2-8 Terminals for Connecting a UDC to a MDI Compliant Hub or Switch Utilizing a Cross-Over Cable
  • 53

    Figure 2-22 Ethernet Communications Option Without Adaptor Board
  • 54

    Table 2-9 Terminals for Connecting a UDC Directly to a PC Utilizing a Straight-Through Cable
  • 54

    Figure 2-23 Digital Inputs
  • 55

    Figure 2-24 Optional Electromechanical Relay Outputs
  • 55

    Figure 2-25 Transmitter Power for 4-20 Ma - 2 Wire Transmitter Using Open Collector Output
  • 56

    Figure 2-26 Transmitter Power for 4-20 Ma - 2 Wire Transmitter Using Second Current Output

• 57

  Configuration

  • 57

    Overview
  • 57

    Table 3-1 Configuration Topics
  • 59

    Configuration Prompt Hierarchy
  • 59

    Table 3-2 Configuration Prompt Hierarchy
  • 62

    Configuration Procedure
  • 62

    Table 3-3 Configuration Procedure
  • 63

    Loop 1 Tuning Set Up Group
  • 63

    Table 3-4 TUNING Group Function Prompts
  • 67

    Loop 2 Tuning Set Up Group
  • 67

    Table 3-5 TUNING 2 Group Function Prompts
  • 70

    SP Ramp Set Up Group
  • 70

    Table 3-6 SPRAMP Group Function Prompts
  • 76

    Accutune Set Up Group
  • 77

    Table 3-7 ACCUTUNE Group Function Prompts
  • 81

    Algorithm Set Up Group
  • 81

    Table 3-8 ALGORTHM Group Function Prompts
  • 94

    Figure 3-1 Mass Flow Example
  • 96

    Math Set Up Group
  • 96

    Table 3-9 MATH Group Function Prompts
  • 102

    Figure 3-2 Example of Eight Segment Characterizer
  • 103

    Logic Gates Set Up Group
  • 103

    Table 3-10 LOGIC Group Function Prompts
  • 110

    Output Set Up Group
  • 110

    Table 3-11 OUTPUT Group Function Prompts
  • 120

    Input 1 Set Up Group
  • 120

    Table 3-12 INPUT 1 Group Function Prompts
  • 124

    Input 2 Set Up Group
  • 124

    Table 3-13 INPUT 2 Group Function Prompts
  • 127

    Input 3 Set Up Group
  • 127

    Table 3-14 INPUT 3 Group Function Prompts
  • 131

    Input 4 Set Up Group
  • 131

    Table 3-15 INPUT 4 Group Function Prompts
  • 134

    Input 5 Set Up Group
  • 134

    Table 3-16 INPUT 5 Group Function Prompts
  • 137

    Control Set Up Group
  • 137

    Table 3-17 CONTROL Group Function Prompts
  • 146

    Control 2 Set Up Group
  • 146

    Table 3-18 CONTROL2 Group Function Prompts
  • 154

    Options Set Up Group
  • 154

    Table 3-19 OPTION Group Function Prompts
  • 164

    Communications Set Up Group
  • 164

    Table 3-20 Communications Group Function Prompts
  • 168

    Alarms Set Up Group
  • 169

    Table 3-21 ALARMS Group Function Prompts
  • 176

    Real Time Clock Set Up Group
  • 176

    Table 3-22 CLOCK Group Function Prompts
  • 177

    Maintenance Set Up Group
  • 177

    Table 3-23 MAINTENANCE Group Function Prompts
  • 180

    Display Set Up Group
  • 180

    Table 3-24 DISPLAY Group Function Prompts
  • 182

    Read Maintenance Set Up Group
  • 182

    Table 3-25 READ MAINTENANCE Group Function Prompts
  • 183

    Time Events Set Up Group
  • 183

    Table 3-26 TIME EVT Group Function Prompts
  • 185

    Tool Ethernet and Email Configuration Screens
  • 185

    Figure 3-3 Ethernet Configuration Screen
  • 186

    Figure 3-4 Email Configuration Screen
  • 188

    Configuration Record Sheet
  • 188

    Table 3-27 Configuration Record Sheet

• 195

  4 Monitoring and Operating the Controller

  • 195

    Overview
  • 196

    Operator Interface
  • 196

    Entering a Security Code
  • 196

    Figure 4-1 Operator Interface
  • 197

    Lockout Feature
  • 197

    Table 4-1 Procedure to Enter a Security Code
  • 198

    Key Error
  • 199

    Monitoring Your Controller
    • 199

      Annunciators
    • 199

      Table 4-2 Annunciators
    • 200

      Viewing the Operating Parameters
    • 200

      Table 4-3 Lower Display Key Parameter Prompts
    • 201

      Diagnostic Messages
  • 202

    Start Up Procedure for Operation
  • 202

    Table 4-4 Procedure for Starting Up the Controller
  • 203

    Control Modes
    • 203

      Mode Definitions
    • 203

      Table 4-5 Control Mode Definitions
    • 204

      What Happens When You Change Modes
  • 204

    Setpoints
  • 204

    Table 4-6 Changing Control Modes
  • 205

    Table 4-7 Procedure for Changing the Local Setpoints
  • 205

    Table 4-8 Procedure for Switching Between Setpoints
  • 206

    Timer
  • 207

    Accutune III
    • 207

      Accutune
    • 207

      Tuning Indicators
    • 209

      Table 4-9 Procedure for Starting "TUNE
    • 209

      Tune for Simplex Outputs
    • 210

      Tune for Duplex (Heat/Cool)
    • 211

      Table 4-10 Procedure for Using AUTOMATIC TUNE at Start-Up for Duplex Control
    • 211

      Using AUTOMATIC TUNE at Start-Up for Duplex (Heat/Cool)
    • 212

      Table 4-11 Procedure for Using BLENDED TUNE at Start-Up for Duplex Control
    • 212

      Using BLENDED TUNE at Start-Up for Duplex (Heat/Cool)
    • 213

      Table 4-12 Procedure for Using MANUAL TUNE for Heat Side of Duplex Control
    • 213

      Table 4-13 Procedure for Using MANUAL TUNE for Cool Side of Duplex Control
    • 213

      Using MANUAL TUNE at Start-Up for Duplex (Heat/Cool)
    • 214

      ACCUTUNE Error Codes
    • 214

      Table 4-14 Procedure for Accessing Accutune Error Codes
    • 214

      Table 4-15 Accutune Error Codes
  • 215

    Fuzzy Overshoot Suppression
  • 215

    Aborting Accutune
  • 216

    Using Two Sets of Tuning Constants
  • 216

    Table 4-16 Set Up Procedure
  • 217

    Table 4-17 Procedure for Switching PID SETS From the Keyboard
  • 218

    Input Math Algorithms
  • 218

    Input Algorithm Selections
  • 219

    Segment Characterizers
  • 220

    Logic Gate Operation
  • 220

    Table 4-18 Logic Gates Constraints and Dynamic Operation Status
  • 220

    Totalizer Reset Via Digital Input
  • 222

    Digital Input Option (Remote Switching)
  • 222

    Table 4-19 Digital Input Option Action On Contact Closure
  • 225

    Table 4-20 Digital Input Combinations "DIG IN1" or "DIG IN2
  • 226

    Table 4-21 Digital Inputs 1 and 2 Combination
  • 227

    Auto/Manual Station
  • 227

    Figure 4-2 Auto/Manual Station
  • 228

    Table 4-22 Auto/Manual Station Mode Configuration Procedure
  • 231

    Two Loops of Control
  • 232

    Figure 4-3 Functional Overview Block Diagram of a Single Loop (Loop #1) or Dual Loop Controller (Loop #1 and Loop #2)
  • 232

    Internal Cascade Control
  • 233

    Figure 4-4 Functional Overview Block Diagram of Internal Cascade Controller
  • 233

    Output Override
  • 234

    Configuring Two Loops of Control
  • 234

    Table 4-23 Procedure for Selecting Two Loop Algorithm
  • 234

    Figure 4-5 Hi/Lo Override Selector
  • 235

    Monitoring Two Loops of Control
  • 235

    Table 4-24 Digital Display Indication-Two Loops
  • 236

    Operating Two Loops of Control
  • 236

    Alarm Setpoints
  • 237

    Table 4-25 Procedure for Displaying Alarm Setpoints
  • 237

    Alarm Setpoints Display
  • 238

    Setpoint Programming Event Alarms
  • 239

    Three Position Step Control Algorithm
  • 239

    Table 4-26 Procedure for Displaying TPSC Motor Position
  • 240

    Setting a Failsafe Output Value for Restart After a Power Loss
  • 240

    Table 4-27 Procedure for Setting a Failsafe Value
  • 241

    Setting Failsafe Mode
  • 241

    Carbon Potential, Oxygen and Dewpoint Algorithms
  • 241

    Table 4-28 Procedure for Setting a Failsafe Mode
  • 242

    Carbon Potential
  • 243

    Figure 4-6 Carbon Potential Control
  • 244

    Healthwatch
  • 244

    Setpoint Rate/Ramp/Program Overview
  • 245

    Setpoint Rate
  • 245

    Setpoint Ramp
  • 245

    Pv Hot Start
  • 245

    Run/Hold Key
  • 246

    Table 4-29 Running a Setpoint Ramp
  • 247

    Setpoint Ramp/Soak Programming
  • 247

    Program Contents
  • 248

    Table 4-30 Program Contents
  • 251

    Figure 4-7 Ramp/Soak Profile Example
  • 252

    Figure 4-8 Program Record Sheet
  • 253

    Run/Monitor the Program
  • 254

    Table 4-31 Run/Monitor Functions
  • 255

    Setpoint Program Event Alarms
  • 256

    Tool Maintenance Screens
  • 256

    Figure 4-9 Loop Data Maintenance Screen
  • 257

    Figure 4-10 Alarm Details Maintenance Screen
  • 257

    Loop Data – Alarm Details
  • 258

    Loop Data – Digital Input Details
  • 259

    Figure 4-11 Status Data Maintenance Screen
  • 260

    Figure 4-12 Diagnostic History Maintenance Screen
  • 260

    Status Data – Diagnostics History
  • 261

    Figure 4-13 Ethernet Status Maintenance Screen
  • 262

    Figure 4-14 Healthwatch Data Maintenance Screen
  • 263

    Figure 4-15 Healthwatch Data Reset Screen
  • 264

    Figure 4-16 Totalizer Maintenance Screen
  • 264

    Totalizer Data
  • 265

    Figure 4-17 Real Time Clock Maintenance Screen
  • 266

    Configuring Your Ethernet Connection
  • 266

    Figure 4-18 IR Communications Address
  • 267

    Figure 4-19 Configuration Upload in Progress
  • 269

    Figure 4-20 Ethernet Communications Address
  • 270

    Figure 4-21 Configuration Upload in Progress

• 271

  5 Input Calibration

  • 271

    Overview
  • 272

    Minimum and Maximum Range Values
  • 272

    Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input Range Values
  • 272

    Calibration Steps
  • 274

    Preliminary Information
  • 274

    Table 5-2 Equipment Needed
  • 274

    Figure 5-1 Input Wiring Terminals
  • 276

    Input Set Up Wiring
    • 276

      Thermocouple Inputs Using an Ice Bath
    • 276

      Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath
    • 276

      Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath
    • 277

      Thermocouple Inputs Using a Thermocouple Source
    • 277

      Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs Using a Thermocouple Source
    • 277

      Figure 5-3 Wiring Connections for Thermocouple Inputs Using a Thermocouple Source
    • 278

      RTD Inputs
    • 278

      Table 5-5 Set Up Wiring Procedure for RTD Inputs
    • 278

      Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device)
    • 279

      Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential Inputs
    • 279

      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)
    • 279

      Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential
    • 280

      Table 5-7 Procedure to Determine Calibration Voltages for Thermocouple Differential Input Types Other Than the Factory Setting
    • 281

      To 10 Volts or -1 to 1 Volts
    • 281

      Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts or -1 to 1 Volts
    • 281

      Figure 5-6 Wiring Connections for 0 to 10 Volts or -1 to 1 Volts
    • 282

      Milliamperes
    • 282

      Table 5-9 Set Up Wiring Procedure for Milliampere Inputs
    • 282

      Figure 5-7 Wiring Connections for Milliampere Inputs
    • 283

      Dual High Level Voltage Inputs
    • 283

      Table 5-10 Set Up Wiring Procedure for Dual High Level Voltage Inputs
    • 283

      Figure 5-8 Wiring Connections for Dual High Level Voltage Inputs
    • 284

      Dual High Level Milliamperes Inputs
    • 284

      Table 5-11 Set Up Wiring Procedure for Dual High Level Milliampere Inputs
    • 284

      Figure 5-9 Wiring Connections for Dual High Level Milliampere Inputs
  • 285

    Input Calibration Procedure
  • 285

    Table 5-12 Input Calibration Procedure
  • 287

    Restore Input Factory Calibration
  • 287

    Table 5-13 Restore Factory Calibration

• 289

  6 Output Calibration

  • 289

    Overview
  • 290

    First Current Output Calibration
  • 290

    Table 6-1 Set Up Wiring Procedure for the First Current Output
  • 290

    Figure 6-1 Wiring Connections for Calibrating the First Current Output
  • 291

    Table 6-2 First Current Output Calibration Procedure
  • 292

    Second Current Output Calibration
  • 292

    Table 6-3 Set Up Wiring Procedure for the Second Current Output
  • 292

    Figure 6-2 Wiring Connections for Calibrating the Second Current Output
  • 293

    Table 6-4 Second Current Output Calibration Procedure
  • 294

    Third Current Output Calibration
  • 294

    Table 6-5 Set Up Wiring Procedure for the Third Current Output
  • 294

    Figure 6-3 Wiring Connections for Calibrating Third Current Output
  • 295

    Table 6-6 Third Current Output Calibration Procedure
  • 296

    Position Proportional and Three Position Step Output Calibration
  • 296

    Position Proportional Control
  • 297

    Table 6-7 Position Proportional and Three Position Step Output Calibration Procedure
  • 299

    Restore Factory Output Calibration
  • 299

    Table 6-8 Restore Factory Calibration

• 301

  7 Troubleshooting/Service

  • 301

    Overview
  • 302

    Troubleshooting Aids
  • 302

    Installation Related Problems
  • 302

    Application Related Problems
  • 303

    Table 7-1 Procedure for Identifying the Software Version
  • 304

    Power-Up Tests
  • 304

    Status Tests
  • 304

    Table 7-2 Procedure for Displaying the Status Test Results
  • 305

    Background Tests and Diagnostic Messages
  • 305

    Table 7-3 Background Tests
  • 309

    Controller Failure Symptoms
  • 309

    Table 7-4 Controller Failure Symptoms
  • 310

    Troubleshooting Procedures
    • 311

      Procedure #1 - Power
    • 311

      Procedure #2 - Current Outputs
    • 311

      Table 7-5 Troubleshooting Power Failure Symptoms
    • 311

      Table 7-6 Troubleshooting Current Output Failure
    • 313

      Procedure #3 - Position Proportional
    • 313

      Table 7-7 Troubleshooting Position Proportional Output Failure
    • 316

      Procedure #4 - Time Proportional
    • 316

      Table 7-8 Troubleshooting Time Proportional Output Failure
    • 317

      Procedure #5 - Current/Time or Time Current/Proportional
    • 317

      Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure
    • 318

      Procedure #6 - Alarm Relays
    • 319

      Table 7-10 Troubleshooting Alarm Relay Output Failure
    • 320

      Procedure #7 - Keyboard
    • 320

      Table 7-11 Troubleshooting a Keyboard Failure
    • 321

      Procedure #8 - Analog Input
    • 321

      Table 7-12 Troubleshooting an Analog Input Failure
    • 322

      Procedure #9 - RS-485
    • 322

      Table 7-13 Troubleshooting a RS-485 Communications Failure
    • 325

      Procedure #10 - Ethernet
    • 325

      Table 7-14 Troubleshooting an Ethernet Communications Failure
    • 326

      Procedure #11 - Email
    • 326

      Table 7-15 Troubleshooting an Email Failure
  • 327

    Restoring Factory Configuration
  • 327

    Table 7-16 Restoring Factory Configuration
  • 328

    Software Upgrades
  • 328

    Table 7-17 Software Upgrades

• 330

  8 Parts List

  • 330

    Exploded View
  • 330

    Figure 8-1 UDC3500 Exploded View
  • 331

    Table 8-1 Parts Identification
  • 331

    Table 8-2 Parts Not Shown
  • 332

    Removing the Chassis
  • 332

    Table 8-3 Software Upgrades (See Section 7.8)

• 333

  9 Modbus Rtu Function Codes

  • 333

    Overview
  • 333

    General Information
  • 334

    Table 9-1 Integer Parameter Type
  • 334

    Table 9-2 Floating Point Parameter Type
  • 334

    Register Address Structure
  • 334

    Register Count
  • 335

    Function Code 20 (14H) - Read Configuration Reference Data
    • 336

      Table 9-3 Register Parameter ID Address Format for Function Code 20
    • 337

      Read Configuration Examples
  • 339

    Function Code 21 (15H) - Write Configuration Reference Data
    • 340

      Table 9-4 Register Parameter ID Address Format for Function Code 21
    • 341

      Write Configuration Examples

• 342

  10 Modbus Read, Write and Override Parameters Plus Exception Codes

  • 342

    Overview
  • 343

    Reading Control Data
  • 344

    Table 10-1 Control Data Parameters
  • 345

    Read Software Options Status
  • 345

    Table 10-2 Option Status
  • 345

    Figure 10-1 Software Option Status Information
  • 346

    Miscellaneous Read Onlys
    • 346

      Register Addresses for Read Onlys
    • 346

      Setpoint Program Read Only Information
    • 346

      Table 10-3 Miscellaneous Read Onlys
    • 346

      Table 10-4 Setpoint Program Read Only Information
  • 347

    Setpoints
  • 347

    Table 10-5 Setpoint Code Selections
  • 348

    Table 10-6 Setpoint Associated Parameters
  • 349

    Using a Computer Setpoint (Overriding Controller Setpoint)
  • 349

    Table 10-7 Computer Setpoint Selection
  • 350

    Table 10-8 Computer Setpoint Associated Parameters for Loop 1
  • 351

    Table 10-9 Computer Setpoint Associated Parameters for Loop2
  • 352

    Configuration Parameters
    • 352

      Tuning Loop 1
    • 352

      Table 10-10 Set-Up Group - Tuning Loop 1
    • 354

      Tuning Loop2
    • 354

      Table 10-11 Set-Up Group - Tuning Loop 2
    • 355

      SP Ramp/Rate/Program
    • 355

      Table 10-12 Set-Up Group - Setpoint Ramp/Rate
    • 362

      Accutune
    • 362

      Table 10-13 Set-Up Group - Adaptive Tune
    • 364

      Algorithm
    • 364

      Table 10-14 Set-Up Group - Algorithm
    • 369

      Math
    • 369

      Table 10-15 Set-Up Group - Math
    • 372

      Logic
    • 372

      Table 10-16 Set-Up Group - Logic
    • 376

      Output Algorithms
    • 376

      Table 10-17 Set-Up Group - Output Algorithms
    • 378

      Input 1
    • 378

      Table 10-18 Set-Up Group - Input 1
    • 380

      Input 2
    • 380

      Table 10-19 Set-Up Group - Input 2
    • 382

      Input 3
    • 382

      Table 10-20 Set-Up Group - Input 3
    • 384

      Input 4
    • 384

      Table 10-21 Set-Up Group - Input 4
    • 386

      Input 5
    • 386

      Table 10-22 Set-Up Group - Input 5
    • 388

      Control
    • 388

      Table 10-23 Set-Up Group - Control
    • 391

      Control Loop 2
    • 391

      Table 10-24 Set-Up Group - Control2
    • 394

      Options
    • 394

      Table 10-25 Set-Up Group - Options
    • 398

      Communications
    • 398

      Table 10-26 Set-Up Group - Communications
    • 400

      Alarms
    • 400

      Table 10-27 Set-Up Group - Alarms
    • 405

      Maintenance
    • 405

      Table 10-28 Set-Up Group - Maintenance
    • 408

      Time Event
    • 408

      Table 10-29 Set-Up Group - Time Event
    • 410

      Display
    • 410

      Table 10-30 Set-Up Group - Display
    • 411

      Clock
    • 411

      Table 10-31 Set-Up Group - Clock
  • 412

    Modbus RTU Exception Codes
  • 413

    Table 10-32 Modbus RTU Data Layer Status Exception Codes

• 414

  11 Further Information

  • 414

    Modbus RTU Serial Communications
  • 414

    Modbus Messaging On Ethernet TCP/IP
  • 414

    How to Apply Digital Instrumentation in Severe Electrical Noise Environments

• 415

  12 Index

• 420

  13 Sales and Service