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UDC3200 Product Manual

1. Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display MAX MAX Tuning and Setpoint Ramp parameters are available for read only No other parameters are viewable AUTO MAN MANUAL AUTO KEY LOCKOUT Allows you to disable the Manual Auto key DISABLE DISABLE ENABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE RUN HOLD RUN HOLD KEY LOCKOUT Allows you to disable the Run Hold key for either SP Ramp or SP Program The Run Hold key is never disabled when used to acknowledge a latched alarm 1 DISABLE DISABLE ENABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE SP SEL SETPOINT SELECT KEY LOCKOUT Allows you to disable the Setpoint Select key DISABLE DISABLE ENABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE 4 08 UDC3200 Universal Digital Controller Product Manual 43 Configuration 3 5 SP Ramp Set Up Group Introduction Set Point Ramp Set Point Programs and Set Point Rates can be configured in this group A single Setpoint Ramp SP RAMP can be configured to occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes A Set Point Rate SPRATE lets you configure a specific rate of change for any local setpoint change A single Set Point Program SP PROG with up to 12 segment
2. Same as above 4 08 UDC3200 Universal Digital Controller Product Manual 47 Configuration 3 6 Accutune Set Up Group Introduction Accutune III automatically calculates GAIN RATE and RESET TIME PID tuning constants for your control loop When initiated on demand the Accutune algorithm measures a process step response and automatically generates the PID tuning constants needed for no overshoot on your process Fuzzy Fuzzy Overshoot Suppression When enabled this configuration will suppress or eliminate any overshoot that may occur as a result of the existing tuning parameters as the PV approaches the setpoint Tune Demand Tuning The tuning process is initiated through the operator interface keys or via a digital input if configured The algorithm then calculates new tuning parameters and enters them in the tuning group Tune will operate with PIDA PIDB PD MR and Three Position Step Control algorithms SP SP Tuning SP tuning continuously adjusts the PID parameters in response to setpoint changes You can select tuning on minimum setpoint changes of 5 up to 15 span Perform SP tuning after you have configured the controller SP Tuning does not operate with the Three Position Step Control algorithm Simplex Tuning is used when a Simplex Control Algorithm is configured and uses the current SP value and alters the output over the Output Limit Range Duplex Tuning is used when a Duplex Control Algorithm is conf
3. cceeeee 99 Set Up GOUD eee eE tarea 37 Set Up Wiring Procedure For Auxiliary Output EEEE EEE EE EEE E EE EEE 146 Setpoint Code SelectiOMS ooooocoincnccioncico 189 Setpoint High LiMit ooooonconnnnnnnncnncnincnonncnnnnnos 74 Setpoint Low Limit c ooononoccnoccnoconoccnononononnnonnnnns 74 Setpoint Ramp cooooooconoccnocconononcnonono nono nonnnonnnnnnonos 44 Setpoint Ramp iii 123 Setpoint Ramp Final Setpoint eee 45 Setpoint Ramp Time ceceeceesseeseereeeeeeeees 44 Setpoint Ramp Soak Programming 4 125 Setpoint Rate iii 45 Setpoint Rate cota cie 4 123 Setpoint Tracking oooonooonnnincnnocoonnoncnoncnonnonanonos 73 Setpoint sisien ii 4 106 189 Med MI Raia EE EENE E 85 SlOWMINE id o a dee 5 Soak Segments c ooconccnocnnonnconnconconnconccnnnonnnonnos 127 Software Ly pe cnc bh cts 188 Software Upgrade Part Number 172 Software Upgrades ooococoniocnocnnoncconconnccnnonnnonnos 171 Software VerslOO coooccconncnconconcononnnononinonacnninnon 188 Software Version Number 155 Solid State Relay Output ooooooocoincinonincnicnnnnnonos 29 Solid State Relays cccceccescceseesceeseeeseeeeeeseeees 13 SP Ramp Set Up Group cee eeeeeeeereeeseeeeeees 44 SP TUNING 5 205062 i E EE eee eae 48 Specifications cceeceseceseeseesceeseeseeeeeeeeenseees 12 Start Segment Number ceeeeeseeeseereeees 126 Start Up Procedure For Operation 104 Status Test
4. Load _ Relay Load Supply Power Td diera e Load Relay Load Supply Power ae aad To terminal 7org Dual Electromechanical relays are rated at 2 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only A Figure 2 11 Dual Electromechanical Relay Option Output See Table 2 6 for relay terminal connections for other Output Algorithm Types N C Load 0 s o Mio 23 180 Supply Power EA tae To terminal 4or6 To terminal 7or9 When the instrument has the Current Output as shown no Alarms are available when using the Time Proportional Duplex or Three Position Step Control Output Algorithms as these outputs require both available relays Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 12 Current Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 4 08 UDC3200 Universal Digital Controller Product Manual 31 Installation Open CW Close CCW Control Relay 1 D Control Relay 2 1 Alarm 2 is not available with this configuration 2 DC3200 EE Electromechanical Relays are rated at 5 amps at 120 Vac or 240 Vac or 24 Vdc DC3200 AA Solid State Relays are rated at 1 amp at 25
5. MANUAL LATCHING Contact closure transition forces the loop to Manual mode Opening the switch has no effect If the MAN AUTO key is pressed while the switch is closed the loop will return to Automatic mode PROCESS VARIABLE HOLD when the switch is closed PV is frozen at last value When switch opens PV resumes DIG 1COMB DISABLE PID2 TO DIR TO SP2 DIS AT TO SP1 RUN DIGITAL INPUT 1 COMBINATION SELECTIONS This selection allows the specified function to occur in addition to the one chosen for DIG IN 1 DISABLE Disables combination function PLUS PID2 Contact closure selects PID Set 2 PLUS DIRECT ACTION Contact closure selects direct controller action PLUS SETPOINT 2 Contact closure puts the controller into setpoint 2 PLUS DISABLE ADAPTIVE TUNE Contact closure disables Accutune process PLUS SETPOINT 1 Contact closure puts the controller into setpoint 1 PLUS RUN SETPOINT PROGRAM RAMP Contact closure starts SP Program Ramp if enabled DIG INP2 Same selections as for Digital Input 1 DIGITAL INPUT 2 SELECTIONS DIG2COMB Same selections as Digital Input 1 Combinations DIGITAL INPUT 2 COMBINATIONS 4 08 UDC3200 Universal Digital Controller Product Manual 83 Configuration 3 13 Communications Group Introduction The Communications group lets you configure the controller to be connected to a host computer via Modbus or Ethernet
6. 4 08 UDC3200 Universal Digital Controller Product Manual 115 Monitoring and Operating the Controller Completing Accutune When Accutune is complete the calculated tuning parameters are stored in their proper memory location and can be viewed in the TUNING Set up Group and the controller will control at the local setpoint using these newly calculated tuning constants 4 11 Fuzzy Overshoot Suppression Introduction Fuzzy Overshoot Suppression minimizes Process Variable overshoot following a setpoint change or a process disturbance This is especially useful in processes which experience load changes or where even a small overshoot beyond the setpoint may result in damage or lost product How it works The Fuzzy Logic in the controller observes the speed and direction of the PV signal as it approaches the setpoint and temporarily modifies the internal controller response action as necessary to avoid an overshoot There is no change to the PID algorithm and the fuzzy logic does not alter the PID tuning parameters This feature can be independently Enabled or Disabled as required by the application to work with the Accutune algorithm Fuzzy Tune should not be enabled for processes that have an appreciable amount of deadtime Configuration To configure this item refer to Section 3 Configuration Set Up Group ACCUTUNE Function Prompt FUZZY Select ENABLE or DISABLE Use 4 or Ww 4 12 Using Two Sets of T
7. Input 1 13 IN Connections x gt d Q XXXX Figure 5 1 Input 1 and Input 2 Wiring Terminals Equipment Needed Table 5 2 lists the equipment you will need to calibrate the specific types of inputs that are listed in the table You will need a screwdriver to connect these devices to your controller Table 5 2 Equipment Needed Type of Input Equipment Needed Thermocouple e A calibrating device with at least 0 02 accuracy for use as a Inputs Ice Bath signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input e Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the mV source e Two containers of crushed ice Thermocouple e A calibrating device with at least 0 02 accuracy for use as a Inputs T C Source signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with controller input RTD Resistance e A decade box with at least 0 02 accuracy capable of providing Thermometer stepped resistance values over a minimum range of 0 to 1650 ohms Device with a resolution of 0 001 ohm e Three insulated copper leads of equal length for connecting the decade box to the controller Milliampere e A calibrating device with at least 0 02 accuracy for use as a Millivolt Vo
8. TIMER DISABLE ENABLE TIMER allows you to enable or disable the timer option The timer option allows you to configure a timeout period and to select timer start by either the keyboard RUN HOLD key or Alarm 2 A digital input can also be configured to start the timer When the timer is enabled it has exclusive control of the alarm 1 relay any previous alarm configuration is ignored At timeout the timer is ready to be re activated by whatever action has been configured Alarm 1 is activated at the end of the timeout period PERIOD 0 00 to 99 59 PERIOD allows you to configure the length of timeout period from 0 to 99 hours 59 minutes 52 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display START KEY START allows you to select whether the timer starts ALARM 2 with the keyboard Run Hold key or Alarm 2 LOW DISP TI REM LOW DISP allows you to select whether time E TIME remaining TI REM or elapsed time E TIME is displayed for the timer option The time is shown on the lower display in HH MM format along with a rotating clock character If the clock rotation is clockwise elapsed time is indicated e If the clock rotation is counterclockwise time remaining is indicated RESET KEY RESET allows you to reset the timer with the ALARM 1 keyboard
9. The Reference Type definition is always 06 See examples in Subsection 9 3 1 File Number The file number word contains the register number from the register address structure tables on page 3 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address word represents the tag ID number for the parameter s being accessed The register address word is made up of two bytes the MSB 00 always The LSB contains the tag ID number The tag ID numbers represent the parameter s register address es See Section 3 for the tag ID numbers Table 9 3 Register Address Format for Function Code 20 Register Register Address es Address es Decimal Hex 001 to 125 0001 to 007D analog formatted data 2 registers IEEE 32 bit floating point 128 to 255 0080 to OOFF integer formatted data 1 register 16 bit integer 4 08 UDC3200 Universal Digital Controller Product Manual 179 Modbus RTU Function Codes 9 3 1 Read Configuration Examples Example 1 The following is an example of a request to read the Gain 1 value using Function code 20 Request Message Read Gain 1 ID Tag 001 02 14 07 06 00 03 00 01 00 02 CRC16 Where 02 Address 14 Function Code 20 14 hex 07 Byte Count 06 Reference Type 00 03 File Number Access Data Value 00 01 Register Address S
10. UDC3200 Universal Digital Controller Product Manual 63 Configuration 3 9 Input 1 Set Up Group Introduction This data deals with various parameters required to configure Input 1 Function Prompts Table 3 9 INPUT 1 Group Function Prompts Function Prompt Selections or Lower Display Range of Setting Upper Display Parameter Definition IN1 TYPE ATTENTION Changing the input type will result in the DISABLE loss of Field BTC Calibration values and E TC H will restore Factory ETCL Calibration values JTCH JTCM JTCL KTCH K TC M KTCL NNM H NNM L NIC H NIC L RTC S TC TTCH TTCL W TCH WTCL 100 PT 100 LO 200 PT 500 PT RAD RH RAD RI 0 20mA 4 20mA 0 10mV 0 50mV 0 100mV 0 5 V 1 5 V 0 10 V TC DIFF CARBON OXYGEN INPUT 1 ACTUATION TYPE This selection determines what actuation you are going to use for Input 1 DISABLE Disables Input B TC B Thermocouple E TC H E Thermocouple High E TC L E Thermocouple Low J TC H J Thermocouple High J TC M J Thermocouple Med J TC L J Thermocouple Low K TC H K Thermocouple High K TC M K Thermocouple Med K TC L K Thermocouple Low NNM H Ni Ni Moly Thermocouple High NNM L Ni Ni Moly Thermocouple Low NIC H Nicrosil Nisil Thermocouple High NIC L Nicrosil Nisil Thermocouple Low R TC R Thermocouple S TC S Thermocouple T TC H T Thermocouple High T TC L T Thermocouple Low W TC H W5W26 Ther
11. ooonocinoninonconnconnconnconnono nono noconoconoconn cnn nc narrar r raras 116 413 Alar SetpoiMtS iria ti AA AAA A A A dis 118 4 14 Three Position Step Control Al gorithim cccccccccscessecsseceseceseceseceseceeeeseeeseeeeeseeeseeeseeeaeeaaes 120 4 15 Setting a Failsafe Output Value for Restart After a Power LOSS oooonocnnncnnncononconnconncnoncnanonnnos 121 4 16 Setting Failsafe Mode cc eeccesccssseesscesseeeseeeseeeseecseecsaecsaecaeceseceseceseseeeseeeseeeeeseseseeeseeeaeeaaes 122 4 17 Setpoint Rate Ramp Program Overview cccccecssessseesseeseeeseceseceseceseeeeeseeeeeaeseseesseeeseeesaeesaes 122 AIS Setpoint Rate cca ces tina int es ii cans e 123 ALO SEPO RAD RN TONE 123 4 20 Setpoint Ramp Soak Programming ccccccccsseesseeseesecsseceseceseceseceseceseesceeseseeeseeeseeeeeenaeeaaes 125 INPUT CALIBRATION isicuicoicacicondaiainar reinado raider erica boards 132 Del SOV EL VIC Wired aten a a wg A A AA A ada e bs 132 5 2 Minimum and Maximum Range Values cccecccccsseesseesceesseeseecnseceseceseceseceeeseeeeeaeseaeeeseeeeeeaaes 133 5 3 ISS 135 34 Tnput dor 2 Set Up Wind a e a dada tt anche tages 136 5 4 1 Thermocouple Inputs Using an Ice Bathe ccc cccccccsseceseceseceeeeeeceeeeeeeeeeneesseeeseeesseenaes 136 5 4 2 Thermocouple Inputs Using a Thermocouple SOurC8 ooooccioconococonoconaconananonannnnnncon ccoo nooo 137 DAS SRT ANP US e ean id Lt A AE Gees des ds 137 5 4 4 Radiamatic Millivolts Vo
12. 400 0 Value of Local Setpoint 1 05 Data Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 44 60 0000 896 0 Value of Local Setpoint 2 CRC16 UDC3200 Universal Digital Controller Product Manual 181 Modbus RTU Function Codes 9 4 Function Code 21 15h Write Configuration Reference Data Introduction Function Code 21 15 Hex is used in this instrument to allow writes of integer and floating point values to the configuration database and override values The configuration database of this instrument is located in EEROM The override values are stored in RAM Integer format is used to write to Digital configuration items Floating Point format is used to write to Analog configuration items as defined by the configuration ID tags Write Restrictions Care should be taken not to exceed the 100 000 write limit of the EEROM Request and Response Formats The Request and Response formats for Function code 21 15 Hex are shown below Details for each block reference follow Request Message Format Slave Function Byte Reference File Register Register Address Code 15 Count Type Number Address Count File CRC CRC Data sas DONES Response Message Format echo back of request Slave Function Byte Reference File Register Register Address Code 15 Count Type Number Address Count File CRC CRC Data coe The register address is interpreted by this instrument as
13. Press Tan i 1 Select Automatic A indicator is on Mode Upper Display H and PV value Lower Display SP and Present value Nw 2 Set Start Setpoint Until start SP value is in lower display Upper Display H and PV value Lower Display SP and start SP value You will see Upper Display R and a changing PV value Lower Display SP and a changing SP value increasing or decreasing toward the final SP value 3 Start the Ramp 4 Hold Run the P Run Y This holds the ramp at the current setpoint value Press Ramp N Hold y again to continue 5 View the ao Until you see remaining ramp Display Upper Display PV value time Lower Display RAMPXXXM time remaining in minutes 6 End the Ramp When the final setpoint is reached R changes to H in the upper display and the controller operates at the new final setpoint 7 Disable SPRAMP See Section 3 Configuration group SPRAMP for details Power Outage If power is lost during a ramp upon power up the controller will be in HOLD and the setpoint value will be the setpoint value prior to the beginning of the setpoint ramp The ramp is placed in hold at the beginning Configure the mode at Set Up Group CONTROL function prompt PWR MODE See Subsection 3 11 CONTROL SETUP GROUP Prompts 124 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 20 Setpoint Ramp Soak Program
14. means no output rate OUTHIiLIM HIGH OUTPUT LIMIT T his is the highest value of output beyond which you do not want the controller automatic output to exceed 0 to 100 For relay output types 5 to 105 For current output types OUTLoLIM LOW OUTPUT LIMIT T his is the lowest value of output below which you do not want the controller automatic output to exceed 0 to 100 For relay output types 5 to 105 For current output types Hi LIM Within the range of the HIGH RESET LIMIT This is the highest value of output limits output beyond which you do not want reset action to Note 5 occur I Lo LIM Within the range of the LOW RESET LIMIT This is the lowest value of output limits output beyond which you do not want reset action to Note 5 occur DROPOFF 5 to 105 of output CONTROLLER DROPOFF VALUE Ouiput value below which the controller output will drop off to the Note 5 low output limit value set in prompt OUTLoLIM DEADBAND DEADBAND is an adjustable gap between the operating ranges of output 1 and output 2 in which neither output operates positive value or both outputs operate negative value 5 0 to 25 0 Time Duplex 0 0 to 25 0 On Off Duplex 0 5 to 5 0 Position Proportional and Three Position Step OUT HYST 0 0 to 100 0 of PV span HYSTERESIS OUTPUT RELAY is an adjustable overlap of the ON OFF states of each control output This is the difference between the value of the process variable at which t
15. Description Action Select Automatic or Manual Calibration DO AUTO Set 0 value DO AUTO Set 100 value DO MAN Set 0 value N until you see Upper Display DISABLE Lower Display POS PROP You can calibrate the controller output manually or let the controller calibrate the output automatically If the slidewire has never been calibrated you must use DO AUTO first In the Automatic Calibration Mode DO AUTO the controller relays automatically move the motor in the proper direction If desired however the motor may be manually positioned to 0 and 100 positions Disconnect the relay wires Use DO MAN In the Manual Calibration Mode DO MAN the motor does not move Instead the existing 0 and 100 values may be changed with the 4 or w key to select automatic or manual calibration Upper Display DO AUTO or DO MAN Lower Display POS PROP If you select Then DO AUTO go to Step 3 DO MAN go to Step 5 ATTENTION When calibration is terminated this selection reverts to DISABL The decrement relay is turned on to move the motor to 0 position Upper Display counts of slidewire feedback 0 3000 Lower Display ZERO VAL When the motor stops the display should stop counting then go to the next step The increment relay is turned on to move the motor to 100 position Upper Display counts of slidewire feedback 0 3000 Lower Displ
16. Input 2 e PV SP Output Register Addresses Use the identifying codes listed in Table 10 1 to read the specific items A Write request for these codes will result in an Error message 186 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes Table 10 1 Control Data Parameters Parameter Register Data Data Range or Description Address Type Enumerated Selection Input 1 007B 123 FP In Engineering Units or Percentage Input 2 007C 124 FP In Engineering Units or Percentage PV SP Output 007A 122 FP In Engineering Units or Percentage 10 3 Read Software Options Status Read Doing a Read of register address 00B9 listed in Table 10 2 will tell you which of the available options are enabled installed or disabled not installed Table 10 2 Option Status Parameter Register Data Data Range or Description Address Type Enumerated Selection Option Status 00B9 185 INT See Figure 10 1 Read only The data field in the response message will be a decimal number from 0 to 255 Convert the decimal number to binary as shown in Figure 10 1 to determine which options are or are not active OT 0 to 255 Convert decimal to binar SP Programming Math 0 not installed 1 installed EXAMPLE 2 snay 010 0 0 0 0 410 srProgamming insta Figure 10 1 Software Option Status Information 4 08 UDC3200 Universal Digital Controller Product Manual 18
17. Operation and Troubleshooting of your UDC3200 Controller World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL Corporate http www honeywell com Honeywell Process Solutions http hpsweb honeywell com Technical Tips http content honeywell com ipc faq Telephone Contact us by telephone at the numbers listed below Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 800 525 7439 Service 4 08 UDC3200 Universal Digital Controller Product Manual Symbol Definitions The following table lists those symbols used in this document to denote certain conditions 4 08 Symbol Definition A AX Y IP I IE E gt This CAUTION symbol on the equipment refers the user to the Product Manual for additional information This symbol appears next to required information in the manual WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 VDC may be accessible Failure to comply with these instructions could result in death or serious injury ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices Protective Earth PE terminal Provided for connection of the protective earth green or green yel
18. Output Relay 0 0 ce eeeeeseeeeeeees 75 LJ Infrared a tas Gated els 7 Infrared Communications ooocononccccnnnnccnnnnnns 8 14 Input 1 Actuation Type 64 Input 1 And Input 2 Wiring Terminals 135 Input 1 Calibration Procedure 0 0 eee eee 140 Input 1 Connecti0NS ooooonccnncnnonnoonnonnconccnnonnnos 26 Input 1 High Range Value eee eee 65 Input 1 Low Range Value 65 Input 1 Set Up Group ccoocccconccoccninonaconaninnacannnos 64 Input 1 Set Up Wiring ooooonoocnoncnoccnonccononnnonnss 136 Input 2 Actuation TyYPO oooononnoniccnocnconncononnnoo 68 Input 2 Connecti0NS oooonconncnnonnoonconnconccononnnoos 27 Input 2 Set Up Group ccooccccocccononinonaconaninanacannnos 68 Input Calibration cccceseeseeseeeteeeteeneeenes 132 Installation ooooonocnncninonicononononnconcconoconcnrccnrocnnoos 11 Installation Category oooocoocnoccnoconoconononncinncnnnonoss 9 Installation Related Problems 154 IR Communications Port o oooooonnnincnicnnonnnonnnonoss 84 Isolation 13 K Key Elf miso its 99 Key Lockout iconos 43 99 Keyboard Failure oooooonnonnoninnnocnnocnconccononnnonoos 166 Keys And Functions oooooocnoocnonoconnconcconccnnonnnonnos 6 L E ausccceties we Ges ae oes 122 Line Voltage Wikld8 oooocccionnnnicnnocnconnconncnnoo 20 Local Setpoint SoutCE oooconnccoonconnocnconnconononoo 72 Lock oli 42 Lockout Feature 98 Lockout Level iii ia 98 Loop Break kece ineo 8
19. Reset action MANUAL FAILSAFE OUTPUT Controller goes to Manual mode output goes to the Failsafe value ATTENTION This will cause a bump in the output when switching from Automatic to Manual The switch back from Manual to Automatic is bumpless When the switch is closed the output can be adjusted from the keyboard KEYBOARD LOCKOUT Contact closure disables all keys Lower display shows LOCKED if a key is pressed UDC3200 Universal Digital Controller Product Manual 81 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition 82 TO Aout TIMER AM STA TO TUNE SP Init TRACK TO RSP RST FB To PURGE AUTOMATIC OUTPUT Contact closure sends output to the value set at Control prompt AUTO OUT when the controller is in the Automatic mode Reopening the contact returns the controller to the normal output ATTENTION Does not apply to Three Position Step Control TIMER Contact closure starts timer if enabled Reopening the switch has no effect TO AUTO MANUAL STATION Contact closure causes the control loop to perform as follows PV Input 2 Action Direct Control algorithm PD MR PID SET 2 SP LSP 2 INITIATE LIMIT CYCLE TUNING Contact closure starts the tuning process The lower display shows TUNE ON Opening the contact has no effect SETPOINT INITIALIZATION Contact closure
20. SETPOINT Represents the value of the setpoint currently in use LSP1 LSP2 LSP3 RSP or CSP and is shown in the same units as those used by the PV LOCAL SETPOINT ONE Auxiliary output represents Local Setpoint 1 regardless of active setpoint REMOTE SETPOINT Represents the configured RSP regardless of the active SetPoint INPUT ALGORITHM 1 OUTPUT Represents the output from input algorithm 1 CO RANGE 4 08 4 20mA 0 20mA AUXILIARY CURRENT OUTPUT RANGE Allows the user to easily select 4 20mA output or 0 20mA output operation without the need for recalibration of the instrument ATTENTION Changing the Auxiliary Current Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values UDC3200 Universal Digital Controller Product Manual 79 Configuration 80 NONE TO MAN TO LSP TO 2SP TO 3SP TO DIR UDC3200 Universal Digital Controller Product Manual Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display LOW VAL Low Scale Value within AUXILIARY OUTPUT LOW SCALING FACTOR the range of the selected This is a value in engineering units used to variable to represent the represent all AUX OUT parameters except Output minimun output 0 or 4 Me mA For Output this is a value in percent and can be any value between 5 and 105 However keep in mind that
21. below 800 mVdc then the Dew Point is calculated as if the sensor voltage was at 800 mVdc MATH K 0 001 to 1000 floating WEIGHTED AVERAGE RATIO OR MASS FLOW ORIFICE CONSTANT K FOR MATH SELECTIONS Only applicable for algorithms W AVG or General Math selections VMuDIV MULT MuDIV or MULT CALC HI 999 To 9999 Floating in engineering units CALCULATED VARIABLE HIGH SCALING FACTOR FOR INPUT ALGORITHM 1 Used only when either Summer Input Hi Lo or one of the General Math functions was selected as the Input Algorithm See Note 2 CALC LO 999 To 9999 Floating in engineering units CALCULATED VARIABLE LOW SCALING FACTOR FOR INPUT ALGORITHM 1 Used only when either Summer Input Hi Lo or one of the General Math functions was selected as the Input Algorithm See Note 2 ALG1 INA INPUT 1 INPUT 2 OUTPUT ALGORITHM 1 INPUT A SELECTION will represent one of the available selections Input 1 Input 2 Output Should not be used for Three Position Step Control applications ALG1 INB INPUT 1 INPUT 2 OUTPUT ALGORITHM 1 INPUT B SELECTION will represent one of the available selections Input 1 Input 2 Output Should not be used for Three Position Step Control applications ALG1 INC NONE INPUT 1 INPUT 2 OUTPUT ALGORITHM 1 INPUT C SELECTION will represent one of the available selections None Input 1 Input 2 Output Should not be used
22. 00 BIAS IN2 0 FILTER 2 1 BURNOUT2 NONE EMMISIV2 0 00 NOTE 1 Model Number dependent 94 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Group Function Value or Factory Group Function Value or Factory Prompt Prompt Selection Setting Prompt Prompt Selection Setting CONTROL PV SOURC INPUT 1 ALARMS A1S1TYPE NONE PID SETS 1 ONLY A1S1 VAL 90 SW VALUE 0 00 A1S1 HL HIGH LSP S 1 ONLY A1S1 EV RSP SRC NONE A1S2TYPE NONE AUTOBIAS DISABLE A1S2 VAL 10 SP TRACK NONE A1S2HL LOW PWR MODE MANUAL A1S2 EV PWR OUT LAST A2S1TYPE NONE SP HiLIM 1000 A2S1 VAL 95 SP LoLIM 0 A2S1 HL HIGH ACTION REVERSE A2S1 EV OUT RATE DISABLE A2S2TYPE NONE PCT M UP 0 A2S2 VAL 5 PCT M DN 0 A2S2 HL LOW OUTHIiLIM 100 A2S2 EV OUTLoLIM 0 0 AL HYST 0 1 Hi LIM 100 0 ALM OUT1 NoLATCH Lo LIM 0 0 BLOCK DISABLE DROPOFF 0 DIAGNOST DISABLE DEADBAND 1 0 OUT HYST 0 5 FAILMODE NoLATCH FAILSAFE 0 0 MAN OUT 0 0 AUTO OUT 0 0 PBorGAIN GAIN MINorRPM MIN OPTIONS AUX OUT DISABLE DISPLAY DECIMAL NONE CO RANGE 4 20mA TEMPUNIT NONE LOW VAL 0 0 PWR FREQ 60 HZ HIGH VAL 100 0 RATIO 2 DISABLE DIG INP1 NONE LANGUAGE ENGLISH DIG1COMB DISABLE DIG INP2 NONE DIG2COMB DISABLE COM Com ADDR 3 Ethernet MAC Add gt ComSTATE DISABLE Accessible IP Address 10 0 0 2 IR ENABLE ENABLE via PIE Subnet Mask 225 225 225 0 BAUD 19200 Tool Default Gate 0 0 0 0 TX DELAY 1 To Email WS FLOAT FPB SMTP Add 0 0 0 0 SHEDENAB DI
23. 10 7 10 Table 10 18 lists all the register addresses and ranges or selections for the function parameters in Set up Group Communications Modbus Read Write and Override Parameters plus Exception Codes Communications Table 10 18 Set up Group Communications Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Shed Time 004F 79 INT R W 0 No Shed 1 255 sample periods Shed Modeand 00A2 162 INT R W 0 Last Mode and Last Output Cup 1 Manual Mode Last Output 2 Manual Mode Failsafe Output 3 Automatic Mode 00A3 163 INT R W 0 To Last Local Setpoint used Shed Setpoint Recall 1 CSP 005A Computer Setpoint Ratio Communication 004D Address Communications Type IR Port Enable OOF 1 Baud Rate Transmit Delay 004E Floating Point Byte Order Shed Time 009A Shed Enable OOEA 90 T1 FP R W 231 INT R W 20 00 to 20 00 FP R W Computer 005B 91 FP R W 999 to 9999 Setpoint Bias 1 99 0 None 1 Disable 2 RS 485 Modbus 3 Ethernet 0 Disable 1 Enable 0 4800 1 9600 2 19200 3 38400 Response Delay in ms 1 to 500 6ms 0 Big Endian 1 Big Endian Byte Swap 2 Little Endian 3 Little Endian Byte Swap 0 Enable 1 Disable 0 No Shed 1 255 sample periods Comm Data 00A
24. 163 164 165 166 167 168 169 170 171 174 174 174 177 177 179 183 187 187 188 188 189 190 190 191 192 194 Table 10 11 Table 10 12 Table 10 13 Table 10 14 Table 10 15 Table 10 16 Table 10 17 Table 10 18 Table 10 19 Table 10 20 Table 10 21 xi Set up Group Adaptive Tune Set up Group Algorithm Set up Group Output Set up Group Input 1 Set up Group Input 2 Set up Group Control Set up Group Options Set up Group Communications Set up Group Alarms Set up Group Display Modbus RTU Data Layer Status Exception Codes UDC3200 Universal Digital Controller Product Manual 197 198 201 203 206 209 212 215 216 218 220 4 08 Figures Figure 1 1 UDC3200 Operator Interface 5 Figure 1 2 Screen capture of Process Instrument Explorer running on a Pocket PC 7 Figure 1 3 Depiction of infrared communications 8 Figure 2 1 Model Number Interpretation 16 Figure 2 2 Mounting Dimensions not to scale 18 Figure 2 3 Mounting Methods 19 Figure 2 4 Composite Wiring Diagram 24 Figure 2 5 Mains Power Supply 25 Figure 2 6 Input 1 Connections 26 Figure 2 7 Input 2 Connections 27 Figure 2 8 Electromechanical Relay Output 28 Figure 2 9 Solid State Relay Output 29 Figure 2 10 Open Collector Output 30 Figure 2 11 Dual Electromechanical Relay Option Output 31 Figure 2 12 Current Output 31 Figure
25. 1900 Vdc for 2 seconds per Annex K of EN61010 1 Analog Inputs and Outputs Are isolated from each other and all other circuits at 850 Vdc for 2 seconds Digital Inputs and Digital Outputs Electrically isolated from all other circuits to withstand a HIPOT potential of 850 Vdc for 2 seconds per Annex K of EN61010 1 4 08 UDC3200 Universal Digital Controller Product Manual 13 Installation Specifications Relay Contacts With a working voltage of 115 230 Vac these are electrically isolated from all other circuits to withstand a HIPOT potential of 345 Vdc for 2 seconds per Annex K of EN61010 1 RS422 485 Modbus RTU Communications Interface Optional Baud Rate 4800 9600 19 200 or 38 400 baud selectable Data Format Floating point or integer Length of Link 2000 ft 600 m max with Belden 9271 Twinax Cable and 120 ohm termination resistors 4000 ft 1200 m max with Belden 8227 Twinax Cable and 100 ohm termination resistors Link Characteristics Two wire multi drop Modbus RTU protocol 15 drops maximum or up to 31 drops for shorter link length Ethernet TCP IP Communications Interface Optional Type 10Base T Length of Link 330 ft 100 m maximum Link Characteristics Four wire single drop five hops maximum IP Address IP Address is 10 0 0 2 as shipped from the Factory Recommended network configuration Use Switch rather than Hub in order to maximize UDC Ethernet performance Infrared Communi
26. 2 13 Position Proportional or Three Position Step Control Connections w o Dual Relay Option 32 Figure 2 14 Position Proportional or Three Position Step Control Connections with Dual Relay Option 32 Figure 2 15 RS 422 485 Communications Option Connections 33 Figure 2 16 Ethernet Communications Option Connections 33 Figure 2 17 Auxiliary Output and Digital Inputs Option Connections 34 Figure 2 18 Transmitter Power for 4 20 mA 2 wire Transmitter Using Open Collector Alarm 2 Output35 Figure 2 19 Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output 35 Figure 3 1 Mass Flow Example 58 Figure 4 1 Operator Interface 97 Figure 4 2 Functional Overview Block Diagram of the UDC3200 Controller 103 Figure 4 3 Ramp Soak Profile Example 128 Figure 4 4 Program Record Sheet 129 Figure 5 1 Input 1 and Input 2 Wiring Terminals 135 Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath 136 Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source 137 Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device 137 Figure 5 5 Wiring Connections for Radiamatic Thermocouple Differential Millivolts or Volts Except 0 to 10 Volts 138 Figure 5 6 Wiring Connections for 0 to 10 Volts 139 Figure 5 7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs 139 Figure 6 1 Wiring Connections for Calibrating Current Proportional Output 144 Figure 6 2 Wiring Conn
27. 4 08 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source Table 5 5 Voltage Milliamp and Resistance Equivalents for Input Range Values Equipment Needed Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath Set Up Wiring Procedure for RTD Inputs 133 135 136 137 137 Table 5 6 Set Up Wiring Procedure for Radiamatic Millivolts Volts or Thermocouple Differential Inputs Except 0 10 Volts Table 5 7 Table 5 8 Table 5 9 Input 1 or 2 Calibration Procedure Table 5 10 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 Table 7 7 Table 7 8 Table 7 9 Table 7 10 Table 7 11 Table 7 12 Table 7 13 Table 7 14 Table 7 15 Table 7 16 Table 8 1 Table 8 2 Table 8 3 Table 9 1 Table 9 2 Table 9 3 Table 9 4 Table 10 1 Table 10 2 Table 10 3 Table 10 4 Table 10 5 Table 10 6 Table 10 7 Table 10 8 Table 10 9 Table 10 1 4 08 Set Up Wiring Procedure for 0 to 10 Volts Set Up Wiring Procedure for Milliampere Inputs Restore Factory Calibration Set Up Wiring Procedure for Current Output Current Output Calibration Procedure Set Up Wiring Procedure for Auxiliary Output Auxiliary Output Calibration Procedure Position Proportional and Three Position Step Output Calibration Procedure Restore Factory Calibration Pro
28. 90 to normalize the equation Q sorm DP MINS 14 7 Tret gt e50 90 IN2 460 Pret Rearranging terms iis IN2 460 x 90 x Prof x 650 Example continued on next page Variable Constant K 22049 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Example Mass Flow Compensation continued Determined value of K K2 1 X Tref 600 90 0 14914 90 Pret 90 44 7 Therefore K 0 386 Qscru 0 386 650 DPI In H20 NS 147 IN2 460 Calc y Calc o Summary of Flow Values At Values Conditions Temp T Pressure T OMS OM eR psia DPf 45 H20 50 DP 90 H2O 100 Reference 4 08 UDC3200 Universal Digital Controller Product Manual 59 Configuration 3 8 Output Set Up Group Introduction This group deals with various output types in the controller the Digital Output Status and the Current Output operation ATTENTION The Tuning Group is automatically configured to have two PID sets when a Duplex Control Algorithm is selected Function Prompts Table 3 8 OUTPUT Group Function Prompts Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition OUT ALG 60 TIME CURRENT POSITON The OUTPUT ALGORITHM lets you select the type of output you want Not applicable with Control algorithm prompt 3PSTEP Selections are hardware dependent For exampl
29. ATTENTION Only appears when PID SETS selection is configured for either 2 PVSW or 2 SPSW LSP S 1 ONLY TWO THREE LOCAL SETPOINT SOURCE This selection determines what your local setpoint source will be LOCAL SETPOINT T he setpoint entered from the keyboard TWO LOCAL SETPOINTS This selection lets you switch between two local setpoints using the Fary key THREE LOCAL SETPOINTS This selection lets you switch between three local setpoints using the Sele dkey 72 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition RSP SRC NONE INPUT 2 IN ALG1 REMOTE SETPOINT SOURCE This selection determines what your remote setpoint source will be when toggled by the SP Select key or Digital Input NONE No remote setpoint INPUT 2 Remote Setpoint is Input 2 IN AL1 Remote Setpoint using Input 1 algorithm ATTENTION To cycle through the available local setpoints and remote setpoint press and hold in the REL key When the key is released the setpoint selection currently displayed will be the new setpoint selection AUTOBIAS DISABLE ENABLE AUTOBIAS is used for bumpless transfer when transferring from local setpoint to remote setpoint Auto Bias calculates and adds a bias to remote setpoint input e
30. Algorithm 1 00CC 204 INT R W 0 None 1 Weighted Average LSP f 2 Feedforward Input source selected via ID Summer t 205 206 207 3 Feedforward Multiplier y 4 Unused 5 Summer with ratio and bias f 6 Input High Select with ratio and bias f 7 Input low Select with ratio and bias f 8 General Math A sq rt mult div y 9 General Math B sq rt mult 10 General Math C mult div 11 General Math D mult y 12 Carbon A 13 Carbon B 14 Carbon C 15 Carbon D 16 Carbon FCC 17 Dewpoint 18 Oxygen 002D 045 FP R W 0001 to 1000 Calc High 001F 031 FP R W 999 0 to 9999 in Engineering Units Calc Low 0020 032 FP R W 999 0 to 9999 in Engineering Units PV Range Low 0036 054 FP RD 999 0 to 9999 in Engineering Units PV Range High 0037 055 FP RD 999 0 to 9999 in Engineering Units 4 08 UDC3200 Universal Digital Controller Product Manual 199 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Range or Description Address Enumerated Selection Hex Decimal Input Algorithm 1 0OCD 205 INT R W 0 Input 1 Input A Selection 1 Input 2 used with ID 204 2 Output math calculations Input Algorithm 1 00CE 206 INT RW 0 Input 1 Input B Selection 1 Input 2 used with ID 204 2 Output math calculations Input Algorithm 1 OOCF 207 INT
31. BAUD RATE is the transmission speed in bits per second This value is used for both RS 485 and IR Communications but for IR Communications values below 19200 baud are interpreted as being 19200 baud 4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD 84 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition TX DELAY 1 to 500 milliseconds TX DELAY Configurable response delay timer allows you to force the instrument to delay its response for a time period of from 1 to 500 milliseconds compatible with the host system hardware software WS FLOAT FP_B FP_BB FP_L FP_LB Defines word byte order of floating point data for communications Byte values 0 1 2 3 seeeecee emmmmmmm mmmmmmmm mmmmmmmm Where s sign e exponent m mantissa bit NUO O Ono ot WP ONOG SHED ENAB DISABLE ENABLE SHED ENABLE Disables enables shed functionaliy Applies to Modbus protocol only SHEDTIME 0 to 255 SHED TIME The number that represents how many sample periods there will be before the controller sheds from communications Each period equals 1 3 seconds 0 equals No shed Note If ComSTATE is set to MODBUS or MB3K and if SHEDENAB is set to DISABL Shed Time will not be configurable SHEDMODE LAST TO MAN FSAFE TO AUTO SHED CONTROLLER MODE AND O
32. C and derated linearly to 0 5 amps at 55 C Customer should size fuses accordingly Use Fast Blo fuses only 3 See Input 2 Wiring Diagram for Slidewire Connections Figure 2 13 Position Proportional or Three Position Step Control Connections models DC3200 EE or DC3200 AA Control Relay 2 Control Relay 1 D Alarm 2 is available with with this configuration D DC3200 R_ Dual Electromechanical relays are rated at 2 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only See Input 2 Wiring Diagram for Slidewire Connections Figure 2 14 Position Proportional or Three Position Step Control Connections model DC3200 R_ 32 UDC3200 Universal Digital Controller Product Manual 4 08 Installation COMMUNICATION MASTER D B SHLD D A 16 SHLD 17 D B 18 D A 120 OHMS Connect shield TO OTHER to ground at one COMMUNICATION CONTROLLERS end only D D 120 OHMS ON LAST LEG Do not run the communications lines in the same conduit as AC power Use shielded twisted pair cables Belden 9271 Twinax or equivalent Figure 2 15 RS 422 485 Communications Option Connections COMMUNIGTION MASTER OR SWITCH SHLD TXD TXD RXD RXD Do not run the communications lines in the same conduit as AC power Correct connections may require the use of an Ethernet cross over cable Use Shielded twisted p
33. Cool tuning without further operator intervention Table 4 11 Procedure for Using AUTOMATIC TUNE at Start up for Duplex Control sep Operation press mesa 1 Configure LSP1 Until SP Local Setpoint 1 shows in the lower display 2 Until LSP1 is a value within the Heat Zone output above 50 3 Configure LSP2 Until 2SP Local Setpoint 2 shows in the lower display 4 Until LSP2 is a value within the Cool Zone output below 50 5 Switch to Until the A indicator is lighted on Automatic Mode controllers with Manual option 6 Show Tuning Until TUNE OFF is shown on Prompt lower display 7 Initiate Tuning Select DO SLOW or DO FAST in lower display Upper display will show a T as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NO TUNE prompt Tuning in operation 112 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 10 4 Using BLENDED TUNE at start up for Duplex Heat Cool When DUPLEX has been configured for DISABLE This is the preferred selection for Heat Cool applications which use a highly insulated chamber a chamber which will lose heat very slowly unless a cooling device is applied Only one local setpoint LSP 1 is needed for this selection This selection results in performance tuning over the full range utilizing both Heat and Cool outputs
34. Decimal Gain 1 or PB 0001 001 FP R W 0 01 to 1000 Gain Note 1 0 1 to 1000 PB Rate 1 0002 002 FP R W 0 00 to 10 00 Note 1 Reset 1 0003 003 FP R W 0 02 to 50 00 Note 1 000D 013 FP R W 100 to 100 Gain 2 or PB 2 0004 004 FP R W 0 01 to 1000 Gain Note 1 0 1 to 1000 PB Rate 2 0005 005 FP R W 0 00 to 10 00 Note 1 Reset 2 0006 006 FP R W 0 02 to 50 00 Note 1 Cycle Time 1 0015 21 INT R W 1 to 120 seconds Cycle Time 2 0016 22 INT R W 1 to 120 seconds 192 UDC3200 Universal Digital Controller Product Manual 4 08 Parameter Description Lockout keyboard only Changes to data are always possible via communications regardless of this configuration Security Code Man Auto Key Lockout Run Hold Key Lockout Setpoint Key Lockout Modbus Read Write and Override Parameters plus Exception Codes Register Address Hex Decimal Data Range or Enumerated Selection 0084 132 INT R W 0 No Lockout 1 Calibration Locked out 2 Configuration Timer Tuning SP Ramp Accutune are read write 3 View Tuning and SP Ramp are read write no other parameters are available 4 Maximum Lockout 0050 080 INT R W 0 to 9999 OOBF 191 INT R W 0 Disable 1 Enable OOEE 238 INT R W 0 Disable 1 Enable 00ED 237 INT R W 0 Disable 1 Enable NOTE 1 Writes to these locations
35. F For higher temperatures the RH specification is derated to maintain constant moisture content 14 UDC3200 Universal Digital Controller Product Manual 4 08 Installation 2 3 Model Number Interpretation Introduction Write your controller s model number in the spaces provided below and circle the corresponding items in each table This information will also be useful when you wire your controller Instructions Select the desired key number The arrow to the right marks the selection available Make the desired selections from Tables through VI using the column below the proper arrow A dot denotes availability Key Number i T I Hl _ Iv i Vv ry KEY NUMBER UDC3200 Single Loop Controller Description Selection Availability Digital Controller for use with 90 to 264Vac Power DC3200 y Digital Controller for use with 24Vac dc Power Ea ES TABLE Specify Control Output and or Alarms Current Output 4 to 20ma 0 to 20 ma Electro Mechanical Relay 5 Amp Form C Output 1 Solid State Relay 1 Amp Open Collector transistor output Dual 2 Amp Relays Both are Form A Heat Cool Applications No Additional Outputs or Alarms One Alarm Relay Only E M Relay 5 Amp Form C Plus Alarm 1 5 Amp Form C Relay Solid State Relay 1 Amp Plus Alarm 1 5 Amp Form C Relay Open Collector Plus Alarm 1 5 Amp Form C Relay Output 2 and Alarm 1 or Alarms 1 and 2 TABLE Il Communications and Software Selecti
36. Honeywell S p A Phone 39 02 92146 307 395 FAX 39 0292146377 The Netherlands Honeywell B V Phone 31 0 20 5656200 FAX 31 0 20 5656210 Norway Honeywell A S Phone 45 39 55 55 55 Poland Honeywell Sp zo o Phone 48 22 6060900 FAX 48 22 6060901 Portugal Honeywell Portugal Lda Phone 351 21 424 5000 FAX 351 21 424 50 99 Romania Honeywell Bucharest Phone 40 0 21 2316437 FAX 40 0 21 2316439 Russian Federation RF ZAO Honeywell Phone 7 095 796 98 00 FAX 7 495 797 99 64 Slovak Republic Honeywell s r o Phone 421 2 58247 410 FAX 421 2 58247 415 Spain Honeywell S A Phone 34 0 91313 61 00 FAX 34 0 91313 61 30 Sweden Honeywell AB Phone 46 8 775 55 00 FAX 46 8 775 56 00 Switzerland Honeywell AG Phone 41 18552448 FAX 41 1 855 24 45 Turkey Honeywell Turkey A S Phone 90 216 578 71 00 FAX 90 216 575 66 35 Ukraine Honeywell Tel 380 44 201 44 74 Fax 380 44 201 44 75 United Kingdom Honeywell Control Systems Ltd Phone 44 0 1344 655251 FAX 44 0 1344 655554 MIDDLE EAST Abu Dhabi U AE Middle East Headquarters Honeywell Middle East Ltd Phone 971 2 4041246 FAX 971 2 4432536 Sultanate of Oman Honeywell amp Co Oman LLC Phone 968 24 701153 Ext 33 FAX 968 24 787351 Saudia Arabia Honeywell Turki Arabia Ltd Jubail Office Phone 966 3 341 0140 Fax 966 3 341 0216 Honeywell ATCO Dammam
37. Instrumentation in Severe Electrical Noise Environments 222 13 ONDEX iinei iaaa aoaaa raaa eaea a a aaa aa aa aaaea aaa aaa a eaeh anaana Ra 223 14 SALES AND SERVICE ccoooocccccnnccnnncnononananannnnnnnonennnnnnnnnnnnnnnnnrnennnannnnnnncnnnnnnnnns 227 4 08 UDC3200 Universal Digital Controller Product Manual viii Tables Table 2 1 Condensed Specifications Table 2 2 Control Relay Contact Information Table 2 3 Alarm Relay Contact Information Table 2 4 Mounting Procedure Table 2 5 Permissible Wiring Bundling Table 2 6 Universal Output Functionality and Restrictions Table 2 7 Terminals for connecting a UDC to a MDI Compliant Hub or Switch Table 2 8 Terminals for connecting a UDC directly to a PC utilizing a straight through cable Table 3 1 Configuration Topics Table 3 2 Configuration Prompt Hierarchy Table 3 3 Configuration Procedure Table 3 4 TUNING Group Function Prompts Table 3 5 SPRAMP Group Function Prompts Table 3 6 ACCUTUNE Group Function Prompts Table 3 7 ALGORTHM Group Function Prompts Table 3 8 OUTPUT Group Function Prompts Table 3 9 INPUT 1 Group Function Prompts Table 3 10 INPUT 2 Group Function Prompts Table 3 11 CONTROL Group Function Prompts Table 3 12 OPTION Group Function Prompts Table 3 13 Communications Group Function Prompts Table 3 14 ALARMS Group Function Prompts Table 3 15 DISPLAY Group Function P
38. KEYRESET TOBEGIN KEYRESET RERUN HOTSTART 126 Table 4 24 Program Contents Associated Contents Definition Prompts Start segment number End segment number Recycle number Program state Program termination state Reset Program to Beginning Rerun current segment Hot Start The start segment number designates the number of the first segment Range 1 to 11 The end segment number designates the number of the last segment it must be a soak segment even number Range 2to12 The recycle number allows the program to recycle a specified number of times from beginning to end Range 0 to 99 The program state selection determines the program state after completion The selections are e DISABLE program is disabled so program value changed to DISABLE e HOLD program on hold The program termination state function determines the status of the controller upon completion of the program The selections are e LAST controls to last setpoint e FAILSAFE manual mode and failsafe output When enabled this selection allows you to reset the program via the keyboard to the beginning of the program When enabled this selection allows you to reset the program via the keyboard to the beginning of the current segment This function determines whether LSP1 or PV is used as the setpoint when the program is initially changed from HOLD to RUN The selections are DISABLE When the program
39. Operation Burnout Selections Upscale Downscale Failsafe or None Thermocouple Health Good Failing Failure Imminent or Failed Failsafe Output Level Configurable 0 100 of Output range Stray Rejection Common Mode AC 50 or 60 Hz 120 dB with maximum source impedance of 100 ohms or 1 LSB least significant bit whichever is greater with line voltage applied DC 120 dB with maximum source impedance of 100 ohms or a 1 LSB whichever is greater with 120 Vdc applied DC to 1 KHz 80 dB with maximum source of impedance of 100 ohms or 1 LSB whichever is greater with 50 Vac applied Normal Mode AC 50 or 60 Hz 60 dB with 100 span peak to peak maximum Digital Inputs Two 30 Vdc source for external dry contacts or isolated solid state contacts Digital Inputs are Optional isolated from line power earth ground analog inputs and all outputs except for the Second Current Output The second Digital Input is mutually exclusive with the Second Current Output 12 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Specifications Controller Output Types Electromechanical Relays One or Two SPDT contacts Both Normally Open and Normally Closed contacts are brought out to the rear terminals Internally socketed Resistive Load 5 amps 120 Vac or 240 Vac or 30 Vdc Inductive Load coso 0 4 3 amps O 130 Vac or 250 Vac Inductive Load L R 7 msec 3 5 amps O 30
40. Outputs can be easily configured via the keyboard for either direct or reverse action and for either 0 to 20 mA or 4 to 20 mA without field calibration Both current outputs can be used in an Auxiliary Output mode This Auxiliary Output can be configured to represent Input PV Setpoint Deviation or Control output The range of an Auxiliary Output can be scaled per the range of the selected variable and can be set anywhere between 0 to 21 mA The Second Current Output is mutually exclusive with the second Digital Input Resolution 14 bits over 0 to 21 mA Accuracy 0 05 of full scale Temperature Stability 0 01 F S C Load Resistance 0 to 1000 ohms Alarm Outputs Optional One SPDT Electromechanical relay A second alarm is available if the second control relay is not used for control purposes or when the Dual Relay Option is used Up to four setpoints are independently set as high or low alarm two for each relay Setpoint can be on any Input Process Variable Deviation Manual Mode Failsafe PV Rate RSP Mode Communication Shed or Output A single adjustable hysteresis of 0 0 to 100 0 is provided The alarm can also be set as an ON or OFF event at the beginning of a Setpoint ramp soak segment Alarm Relay Contacts Rating Resistive Load 5 amps at 120 Vac or 240 Vac or 30 Vdc Isolation Functional AC Power Electrically isolated from all other inputs and outputs and earth ground to withstand a HIPOT potential of
41. TIME D TIME DUPLEX T his output algorithm uses Digital Outputs 1 and 2 for Duplex Time Proportional Control The outputs are updated per the Loop sampling rate selection Time Proportional Output has a resolution of 4 44 msec Cycle Time is adjustable from 1 second to 120 seconds CURD CUR TI TI CUR CURRENT DUPLEX is similar to current simplex but uses a second current output The second output is usually scaled so that zero and span correspond with 0 and 50 output cool zone When the output is 0 to 50 the controller uses tuning parameter set 2 when the output is 50 to 100 it uses set 1 ATTENTION Other prompts affected OUT RNG CURRENT TIME DUPLEX is a variation of duplex with current active for 0 to 50 output tuning set 2 and time is active 50 to 100 output tuning set 1 Relay controls heat current controls cool ATTENTION Other prompts affected OUT RNG TIME CURRENT DUPLEX is similar to CUR TI except that current is active for 50 to 100 and time is active for 0 to 50 Relay controls cool current controls heat ATTENTION Other prompts affected OUT RNG OUT RNG 4 08 50 PCT CURRENT DUPLEX RANGE ALGORITHM Used with Output Algorithm selections CUR D CUR TI or TI CUR CURRENT DUPLEX RANGE SPLIT This setting should be used for Relay Current and Current Relay Duplex Outputs It can also be used for Current D
42. Type 1 NOT SUPPORTED 16 bit Unsigned Integer 2 Attribute NOT SUPPORTED 1 Read Only 2 Read Write Value 16 bit integer Read Write EAST 4 _ NotUsed NOTSUPPORTED Low Range 16 bit integer NOT SUPPORTED 3 3 6 NotUsed NOTSUPPORTED 7 High Range 16 bit Integer NOT SUPPORTED 8 NotUsed NOTSUPPORTED 9to13 Description Text ASCII string NOT SUPPORTED Table 9 2 Floating Point Parameter Type Register Numbers Dec Type 2 NOT SUPPORTED Type 2 NOT SUPPORTED IEEE Floating Point Attribute NOT SUPPORTED 1 Read Only 2 Read Write Value float high word Read Write pO Low Range float high word NOT SUPPORTED __ Low Range float low word NOT SUPPORTED _ High Range float high word NOT SUPPORTED ______ High Range float low word NOT SUPPORTED __ IO Value float low word NOT SUPPORTED 9 to 13 Description Text ASCII string NOT SUPPORTED Register Count The register count depends on the data format of the registers being read or written Integer data is represented in sixteen bits and is transferred high byte first Floating point data is transferred in IEEE 32 bit format The register count definitions are 0001 Integer Data 0002 Floating Point Data 4 08 UDC3200 Universal Digital Controller Product Manual 177 Modbus RTU Function Codes 9 3 Function Code 20 14h Read Configuration Reference D
43. Up group Sequentially displays the other function prompts of the Set Up group you have selected Stop at the function prompt that you want to change then proceed to the next step 4 Change the ALorw Increments or decrements the value or selection that appears for Value or the selected function prompt If you change the value or selection Selection of a parameter while in Set Up mode but then decide not to enter it press the MAN AUTO key once This will recall the original configuration This recall procedure does not work for a Field Calibration process Field Calibration is a one way operation Enters value or selection made into memory after another key is pressed 5 Enter the Value or Selection Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode It stores any changes you have made If you do not press any keys for 30 seconds the controller times out and reverts to the mode and associated display used prior to entry into Set Up mode 6 Exit Configuration 4 08 UDC3200 Universal Digital Controller Product Manual 39 Configuration 3 4 Tuning Set Up Group Introduction Tuning consists of establishing the appropriate values for the tuning constants you are using so that your controller responds correctly to changes in process variable and setpoint You can start with predetermined values but you will have to watch the system to see how to modif
44. Upper RESTORE Lower 5 Press the 4 key The instrument will now display CONFIG Upper RESTORE Lower 6 Press the Function Key The instrument will now display DOIN RESTORE 7 When the instrument finishes the restore operation it automatically resets itself and restarts in the product mode The instrument configuration will now be the same as it was when the instrument left the factory and all user entered configurations since that time have been overwritten UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service 7 9 Software Upgrades Introduction This procedure enables software features that were not ordered from the factory See Table 8 3 for a list of the available Software Upgrades ATTENTION This procedure cannot be undone it is a one way process Each instrument has a unique code number sequence so the following procedure must be performed on each instrument to be upgraded Table 7 16 explains how to enable new software features Table 7 16 Software Upgrades Step What to do 1 Turn off the power to the instrument for at least five seconds 2 Turn the power back on and simultaneously press the FUNCTION and 4 keys This must be done while TEST DONE is being displayed 3 If step 2 was performed correctly the instrument will now display UDC Upper UPDATE Lower 4 Press the Function Key The instrument will no
45. Vdc Motor 1 6 H P Dual Electromechanical Relays Two SPST relays One Normally Closed contact for each relay is brought out to the rear terminals This option takes the place of one of the above electromechanical relays and is especially useful for Time Duplex or Three Position Step Control or Position Proportional Control applications Instruments with this option can have a total of 4 relays plus one current output Internally socketed Resistive Load 2 amps 120 Vac 240 Vac or 30 Vdc Inductive Load coso 0 4 1 amp 130 Vac or 250 Vac Inductive Load L R 7 msec 1 amp 30 Vdc Solid State Relays One or Two Zero crossing type SPST solid state contacts consisting of a triac N O output Internally socketed Resistive Load 1 0 amp 25 C and 120 or 240 Vac 0 5 amp 55 C and 120 or 240 Vac Inductive Load 50 VA 120 Vac or 240 Vac Minimum Load 20 milliamps Open Collector Outputs One or Two Socketed assembly replacing a relay Opto isolated from all other circuits except current output and not from each other Internally powered 30 Vdc Note Applying an external power supply to this output will damage the instrument Maximum Sink Current 20 mA Short circuit current limit 100 mA Current Outputs One or Two These outputs provide a 21 mA dc maximum into a negative or positive grounded load or into a non grounded load Current outputs are isolated from each other line power earth ground and all inputs
46. all inputs but can only be configured for linear or square root transmitter characterization See the example in IN1 HI RATIO 2 20 00 to 20 00 RATIO ON INPUT 2 Select the Ratio value you Floats to 3 decimal places want on Input 1 BIAS IN2 999 to 9999 BIAS ON INPUT 2 Bias is used to compensate in engineering units the input for drift of an input value due to deterioration of a sensor or some other cause Select the bias value you want on Input 1 FILTER 2 0 to 120 seconds FILTER FOR INPUT 2 A software digital filter is No filter 0 provided for Input 1 to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter 0 BURNOUT BURNOUT PROTECTION SENSOR BREAK provides most input types with upscale or downscale protection if the input fails NONE NO BURNOUT f Input 2 is being used in the 4 08 Control Algorithm such as the PV or RSP input parameter then the pre configured Failsafe output selected in the CONTROL Set up Group is applied when a failed input is detected does not apply for an input out of range Diagnostic message IN2 FAIL is intermittently flashed on the lower display UDC3200 Universal Digital Controller Product Manual 69 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition UP DOWN NO FS UPSCALE BURNOUT will force the Input 2 si
47. are not available when Accutune is enabled 4 08 UDC3200 Universal Digital Controller Product Manual 193 Modbus Read Write and Override Parameters plus Exception Codes 10 7 2 SP Ramp Rate Program Table 10 10 lists all the register addresses and ranges or selections for the function parameters in Set up Group Setpoint Ramp Rate Table 10 10 Set up Group Setpoint Ramp Rate Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal SP Ramp 0096 150 INT IRW 0 Disabled 1 Enabled Single SP Ramp 0019 25 FP R W 0 to 255 minutes Time Final Ramp SP 001A 026 FP R W PV Range in Engineering Value Units SP Rate OOFO 240 0 Disabled 1 Enabled Rate Up EU HR 006C lt R W 0 to 9999 Rate Down 006D 109 R W 0 to 9999 EU HR Setpoint 00B2 178 0 Disabled Program 1 Enabled Senseo CA CC rw End Segment 00BO 0 Soak 2 Soak 1 Soak 4 2 Soak 6 3 Soak 8 4 Soak 10 5 Soak 12 Engineering Units 0OB6 182 INT R W 0 HRS MIN or Ramp 1 Degrees Minute Segments 2 EU Hour Program Recycles 0059 89 FP R W 0 to 100 Guaranteed Soak 0057 087 FP R W 0 to 99 9 0 no soak Deviation Program End 00B5 181 INT R W 0 Disable SP Program State 1 Hold at Program End 194 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write a
48. configuration the Input 2 low range and the Sooting diagnostic messages are disabled 4 08 UDC3200 Universal Digital Controller Product Manual 57 Configuration 58 Figure 3 1 Mass Flow Example Example Mass Flow Compensation A gas flow rate of 650 SCFM develops a differential pressure of 90 H O across an orifice plate at reference conditions of 30 psig and 140 F Compensate this gas flow for temperature and pressure variations Where Flow K DP x Pi Tret f flowing conditions s Tt Pret ref reference conditions in absolute units Apply Multiplier Divider Algorithm Input A x Ratio A BiasA x Input C x Ratio c Bias py k MP n P c X Calc HI Calc Lo Input B x Ratio B Bias B Assign inputs using Engineering units Let Input A DP IN1 in H 20 Input B T IN2 Bias2 IN2 F 460 eR Input C P IN3 Bias3 IN3psig 14 7 psia Tref 140 F 460 600 R Prot 30 psig 14 7 44 7 psia Cale h 680 0 gt Flow in SFCM at Reference Conditions Calc 0 0 K to be determined next Note If temperature and pressure signals are already ranged in absolute units no Bias is required for inputs B and C PV Qsorm DP x N3 147 2 E e K IN2 460 A Note When IN2 and IN3 are at the reference conditions of 600 R 140 F and 44 7psia 30 psig respectively and DP 90 H O the equation must calculate 650 SCFM To accomplish this divide the DP value by
49. due to a communication error No response is returned The master program will eventually process a time out condition for the query e Slave receives the query but detects a communication error parity LRC or CRC No response is returned The master program will eventually process a time out condition for the query e Slave receives the query without a communication error but cannot handle it i e request is to a non existent coil or register The slave will return with an exception response informing the master of the nature of the error Illegal Data Address The exception response message has two fields that differentiate it from a normal response Function Code Field In a normal response the slave echoes the function code of the original query in the function code field of the response All function codes have a most significant bit MSB of 0 their values are below 80 hex In an exception response the slave sets the MSB of the function code to 1 This makes the function code value in an exception response exactly 80 hex higher than the value would be for a normal response With the function code s MSB set the master s application program can recognize the exception response and can examine the data field for the exception code Data Field In a normal response the slave may return data or statistics in the data field In an exception response the slave returns an exception code in the data field This defines the
50. field calibration will be lost if a change in input type configuration is implemented at a later time The original factory calibration data remains available for later use after a field calibration is done See subsection 5 6 if you want to restore factory calibration values What s in this section The following topics are covered in this section 5 1 Overview 132 5 2 Minimum and Maximum Range Values 133 5 3 Preliminary Information 135 5 4 Input 1 or 2 Set Up Wiring 136 5 5 Input 1 or 2 Calibration Procedure 140 5 6 Restore Factory Calibration 141 132 UDC3200 Universal Digital Controller Product Manual 4 08 Input Calibration Calibration Steps Use the following steps when calibrating an input 1 Find the minimum and maximum range values for your PV input range from Table 5 1 2 Disconnect the field wiring and find out what equipment you will need to calibrate 3 Wire the calibrating device to your controller according to the set up wiring instructions for your particular input Subsection 5 4 4 Follow the calibration procedure given for Input 1 or Input 2 Subsection 5 5 5 2 Minimum and Maximum Range Values Select the Range Values Calibrate the controller for the minimum 0 and maximum 100 range values of your particular input type Two input controllers will need to have each input calibrated separately Select the Voltage Current or Resistance equivalents for 0 and 100 range values from Table 5 1
51. forces the setpoint to the current PV value Opening the contact has no effect OUTPUT TRACKS INPUT 2 Contact closure allows Output to track Input 2 While the switch is open the output is in accordance with its pre defined functionality When the switch is closed the output value in percent will track the Input 2 percent of range value When the switch is reopened the output will start at this last output value and normal PID action will then take over control The transfer is bumpless TO REMOTE SETPOINT Contact closure selects the Remote setpoint EXTERNAL RESET FEEDBACK Contact closure allows Input 2 to override the internal reset value TO PURGE Cortact closure forces the loop to Manual mode with the output set to the Output High Limit configuration MAN lights and the Output value is shown on the lower display Opening the switch has no effect ATTENTION Does not apply to Three Position Step Control UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition Lo FIRE MAN LAT PV Hold LOW FIRE Contact closure forces the loop to Manual mode with the output set to the Output Low Limit configuration MAN lights and the Output value is shown on the lower display Opening the switch has no effect ATTENTION Step Control Does not apply to Three Position
52. is NO RATE applies See Subsection 3 5 Configuration group SPRAMP for details Operation When a change to local setpoint is made this controller will ramp from the original setpoint to the target setpoint at the rate specified The current setpoint value is shown as SPn XXXX on the lower display while the target setpoint is shown as SP XXXX on the lower display Power outages If power is lost before the target setpoint is reached upon power recovery the controller powers up with Sn Current PV value and it automatically Restarts from Sn current PV value up to the original target setpoint 4 19Setpoint Ramp Introduction When you have configured a SETPOINT RAMP the ramp will occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes You can RUN or HOLD the ramp at any time Configuration Check Make sure e SPRAMP is enabled e SP RATE and SPPROG are not running 4 08 UDC3200 Universal Digital Controller Product Manual 123 Monitoring and Operating the Controller e A Ramp Time TIMIN in minutes has been configured e A final setpoint value FINLSP has been configured See Subsection 3 5 Configuration group SPRAMP for details Operation Running a Setpoint Ramp includes starting holding viewing the ramp ending the ramp and disabling it See Table 4 23 Table 4 23 Running A Setpoint Ramp step Operation
53. is CLOSE The Output 1 2 option Single Relay can be any of the following selections Electro Mechanical Relay Solid State Relay or Open Collector Output UDC3200 Universal Digital Controller Product Manual 4 08 Installation Table 2 6 Universal Output Functionality and Restrictions Output Algorithm Output 1 2 Function of Output 1 2 Output 3 Output 4_ Auxiliary Output _ Time Simplex Single Relay Current Output Dual Relay Time Duplex or PROC or Position Current Output 2 Current Simplex Current Dup 100 Single Relay NU Alarm2 Alarm Outputs 1 and Current COOL Current Output Sas 1 and Alarm 2 Alarm 1 Not Needed and HEAT Dual Relay Current Duplex ae A T a a 50 Aux Out COOL Current Time Current COOL Time HEAT Time Current Time COOL Current HEAT TPSC Three Position Step Control N A Not Available This output algorithm type cannot be performed with this Output 1 2 option INU Installed Not Used The installed Output 1 2 option is not used for the configured output algorithm type Not Needed Auxiliary Output is Not Needed to provide the desired output algorithm and can be used for another purpose With the proper configuration Auxiliary Output could also be used as a substitute for the Current Output To obtain this output algorithm type with these Output 1 2 Options 1 Configure the OUTALG selection as TIME D 2 Configure Auxiliary Output fo
54. is initially changed from HOLD to RUN the present LSP1 value is captured as the default setpoint If the program is terminated or the power cycled before the program has completed the LSP1 is used as the control setpoint The beginning segment uses this value as the initial ramp setpoint ENABLE When the program is initially changed from HOLD to RUN the present PV value is captured and used as the beginning setpoint value for the ramp segment If the program is terminated before completion the setpoint value will revert back to the PV value captured at the initial HOLD to RUN transition If the power is cycled before program completion upon power up the setpoint is set to UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Associated Contents Definition Prompts the PV value at power up and when the program is restarted that setpoint value is used initially RAMPUNIT Ramp time or A ramp segment is the time it will take to change the setpoint h i lue in th SEGxRAMP or rate segments to the next setpoint value in the program SEGXRATE Ramps are odd number segments 1 3 11 Segment 1 will be the initial ramp time Ramp time is determined in either TIME Hours Minutes Range 0 99hr 59 min or RATE EU MIN or EU HR Range 0 to 999 This selection of time or rate is made at prompt RAMPUNIT Set this prompt before entering any Ramp values ATTENTION En
55. lle Load oo Relay Load Power ES Toa Tna Supply O Alarm 2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay Option is used O Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 8 Electromechanical Relay Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 28 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Time Simplex Dummy Resistor Output Relay 1 o aly Power Load _2 Supply Power E ad Le il Load _ Supply Power Ra aad eae Time Duplex Load Supply Power Load y Supply Power Eg EA N C Alarm Relay 1 Load o Relay Load Supply To terminal Power e aid 7 or9 O If the load current is less than the minimum rated value of 20 mA then there may be residual voltage across both ends of the load even if the relay is turned off Use a dummy resistor as shown to counteract this The total current through the resistor and the the load must exceed 20 mA Solid State Relays are zero crossing type O Solid State relays are rated at 1 Amp at 25 C and derated linearly to 0 5 Amp at 55 C Customer should size fuse accordingly Use Fast Blo fuses only E Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordin
56. operate at the setpoint set here when ramp is ended ATTENTION If the ramp is on HOLD the held setpoint can be changed by the a and v keys However the ramp time remaining and original ramp rate is not changed Therefore when returning to RUN mode the setpoint will ramp at the same rate as previous to the local setpoint change and will stop if the final setpoint is reached before the time expires If the time expires before the final setpoint is reached it will jump to the final setpoint ATTENTION SP RAMP and SP RATE will cause the SP portion of Accutune to abort PV Tune will continue to function normally Ramp is placed into HOLD while tuning TUNE configuration HOTSTART SP RATE SP Rate operates only when both SP Ramp and SP Programing are in HOLD mode or when both SP Ramp and SP Programming are disabled DISABLE ENABLE DISABLE ENABLE DISABLE LSP1 is used as the initial ramp setpoint ENABLE Current PV value is used as the initial ramp setpoint SETPOINT RATE Lets you configure a specific rate of change for any local setpoint change DISABLE SETPOINT RATE Disables the setpoint rate option ENABLE SETPOINT RATE Allows the SP rate feature EU HR UP 0 to 9999 in engineering units per hour RATE UP Rate up value When making a setpoint change this is the rate at which the controller will change from the original setpoint up to the new one The ramping cur
57. repeat steps 1 to 6 Press the FUNCTION Key The instrument will now display XXXX ENTER1 where XXXX is a unique code number for this particular instrument Using the 4 and w keys enter the new Code 1 number Press the FUNCTION Key The instrument will now display XXXX ENTER2 Using the 4 and W keys enter the new Code 2 number Press the FUNCTION Key The instrument will now display XXXX ENTER3 Using the 4 and W keys enter the new Code 3 number Press the FUNCTION Key The instrument will process the new code numbers and add the new software feature If the code numbers were entered incorrectly or if the wrong code numbers for this particular instrument were entered then the controller will go into Manual Mode and flash the message FAILSAFE on the lower display Check the code numbers being entered and repeat steps 12 through 16 When the instrument finishes the operation it automatically resets itself and restarts in the product mode The instrument configuration now includes the added software feature s UDC3200 Universal Digital Controller Product Manual 4 08 Parts List 8 Parts List 8 1 Exploded View Introduction Figure 8 1 is an exploded view of the UDC3200 Controller Each part is labeled with a key number The part numbers are listed by key number in Table 8 1 Parts not shown are listed in Table 8 2 Figure 8 1 UDC3200 Exploded View 4 08 UD
58. sure the NO or NC contact wiring is correct Refer to Section 2 Installation for relay contact information 4 Change the relay and or the Installation instructions supplied with the current output board new relay or board 5 Change MCU board Installation instructions supplied with the new board 4 08 UDC3200 Universal Digital Controller Product Manual 165 Troubleshooting Service Procedure 7 Table 7 11 explains how to troubleshoot a Keyboard failure Table 7 11 Troubleshooting a Keyboard Failure Step What to do How to do it 1 4 Make sure the keyboard is connected properly to the MCU output and power input boards Controller Keyboard or specific keys may be LOCKED OUT via the security code Run the keyboard test Replace the display keyboard if any keys do not function Withdraw the chassis from the case and visually inspect the connection Use your four digit security code number to change the lockout level Refer to Section 3 Configuration Press the SET UP key and hold in then press the FUNCTION key at the same time The controller will run a display test Then you will see Upper Display KEYS Lower Display TRY ALL Press each key If it works the key name will appear in the lower display Refer to Parts Replacement Procedures in this section 166 UDC3200 Universal Digital Controller Product Manual 4 08 Procedure 8 4 08 Tr
59. that output to the other setting and then changing it back to the original type Refer to Table 6 6 Restore Factory Calibration for procedure ATTENTION A restored factory calibration overwrites any previous field calibration done for the output Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See Section 3 Configuration for specific instructions to set the lockout Table 6 6 Restore Factory Calibration step operaion Pes a 1 Set LOCKOUT to ae until you see NONE NA Upper Display SET UP Lower Display TUNING p7 N Until you see En Upper Display one of the following NONE all parameters are read write CALIB all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted VIEW Tuning and Setpoint Ramp parameters are read write No other parameters can be viewed ALL Tuning and Setpoint Ramp parameters are available for read only No other parameters can be viewed Lower Display LOCKOUT Axor Until NONE is in the upper display 2 Enter OUTPUT i until you see or OPTIONS N J Upper Display SET UP Setup Group Lower Display OUTPUT for the Current Output or sa Lower Display OPTIONS for the Auxiliary Output Function until you see Ne Upper Display the current selection Lower Display CO RANGE Mor ww to change the range configuration to the other se
60. the controller The identifying register addresses listed in Table 10 5 allow you to select which setpoint you want to use and to enter a value in Engineering Units whichever is selected at register address 00A1 for that setpoint via communications Register Addresses Make your selection using register address OOAD and enter the value for the setpoint chosen using register address in Table 10 5 Table 10 5 Setpoint Code Selections Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Local Setpoint 1 0027 039 FP R W Value within the setpoint range limits Local Setpoint 2 0035 053 FP R W Value within the setpoint range limits Local Setpoint 3 0074 116 FP R W Value within the setpoint range limits Number of Local OOAD 173 INT R W 00 Local Setpoint 1 Setpoints only 01 2nd Local Setpoint via keyboard or communications 03 3rd Local Setpoint via keyboard or communications 4 08 UDC3200 Universal Digital Controller Product Manual 189 Modbus Read Write and Override Parameters plus Exception Codes Associated Parameters Refer to Table 10 6 to display or change any of the parameters associated with the setpoint Table 10 6 Setpoint Associated Parameters Parameter Register Address O m a Setpoint Limits 0007 0008 007 008 Computer Setpoint 007D 125 10 6 Using a Computer Setpoint Overriding Contro
61. the tag ID configuration number For Infrared Transactions add three BOFs COhex at the beginning of each message and one EOF Ffhex at the end of each message Reference Type Definitions The Reference Type definition is always 06 See examples in Subsection 9 4 1 182 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus RTU Function Codes File Number The file number word contains the register number from the register address structure shown in Table 9 1 and Table 9 2 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address is used to designate the tag ID number for the parameter being accessed The register address is made up of two bytes the MSB 00 always The LSB contains the RS422 tag ID number The tag ID numbers represent the parameter s register address es See Section 10 for the tag ID numbers Table 9 4 Register Address Format for Function Code 21 Register Register Address es Address es Dec Hex 001 to 125 0001 to 007D analog formatted data 2 registers IEEE 32 bit floating point 128 to 215 0080 to 00D7 integer formatted data amp 255 amp OOFF 2 registers IEEE 32 bit floating point Unrestricted Registers As mentioned previously all register data is stored in the EEROM of this instrument with some exceptions These exceptions were
62. to a different troubleshooting procedure If the symptom still persists refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system 7 7 Troubleshooting Procedures Introduction The troubleshooting procedures are listed in numerical order as they appear in Table 7 4 Each procedure lists what to do if you have that particular failure and how to do it or where to find the data needed to accomplish the task A WARNING SHOCK HAZARD TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE SERVICING Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow e Multimeter Capable of measuring millivolts milliamps and resistance e Calibration sources T C mV Volt etc 160 UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service Procedure 1 Table 7 5 explains how to troubleshoot power failure symptoms Table 7 5 Troubleshooting Power Failure Symptoms Step What to do How to do it 1 Check the AC line voltage Use a voltmeter to measure the AC voltage across terminals L1 and L2 on the rear terminal panel of the controller Check the earth ground connection 2 Make sure the chassis plugs Withdraw the chassis and visua
63. to acquire blended tune values that are then applied to both Heat and Cool tuning parameters Both PID sets are set to the same values Table 4 12 Procedure for Using BLENDED TUNE at Start up for Duplex Control sp Operation press re 1 Configure LSP1 Until SP Local Setpoint 1 shows in the lower display 2 Until the Setpoint is to the desired value 3 Switch to Until the A indicator is lighted on Automatic Mode controllers with Manual option 4 Show Tuning Until TUNE OFF is shown on Prompt lower display 5 Initiate Tuning Select DO SLOW or DO FAST in lower display 6 Tuning in operation Upper display will show a T as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NO TUNE prompt 4 10 5 Using MANUAL TUNE at start up for Duplex Heat Cool When DUPLEX has been configured for MANUAL This selection should be used when tuning is needed only for the HEAT zone or only for the COOL zone but not both If Local Setpoint 1 is used then the controller will perform a HEAT zone tune If Local Setpoint 2 is used then the controller will perform a COOL zone tune Table 4 13 Procedure for Using MANUAL TUNE for Heat side of Duplex Control sep Operation Press res 1 Configure LSP1 Faas Until SP Local Setpoint 1 shows a a in the lower display 2 ALO Until LSP1 is a value within the Heat Zone output a
64. which may occur in the controller Follow the troubleshooting procedures to correct them 7 2 Troubleshooting Aids Overall error messages An error message can occur e At power up See Subsection 7 3 e When the Status Tests are requested See Subsection 7 4 e During continuous background tests while in normal operation See Subsection 7 5 Controller failure symptoms Other failures may occur that deal with the Power Output or Alarms Refer to the controller failure symptom in Table 7 4 to determine what is wrong and the troubleshooting procedures to use to correct the problem Check installation If a set of symptoms still persists refer to Section 2 Installation and ensure proper installation and proper use of the controller in the system 154 UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service Customer support If you cannot solve the problem using the troubleshooting procedures listed in this section you can get technical assistance by dialing 1 800 423 9883 USA and Canada An engineer will discuss your problem with you Please have your complete model number serial number and Software version available The model and serial numbers can be found on the chassis nameplate The software version can be viewed under Setup Group Status See Table 7 1 If it is determined that a hardware problem exists a replacement controller or part will be shipped with instructions for returning the de
65. 0 100mV 0 100mV to 100 Millivolts 0 5 V 0 5 V 0 to 5 Volts 1 5V 1 5 V 1 to 5 Volts 0 10 V 0 10 V 0 to 10 Volts TC DIFF TC DIFF Thermocouple Differential SLIDEW SLIDEW Slidewire For Position Proportional Applications 68 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display XMITTER2 B TC S TC TRANSMITTER CHARACTERIZATION This ETCH TTCH selection lets you instruct the controller to ETCL TTCL characterize a linear input to represent a non linear J TC H WTCH one J TCM WTCL JTCL 100 PT ATTENTION Prompt only appears when a linear KTCH 100 LO actuation is selected at prompt IN2 TYPE K TC M 200 PT NNM H RAD RH If input 2 is a 4 to 20 mA signal but the signal NNM L RAD RI represents a type K thermocouple then select K TC NIC H LINEAR H and the controller will characterize the 4 to 20 mA NIC L SQROOT signal so that it is treated as a type K thermocouple RTC input high range Parameter definitions are the same as in IN2 TYPE IN2 HIGH 999 To 9999 Floating INPUT 2 HIGH RANGE VALUE in engineering units in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization See the example in IN1 HI IN2 LOW 999 To 9999 Floating INPUT 2 LOW RANGE VALUE in engineering units in engineering units is displayed for
66. 00 Universal Digital Controller Product Manual 4 08 Configuration 3 3 Configuration Procedure Introduction Each of the Set Up groups and their functions are pre configured at the factory The factory settings are shown in Table 3 4 through Table 3 14 that follow this procedure If you want to change any of these selections or values follow the procedure in Table 3 3 This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt Procedure ATTENTION The prompting scrolls at a rate of 2 3 seconds when the SET UP or FUNCTION key is held in Also Axor w keys will move group prompts forward or backward at a rate twice as fast Table 3 3 Configuration Procedure step Operation Pres ea 1 Enter Set Up ao Upper Display SETUP Mode m Y Lower Display TUNING This is the first Set Up Group title 2 Select any Set C setup Sequentially displays the other Set Up group titles shown in the Up Group Ne n prompt hierarchy in Table 3 2 Configuration Prompt Hierarchy You can also use the A or w keys to scan the Set Up groups in both directions Stop at the Set Up group title that describes the group of parameters you want to configure Then proceed to the next step 3 Select a Function Function Upper Display the current value or selection for the first function KE Parameter prompt of the selected Set Up group Lower Display the first Function prompt within that Set
67. 1 161 INT R W 0 Percent Units 1 Engineering Units 4 08 UDC3200 Universal Digital Controller Product Manual 215 Modbus Read Write and Override Parameters plus Exception Codes 10 7 11 Alarms Table 10 19 lists all the register addresses and ranges or selections for the function parameters in Set up Group Alarms Table 10 19 Set up Group Alarms Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Alarm Setpoint 1 0009 009 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 1 Setpoint 2 000A 010 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 2 Setpoint 1 000B O11 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 2 Setpoint 2 000C 012 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 1 Setpoint 1 008C 140 INT R W 0 None Type 1 Input 1 2 Input 2 3 PV 4 Deviation 5 Output 6 Alarm on Shed 7 SP Event On 8 SP Event Off 9 Manual 10 Remote Setpoint 11 Failsafe 12 PV Rate of Change 13 Alarm on Digital Input 1 14 Alarm on Digital Input 2 15 Loop Break 16 T C Warning 17 T C Fail 18 PV Hot Start 216 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and
68. 1 Ethernet TCP IP 11 1 Overview 4 08 Ethernet parameters can only be configured via the Process Instrument Explorer software Ethernet IP Address is 10 0 0 2 as shipped from the Factory The MAC address is printed on the case label of each instrument When constructing a network it is recommended that a Switch be used to connect UDCs to a LAN rather than using a Hub This is because a Switch passes only those messages for IP addresses that are connected to the Switch while a Hub passes all message traffic Using a Switch thus improves the overall throughput of the traffic to and from the UDCs UDC3200 Universal Digital Controller Product Manual 221 Further information 12 1 12 2 12 3 222 12 Further information Modbus RTU Serial Communications Refer to Honeywell document 51 52 25 66 Modbus RTU Serial Communications User Manual Modbus Messaging on TCP IP Refer to Honeywell document 51 52 25 121 MODBUS Messaging on TCP IP Implementation Guide How to Apply Digital Instrumentation in Severe Electrical Noise Environments Refer to Honeywell document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments UDC3200 Universal Digital Controller Product Manual 4 08 A Aborting Accutune ooooocococcoonconnoonconnconoconoconos 115 Accutune Error Codes ocooocccocncccocccococonninnonnono 115 Acc tune Micra ta 4 109 Accutune Set Up Group coocooccoccccnonccononinanaconnnon 48
69. 12 Virginia Drive Fort Washington PA 19034 51 52 25 119 Rev 3 0408 Printed in USA http hpsweb honeywell com
70. 162 Table 7 7 Troubleshooting Position Proportional Output Failure Step What to do How to do it Make certain that the controller is configured for Position Proportional output Check the field wiring Check the output Check whether the motor drives in both directions If it does go to Step 6 Check whether the motor drives in either direction If the motor drives only in one direction check the slidewire If the motor does not drive in either direction check the motor Check the output voltage to the slidewire if used Make Output Algorithm Set Up group function prompt OUT ALG POSITON Refer to Section 3 Configuration Refer to Section 2 Installation for details Put the controller into Manual mode and change the output from 0 to 100 See the Position Proportional calibration procedure in Section 6 Output Calibration for motor slidewire calibration Refer to the motor instructions See the Input 2 wiring diagram for terminal designations in Section 2 Installation 1 Measure between the R and the terminals across the entire slidewire This voltage should be between 0 024 volts for a 100 ohm slidewire and 0 200 volts for a 1000 ohm slidewire This voltage should remain steady as the motor moves 2 Measure between the and the terminals across just the wiper section This voltage should be somewhere between 0 002 and 0 200 volts depending upon the total slidewire
71. 1871 0 00 mV 57 12 mV Type RI 0 to 3400 18 to 1871 0 00 mV 60 08 mV RTD Alpha 0 00385 per IEC 60751 1995 100 ohms 300 to 1200 184 to649 25 202 ohms 329 289 ohms 100 ohms low 300 to 300 184 t0149 25 202 ohms 156 910 ohms 200 ohms 300 to 1200 184 to649 50 404 ohms 658 578 ohms 500 ohms 300 to 1200 184 10649 126 012 ohms 1646 445 ohms Linear Milliamps 4 to 20 mA 4 00 mA 20 00 mA 0 to 20 mA 0 00 mA 20 00 mA Millivolts Oto 10mV 0 00 mV 10 00 mV Oto 50mV 0 00 mV 50 00 mV 0 to 100 mV 0 00 mV 100 00 mV Volts 1to 5 Volts 1 00 Volts 5 00 Volts Oto 5 Volts 0 00 Volts 5 00 Volts 0 to 10 Volts 0 00 Volts 10 00 Volts Carbon 0 to 1250 mV 0 00 mV 1250 00 mV Oxygen 30 to 510 mV 30 00 mV 510 00 mV The Factory Calibrated millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450 F 232 C Other thermocouple types and ambient temperature means may be accomplished via Field Calibration of the input with the range value limits being 4 mV to 16 mV for the zero and span values The range values for Radiamatic Type RI are customer configurable within the limits shown 134 UDC3200 Universal Digital Controller Product Manual 4 08 Input Calibration 5 3 Preliminary Information Disconnect the Field Wiring Tag and disconnect any field wiring connected to the input 1 or 42 terminals on the rear of the controller a Y bd e Input 2 Connections
72. 2 Input 2 3 PV 4 Deviation 5 Output 6 SP 7 LSP 8 RSP 9 Input Algorithm 1 Current Output OOEB 235 INT R W 0 4 20 mA Range 1 0 20 mA 4 08 UDC3200 Universal Digital Controller Product Manual 201 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Current Low 0064 100 FP R W Within the range of the Scaling Factor selected variable in ID 242 Current High 0065 101 FP R W Within the range of the Scaling Factor selected variable in ID 242 202 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 7 6 Input 1 Table 10 14 lists all the register addresses and ranges or selections for the function parameters in Set up Group Input 1 Table 10 14 Set up Group Input 1 Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 1 Type 00A8 168 INT R W 1 B TC 2 ETCH 3 ETCL 4 JTCH 5 JTCM 6 JTCL 7 K TC H 8 K TCM 9 K TC L 10 NNMH 11 NNML 12 Nicrosil H TC 13 Nicrosil L TC 14 R TC 15 S TC 16 TTCH 17 TTCL 18 W TC H 19 W TCL 20 100 PT RTD 21 100 PT LO RTD 22 200 PT RTD 23 500 PT RTD 24 Radiamatic RH 25 Radiamatic RI 26 0 20 mA 27 4 20 mA 28 0 10 mV 29 0 50 mV 30 100 m
73. 200 Universal Digital Controller Product Manual 119 Monitoring and Operating the Controller 4 14 Three Position Step Control Algorithm Introduction The Three Position Step Control algorithm allows the control of a valve or other actuator with an electric motor driven by two controller output relays one to move the motor upscale the other to move it downscale without a feedback slidewire linked to the motor shaft Estimated Motor Position The Three Position Step control algorithm provides an output display which is an estimated motor position since there is no slidewire feedback e Although this output indication is only accurate to a few percent it is corrected each time the controller drives the motor to one of its stops 0 or 100 e It avoids all the control problems associated with the feedback slidewire wear dirt and noise e When operating in this algorithm the output display is shown to the nearest percent that is no decimal See Motor Travel Time the time it takes the motor to travel from 0 to 100 in section 3 8 Motor Position Display Table 4 20 Procedure for Displaying 3Pstep Motor Position step operation press Rest 1 Access the az Until you see Displays NpisplayY Upper Display PV Lower Display OT The estimated motor position in 120 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 15Setting a Failsafe Output Value fo
74. 21 Ethernet Tcp Ip Communications Interface 14 Ethernet Tcp Ip Protocol oooconicnncnncicnnncnancnnon 84 External Interface Option Connections 33 34 External Setpoint Program Reset e eee 81 External Wiring cccccecceeeecetecetecsseeseeeeeenes 21 F Factory Calibration 141 151 Failsafe Function Prompt 00 121 122 Failsafe Manual Mode cecesseeseeereeeeeees 156 Failsafe Mode s ii scacteerssatts Bios ones ss 76 Failsafe Mode cita 122 Failsafe Output Value 76 Failsafe Output Value 121 Failsafe Output Value For Restart After A Power OS tic cti t rada 121 Failure Modesiucar aiii 4 ES tivo pats adieu eanee acess 4 Feedforward Multiplier ccccseseeeseereeree 54 Feedforward Summet ceceeeeeeeeeseeeeeeneeeees 53 Field Wine ithe tiles ae 135 A e 66 69 Function Code 20 ooccoconccncccocicnconcnncononinanc nnons 178 Function Code 21 eese 182 Function Codes 20 And 21 176 Function Prompts cesceeseesseeseeeteeeeesneenes 37 Fuzzy LO G16 niise eo eais v 5 Fuzzy Overshoot Suppression 48 116 G Cars de dl 40 CM od dl e ol Seance han 41 Guaranteed Soak ceeeeseeeeeteeeteeeteeseeenes 127 H Heat Cool Duplex Tune oooononicnnocnnocnconccnnonnos 5 High Scaling Factor ceeecceesesseeeeeteeeeees 56 High Select cuca aid 54 Hon tl ete Metra een 46 126 Hydrogen Content 200 0 cccceeseeseeeeeeeeteentees 57 Hysteresis
75. 7 Modbus Read Write and Override Parameters plus Exception Codes 10 4 Miscellaneous Read Onlys 10 4 1 Register Addresses for Read Onlys The identifying register addresses listed in Table 10 3 represent some information that is Read only No Writes allowed Table 10 3 Miscellaneous Read Onlys Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Software Type 009D 157 INT RD READ only UDC3200 50 UDC3200 Software Version 00A7 167 INT RD READ only Value less than 255 10 4 2 SetPoint Program Read Only Information The identifying register addresses listed in Table 10 4 represent some information for SetPoint Programming that is Read only No Writes allowed Table 10 4 SetPoint Program Read Only Information Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Present SPP OOFB 251 INT RD 1 12 Segment Number Segment Time OOFC 252 INT RD 0 59 Minutes Remaining in Minutes Segment Time OOFD 253 INT RD 0 99 Hours Remaining in Hours Cycles Remaining OOFE 254 INT RD 0 100 Current Cycle OOFF 255 INT RD 0 100 Number 188 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 5 Setpoints Overview You can use two separate local setpoints in
76. 8 Installation 2 4 Control and Alarm Relay Contact Information Control Relays ATTENTION Control relays operate in the standard control mode that is energized when output state is on Table 2 2 Control Relay Contact Information Control Relay Control Relay Output 1 or 2 Wiring Contact Indicator Status N O Open N C Closed a Alarm Relays ATTENTION Alarm relays are designed to operate in a failsafe mode that is de energized during alarm sate This results in alarm actuation when power is OFF or when initially applied until the unit completes self diagnostics If power is lost to the unit the alarms will de energize and thus the alarm contacts will close Table 2 3 Alarm Relay Contact Information Alarm Relay Relay Contact 4 08 UDC3200 Universal Digital Controller Product Manual 17 Installation 2 5 Mounting Physical Considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied Adequate access space must be available at the back of the panel for installation and servicing activities e Overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 2 2 e The controller s mounting enclosure must be grounded according to CSA standard C22 2 No 0 4 or Factory Mutual Class No 3820 paragraph 6 1 5 e The front panel is moisture rated NEMA3 and IP55 rated and can be easily upgraded to NEMA4X and IP66 See Mount
77. 8 Program can be placed in RUN HOLD RERUN or BEGIN state through a remote dry contact connected to optional digital input terminals as follows RUN contact closure places Program in RUN state OR HOLD contact closure places Program in HOLD state RERUN contact closure allows the Setpoint Programmer to be reset to the initial segment of its current cycle unit stays in previous mode Opening the contact will cause the Controller to revert to its original state BEGIN Contact closure resets SP Program back to the beginning of the first segment in the program and places the program in the HOLD mode Program cycle number is not affected Reopening switch has no effect Opening the contact will cause the Controller to revert to its original state UDC3200 Universal Digital Controller Product Manual 131 Input Calibration 5 Input Calibration A WARNING SHOCK HAZARD INPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION 5 1 Overview Introduction This section describes the field calibration procedures for Input 1 and Input 2 e All input actuations in every UDC3200 controller are fully factory calibrated and are ready for configuration by the user e Field Calibration can improve the accuracy of the Controller if necessary for a particular application CAUTION The
78. 8 Low Ft tan 83 Low Scaling FactOT ooononconncnoonnocnconnconccnnconnos 56 Low Selecciona aii 54 Lower Display Key Parameter Prompts 101 224 UDC3200 Universal Digital Controller Product Manual M Pollution Degre8 oooonoonncncnonnncnonconcnccnnnonononinnonos 9 Mains Power Supply seser 20 25 Position Proportional Connections a A as ea swansea Aaya 105 Position Proportional Output Failure 102 Manual LatchiN8 oconnonnnncnocnncnncnncconcnononannonnon 83 Position Proportional SimpleX esrses 60 Manual ReSOb coooonconcnocicnnccnononncnncnncononnnonannninnon 41 Power Consumption sssssssssssssseesssssevssseee Mass Flow Orifice Constant K For Math Power Failure Symptoms ceeeeeeeeeneees 161 Selections ici ilatina 56 Power Inrush Current ssssssessssssesssssseenssoee 1 Math Algorithms cocine 53 Power Line Frequency svsssssssessessssssseessseee ze Math Functi0WS ococococonononononnnananonicnnnonannnnonic ns 2 Power Outage cocmmmmmnccccnenneneenenronononnnno 124 131 Minimum And Maximum Range Values 133 Power Up Tests cocino eds 156 ModbUS 84 Pre Installation Information La Modbus Read Write And Override Parameters Process Instrument Explorer 7 a dll ae ed raked 185 O Contents a aiei 29 Modbus RTU Exception Codes 219 Program Record Sheet 129 Modbus RTU Function Codes t a 176 Program State me es 126 Model Number Interpretati
79. A 186 INT R W 0 None 1 1 To Manual 2 To Local Setpoint 1 3 To Local Setpoint 2 4 To Local Setpoint 3 5 To Direct Action 6 To Hold Ramp 7 To PID Set 2 8 PV Input 2 9 Unused 10 Rerun SPP Cycle 11 To Run Ramp 12 Reset SP Program 13 Inhibit Reset 14 To Manual Failsafe Output 15 Disable Keyboard 16 To Automatic Output 17 To Timer 18 To Auto Man Station 19 Initiate Limit Cycle Tuning 20 Setpoint Initialization SP PV 21 Output Tracks Input 2 22 Unused 23 Unused 24 To RSP 25 Unused 26 External Reset Feedback 27 To Purge 28 To Low Fire 29 Manual Latching 30 Unused 31 Unused 32 PV Hold 4 08 UDC3200 Universal Digital Controller Product Manual 213 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Digital Input 00BC 188 INT R W 0 Disable 41 PID2 Combinations Direct LSP2 Disable Accutune LSP1 Run Digital Input 00BB 187 INT R W Same as Digital Input 1 2 Digital Input 00BC 189 INT R W 0 Disable 2 PID2 Combinations Direct LSP2 Disable Accutune LSP1 Run Auxiliary Output and Digital Input 2 are mutually exclusive 214 UDC3200 Universal Digital Controller Product Manual 4 08
80. Alarm Blocking oooooconncciocononocononononnnonnnonnonnnonos 91 Alarm Hysteresis coooonoonnonocnoccononnnoncnncnnnonannninnonos 90 IN 13 Alarm Relay Output Failure 0 eee 165 Alarm Relays ccceccesseesseeseeseeeneeeseeeeeeeeeeeeeees 17 Alarm Setpoints oooocoonconionoocnnononanconnconoconocn noo 118 Alarm Setpoints Display cccesereeees 119 PAV APIS dl lila 3 Alarms Set Up Group ooocococccococononnononinnnonnonanonos 87 Algorithm Set Up Group ccooocccccocncocnconcncncnnnonos 50 Analog Input Signal Failure Operation 12 Analog Inputs oooconocninccnononononononnnonnnnnncnnnnnos 2 12 ANMUNCIALOTS eierniie iiini aih 100 Application Related Problems 154 Approval Body Options s s s 4 Auto Blass 73 Auto Manual Key cooocooccniccncccnoninononononnnonncnnnnnos 99 Automatic With Local Setpoint 105 Automatic With Remote Setpoint 105 Autotune Is Complete oooooooonnccnnoniocnoonconnconos 116 Auxiliary Output coooooconocciocononccononnnonnnonnnnnnonnnonos 78 Auxiliary Output Sessera 3 Auxiliary Output Calibration 0 cee 146 Auxiliary Output Connections cece 34 Auxiliary Output Failure 0 cee eeeeeeeneees 169 Auxiliary Output Range ssec 79 B Background Tests cccescceseeseeseeeseeeeeeeeeees 157 Baud Rate cscs a auch teehee aah 84 A See ce coe tee eo ees Reon 65 69 Burnout Protection ocoooconononccccnnancconnnan
81. C or CYC SX3 PB2 or GAIN2 RATE2MIN RSET2MIN or RSET2RPM CYC2SEC or CYC2SX3 PIDSET1 will be used when PV or SP whichever is selected is greater than the switchover value PIDSET2 will be used when PV or SP whichever is selected is less than the switchover value Until you see Upper Display the switchover value Lower Display SW VAL To select the switchover value in the upper display 4 08 UDC3200 Universal Digital Controller Product Manual 117 Monitoring and Operating the Controller Switch between two sets via keyboard without automatic switch over Table 4 18 Procedure for Switching PID SETS from the Keyboard e e A 1 Select Control Until you see Set up Group Upper Display the PV value Lower Display PIDS X X 1 or 2 2 Aa or To change PID SET 1 to PID SET2 or Vice Versa You can use Accutune on each set To accept changes 4 13 Alarm Setpoints Introduction An alarm consists of a relay contact and an operator interface indication The alarm relay is de energized if setpoint 1 or setpoint 2 is exceeded The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis The relay contacts can be wired for normally open NO energized or normally closed NC de energized using internal jumper placement See Table 2 3 in the Section 2 Installation for alarm relay contact information There are four alarm setpoin
82. C3200 Universal Digital Controller Product Manual 173 Parts List 174 Table 8 1 Parts Identification Key Part Number Description Number 51453143 502 Bezel Assembly and Bezel Gasket 51452845 501 Display Keyboard PWA 3 51452822 502 Power Output PWA 90 264 Vac Operation pE l Power Output PWA 24 Vac dc Operation 4 51452810 501 Auxiliary Output Digital Input RS 422 485 Communications PWA Ma a Auxiliary Output Digital Input Ethernet Communications PWA 51452819 501 MCU Input PWA Output 1 2 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector Output PWA 30756725 501 e Solid State Relay 51452804 501 e Current Output PWA 51452807 501 e Dual Electromechanical Relay PWA 51452759 501 Case Assembly including Mounting Kit with 4 brackets amp screws Output 3 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector Output PWA 30756725 501 e Solid State Relay ef 51452825 501 Optional Input PWA Table 8 2 Parts Not Shown Table 8 3 Software Upgrades see Section 7 9 50004635 501 Math Options 50004635 502 Set Point Programming SPP UDC3200 Universal Digital Controller Product Manual 4 08 Parts List 8 2 Removing the chassis 4 08 Insert thin screwdriver under tabs and twist slightly and gently to disengage front Using a thin screwdriver gently twist the screwdriver to pry the side tabs from the front face Pry just enough to release it otherwise you ll be
83. EGMENT ATTENTION Alarms configured for events will not operate on Setpoint Program segments of zero length 4 08 UDC3200 Universal Digital Controller Product Manual 89 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition A1S2TYPE Same as A1S1 TYPE ALARM 1 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 1 to represent The selections are the same as A1S1TYPE A1S2HL HIGH ALARM 1 SETPOINT 2 STATE Same as LOW A1S1 HL A1S2 EV BEGIN ALARM 1 SEGMENT EVENT 2 Same as A1S1 END EV A2S1TYPE Same as A1S1 TYPE ALARM 2 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not available with Relay Duplex or Position Proportional output types unless using Dual Relay PWA A2S1 HL HIGH ALARM 2 SETPOINT 1 STATE Same as LOW A1S1 HL A2S1 EV BEGIN ALARM 2 SEGMENT EVENT 1 Same as A1S1 END EV A2S2TYPE Same as A1S1 TYPE ALARM 2 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not applicable with Relay Duplex or Position Proportional output types unless using Dual Relay PWA A2S2 HL HIGH ALARM 2 SETPOINT 2 STATE Same as LOW A1S1 HL A2S2 EV BEGIN ALARM 2 SEGMENT EVENT 2 Same as END A1S1 EV ALHYST 0 0 to 100 0 of span or ALARM HYSTERESIS A sing
84. Enumerated Selection Hex Decimal Diagnostic Alarm 009A 154 INT R W 0 Disable 1 Alarm 1 2 Alarm 2 10 7 12 Display Table 10 20 lists all the register addresses and ranges or selections for the function parameters in Set up Group Display Table 10 20 Set up Group Display Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Decimal Point 009B 155 INT R W 0 None Fixed Location 1 One Floating decimal point to one 2 Two Floating decimal point to two 3 Three Floating decimal point to three Temperature 0081 129 INT R W 0 F Units C 2 None Power 00A6 166 INT R W 0 60 Hertz Frequency 1 50 Hertz Language 00CO 192 INT R W 0 English Displays 1 French 2 German 3 Spanish 4 Italian Ratio Input2 00DO 208 INT R W 0 Disable from Front 1 Enable Panel 218 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 8 Modbus RTU Exception Codes Introduction When a master device sends a query to a slave device it expects a normal response One of four possible events can occur from the master s query e Slave device receives the query without a communication error and can handle the query normally It returns a normal response e Slave does not receive the query
85. FO y 250 ohms gt fa INS 7 y Milliampere 26 Input 1 Source 27 Figure 5 7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs 4 08 UDC3200 Universal Digital Controller Product Manual 139 Input Calibration 5 5 Input 1 or 2 Calibration Procedure Preliminary Steps e Apply power and allow the controller to warm up for 30 minutes before you calibrate e Please read Subsection 5 4 Input 1 or 2 Set Up Wiring before beginning the procedure e Make sure you have LOCK set to NONE See Subsection 3 4 Tuning Set Up Group e See Table 5 1 for Voltage vs Resistance equivalents or 0 and 100 range values CAUTION For linear inputs avoid step changes in inputs Vary smoothly from initial value to final 100 value Procedure The calibration procedure for Input 1 or 2 is listed in Table 5 9 Table 5 9 Input 1 or 2 Calibration Procedure sep Operation Fess ea 1 Enter Calibration setup Upper Display CALIB Mode NA Lower Display INPUTn n 1 or 2 until you see Y N Youwill see Cenes Upper Display DISABLE Lower Display CAL INn n 1 or 2 Axorw The calibration sequence is enabled and you will see Upper Display BEGIN Lower Display CAL INn n 1 or 2 At the completion of the sequence the selection automatically reverts to disable 2 Calibrate 0 Function You will see EA Upper Display APPLY Lower Display INn ZERO n 1 or 2 e Adjust your calibr
86. Honeywell UDC3200 Universal Digital Controller Product Manual 51 52 25 119 April 2008 Honeywell Process Solutions Notices and Trademarks Copyright 2008 by Honeywell Revision 4 April 2008 WARRANTY REMEDY Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Honeywell Process Solutions 512 Virginia Drive Fort Washington PA 19034 UDC3200 is a U S registered trademark of Honeywell Other brand or product names are trademarks of their respective owners 4 08 UDC3200 Universal Digital Controller Product Manual ii About This Document Abstract This document provides descriptions and procedures for the Installation Configuration
87. ISABLE DISABLE INPUT 1 INPUT 1 INPUT 2 INPUT 2 PV PV Process Variable DEV DEVIATION OUTPUT OUTPUT SP SETPOINT LSP LOCAL SETPOINT RSP REMOTE IN ALG 1 INPUT ALGORITHM 1 LOW VAL Low Scale Value within CURRENT OUTPUT LOW SCALING FACTOR the range of the selected Used only when CUR OUT is any selection other variable to represent the than DISABLE This is a value in engineering units minimun output 0 or 4 used to represent all CUR OUT parameters except mA Output For Output this is a value in percent and can be any value between 5 and 105 However keep in mind that relay output types can only be scaled 0 to 100 HIGH VAL High Scale Value within CURRENT OUTPUT HIGH SCALING FACTOR the range of the selected Used only when CUR OUT is any selection other variable to represent the than DISABLE This is a value in engineering units maximum output 20 mA used to represent all CUR OUT parameters except Output For Output this is a value in percent and can be any value between 5 and 105 However keep in mind that relay output types can only be scaled 0 to 100 CO RANGE 4 20mA CURRENT OUTPUT RANGE allows the user to 0 20mA easily select 4 20 mA output or 0 20 mA output operation without the need for recalibration of the instrument ATTENTION Changing the Current Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values 4 08
88. L Tuning and Setpoint Ramp parameters are available for read only No other parameters can be viewed Lower Display LOCKOUT ory Until NONE is in the upper display 2 Enter INPUT setup until you see Setup Group Upper Display SET UP Lower Display INPUT n n 1 or 2 Function until you see N 4 Upper Display the current selection Lower Display INn TYPE n 1 or 2 Ao ww to change the current selection to another selection 3 Scroll through Function until the lower display rolls through the rest of the functions and Functions N returns to Upper Display the new selection Lower Display INn TYPE n 1 or 2 Ax orw until you change the input selection in the upper display back to the proper selection You will see Upper Display Original Input Selection that matches your type of sensor Lower Display INn TYPE n 1 or 2 4 Return to Normal to return to Normal operating mode Operation The factory calibration will be restored If the problem is not corrected contact the Honeywell Technical Assistance Center at 1 800 423 9883 USA and Canada 142 UDC3200 Universal Digital Controller Product Manual 4 08 Output Calibration 6 Output Calibration 6 1 Overview Introduction This section describes the field calibration procedures for the following types of outputs e Current Output e Auxiliary Output e Position Proportional Output and Three Position Step Output What s in this section The fol
89. Miscellaneous Read OnlIS coin di da eds its 188 10 4 1 Register Addresses for Read OnlyS ccccccsccssscesscessceseceeeeeeeeeeeeeeseecseecaeeseenseenseenaeens 188 10 4 2 SetPoint Program Read Only Information c ccccecccecseeseeereeeceeseecsaeensecneeseeeeeneenees 188 A tiem 189 10 6 Using a Computer Setpoint Overriding Controller Setpoint 00 cee eeeeeeseeeeceeeeeeeeeeeeens 190 1077 Configuration Param ters ad ti di di ata ba dto 192 10 7 1 A EE 192 10 7 2 SP Ramp Rate Program inn A AA 194 10 7 3 ACCION ta aa air 197 10 7 4 ATOM rd A a titi 198 10 7 5 Output Algorithms lt A ias 201 10 7 6 NN 203 10 7 7 ATO Uo TO NS 206 10 7 8 ONTO lovers as seize onaiecn e e e ela ll le oe cause an ests 209 10 7 9 OPIO ii O till cias 212 107 107 Communications sse ssa meneno ei a aa a eaa O T gleadandendegasselesaveades 215 ITAI Alam 25 asicsescouahesaninvotss a aa a o E A a AA Ea 216 IA A NR RR 218 10 8 Modbus RTU Exception Codes cccccccecccssscssseesseeeseecssecseecssecssecesecesecsseeseeeseeeseaeeeseeeeeenseesaes 219 11 ETHERNET TCP IP aiii otusonsduananevdoausossduasmsninee 221 MAD SOVSEVIS Woe RE 221 12 FURTHER INFORMATION crcscicvsscsticectcetcnesencetcacacecevecedcttescsesceuteatctewsestsuneteeustes 222 12 1 Modbus RTU Serial Communications cooocononionononononnnonnconccon ccoo nono nono nncnnnnnr narran narran rra 222 12 22 Modbus Messaging on TCPMP niin e E A E E E a a E 222 12 3 Howto Apply Digital
90. NT OXYGEN RANGE Make this selection if you are using a Zirconium Oxide Oxygen Probe to measure Percent of Oxygen in a range of 0 to 40 O This algorithm requires a temperature range within the region of 800 F to 3000 F 4 08 UDC3200 Universal Digital Controller Product Manual 55 Configuration Selections or Range of Setting Function Prompt Lower Display Parameter Definition Upper Display ATTENTION The Carbon and Dewpoint selections will automatically set the first input actuation to Carbon The Oxygen selection will automatically set the first input actuation to Oxygen Input 2 can be any input actuation but it is normally a type K R or S thermocouple input depending upon the probe type selected All calculations are performed by the Controller with Percent Carbon shown as the PV display The actual value of each analog input may be viewed on the lower display For all Carbon Types if the value of Percent Carbon falls below 0 1 such as can happen when the Carbon Probe voltage output falls below 900 mVdc then the Controller will continue to update the PV display but the accuracy is unspecified Likewise if the measured temperature falls outside of the specified ranges as noted above for the Carbon Oxygen and Dewpoint input types then the Controller will continue to update the PV display but the accuracy is unspecified For the Dewpoint algorithm if the Carbon Sensor voltage falls
91. None Read only 3 Process Identification failed 4 Accutune aborted on command 5 Running 4 08 UDC3200 Universal Digital Controller Product Manual 197 Modbus Read Write and Override Parameters plus Exception Codes 10 7 4 Algorithm Table 10 12 lists all the register addresses and ranges or selections for the function parameters in Set up Group Algorithm Table 10 12 Set up Group Algorithm Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal omi 0080 128 INT R W 0 ON OFF orithm Selection 1 PID A Selection here will 2 PID B affect ID code 160 in 3 PD A with Manual Output Algorithms Reset 4 Three Position Step 5 Disable Timer 00D8 216 INT R W 0 Disable 1 Enable 0063 099 FP R W 00 00 TO 99 59 Start Initiation 00D9 217 INT R W 0 Key Run Hold Key 1 Alarm 2 LDISP Selection OODA 218 INT R W 0 TI REM 1 Elapsed Time Timer Reset 00D6 214 INT R W 0 Key Run Hold Key 1 ALI Alarm 1 or Key Timer Increment 00D7 215 INT R W 0 Minutes Counts hr minute 1 Sec Counts min sec 198 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input
92. OG function prompts STRSEG and ENDSEC CAL MTR Slidewire calibration never performed Field Calibrate the slidewire See Section 6 4 SW FAIL Position Proportional slidewire input failure See the Trouble Shooting Procedure in Section 7 7 SOOTING Percent Carbon falls outside sooting Check process for correct operation boundary TCx WARN Thermocouple on Input x 1 or 2 is This diagnostic message means that the controller starting to burnout has detected that the thermocouple is starting to burnout This error message may also be created if the resistance of the wires used to connect the thermocouple to the instrument is above 100 ohms TCxFAIL The Thermocouple on Input x 1 or 2 isin This diagnostic message means that the controller imminent danger of burning out has detected that the thermocouple will soon fail User should consider replacing the thermocouple as soon as possible This message will also be generated if the resistance of the wires used to connect the thermocouple to the instrument is above 180 ohms CURFAIL Current Output is less than 3 5 mA The current output is open circuit Check the field wiring See Procedure 2 AXFAIL Auxiliary Output is less than 3 5 mA The auxiliary output is open circuit Check the field wiring See Procedure 9 7 6 Controller Failure Symptoms Introduction In addition to the error message prompts there are failure symptoms that can be identified by noting how the controller dis
93. Office Phone 0096638304584 Fax 0096638338059 Kuwait Honeywell Kuwait KSC Phone 965 242 1327 to 30 Fax 965 242 8315 and Phone 965 326 2934 1821 Fax 965 326 1714 UDC3200 Universal Digital Controller Product Manual AFRICA Mediterranean amp African Distributors Honeywell SpA Phone 39 02 250 10 604 FAX 39 02 250 10 659 South Africa Republic of and sub saharan Honeywell Southern Africa Honeywell S A Pty Ltd Phone 27 11 6958000 FAX 27 118051504 NORTH AMERICA Canada Honeywell LTD Phone 1 800 737 3360 FAX 1 800 565 4130 USA Honeywell Process Solutions Phone 1 800 343 0228 FAX 1 717 771 8251 Email sc cp appssales honeywell com LATIN AMERICA Argentina Honeywell S A C Phone 54 11 4383 3637 FAX 54 11 4325 6470 Brazil Honeywell do Brasil amp Cia Phone 55 11 7266 1900 FAX 55 11 7266 1905 Chile Honeywell Chile S A Phone 56 2 233 0688 FAX 56 2 231 6679 Mexico Honeywell S A de C V Phone 52 55 5259 1966 FAX 52 55 5570 2985 Puerto Rico Honeywell Inc Phone 809 792 7075 FAX 809 792 0053 Trinidad Honeywell Inc Phone 868 624 3964 FAX 868 624 3969 Venezuela Honeywell CA Phone 58 2 238 0211 FAX 58 2 238 3391 227 228 UDC3200 Universal Digital Controller Product Manual 4 08 4 08 UDC3200 Universal Digital Controller Product Manual 229 Honeywell Honeywell Process Solutions 5
94. Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Alarm 1 Setpoint 2 008E 142 INT R W Same as 140 Type Alarm 2 Setpoint 1 0090 144 INT R W Same as 140 Type Alarm 2 Setpoint 2 0092 146 INT R W Same as 140 Type Alarm 1 Setpoint 1 008D 141 INT R W 0 Low Alarm Event 1 High Alarm Alarm 1 Setpoint 2 008F 143 INT R W 0 Low Alarm Event 1 High Alarm Alarm 2 Setpoint 1 0091 145 INT R W 0 Low Alarm Event 1 High Alarm Alarm 2 Setpoint 2 0093 147 INT R W 0 Low Alarm Event 1 High Alarm Alarm Hysteresis 0029 041 FP R W 0 0 to 100 of output or span Alarm Latching for 00C8 200 INT R W 0 Non Latching Output 1 1 Latching Alarm 1 Blocking 00CA 202 INT R W 0 Disable 1 Block 1 2 Block 2 3 Block 1 2 00C9 201 INT R W State 0 Not in Alarm State 1 In Alarm Bit 0 Alarm 11 State Bit 1 Alarm 12 State Bit 2 Alarm 21 State Bit 3 Alarm 22 State Event 0 Low Event 1 High Bit 4 Alarm 11 Event Bit 5 Alarm 12 Event Bit 6 Alarm 21 Event Bit 7 Alarm 22 Event 4 08 UDC3200 Universal Digital Controller Product Manual 217 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type
95. PLE WARNING NOTE 5 TCFAIL THERMOCOUPLE FAIL NOTE 6 PVHOLD PV HOLD ATTENTION NOTE 1 When the controller is configured for Three Position Step Control alarms set for Output will not function NOTE 2 Alarm 1 is not available if the Timer is enabled because Alarm 1 is dedicated to Timer output NOTE 3 This Deviation Alarm is based upon deviation from the 2nd Local Setpoint or Remote SP regardless of whichever SP is active NOTE 4 Loop Break monitors the control loop to determine if it is working When enabled the control output is checked against the minimum and maximum output limit settings When the output reaches one of these limits a timer begins If the timer expires and the output has not caused the PV to move by a pre determined amount then the alarm activates thus signalling that the loop is broken The loop break timer value must be configured by the operator as the AxSx VAL entry This value is in seconds with a range of 0 to 3600 seconds A setting of 0 is equivalent to an instantaneous loop break when the output reaches one of its limit UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition values The amount of PV Movement required is determined by the UNITS setting in the Display Setup Group For the Degrees F configuration the PV must move by 3 in the de
96. POINT RATIO Computer setpoint ratio CSP BIAS 999 to 9999 COMPUTER SETPOINT BIAS Computer setpoint engineering units bias in Engineering Units LOOPBACK LOCAL LOOPBACK tests the RS 485 communications port It is not used for any other communications port DISABLE Disables the Loopback test ENABLE Allows loopback test The instrument goes into Loopback mode in which it sends and receives its own message The instrument displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running The instrument will go into manual mode when LOOPBACK is enabled with the output at the Failsafe value The test will run until the operator disables it here or until power is turned off and on ATTENTION The instrument does not have to be connected to the external communications link in order to perform this test If it is connected only one instrument should run the loopback test at a time The host computer should not be transmitting on the link while the loopback test is active 86 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration 3 14 Alarms Set Up Group Introduction An alarm is an indication that an event that you have configured for example Process Variable has exceeded one or more alarm limits There are two alarms available Each alarm has two setpoints You can configure each of these two setpoints to alarm on various controller
97. Proportional output prompt OUTALG RLY or RLYD Refer to Section 3 Configuration 2 Check the field wiring Make sure the NO or NC contact wiring is correct Refer to Section 2 Installation for details 3 Check the output Put the controller into Manual mode Vary the output above and below the present value Observe OUT1 indicator on the operator interface Contact should change state 0 open 100 closed Listen for a click from the relay when the OUT1 indicator changes state 4 Check relay Change relay 5 Change MCU board Installation instructions supplied with the new board 4 08 UDC3200 Universal Digital Controller Product Manual 163 Troubleshooting Service Procedure 5 164 Table 7 9 explains how to troubleshoot Current Time or Time Current Proportional Output failure Table 7 9 Troubleshooting Current Time or Time Current Proportional Output Failure Step What to do How to do it 1 Make sure the controller is configured Make Output Algorithm Set Up group function for Time Current or Current Time prompt OUT ALG TCUR or CURT Proportional output Refer to Section 3 Configuration 2 Check the field wiring Make sure the NO or NC contact wiring selection is correct Refer to Section 2 Installation for details 3 Check the relay output Put the controller into Manual mode Vary the output above and below the present value Observe OUT1 indicator on the operator interface List
98. R W 0 None Input C Selection 1 Input 1 used with ID 204 2 Input 2 math calculations 3 Output Algorithm bias 005C 092 FP R W 999 0 to 9999 in Engineering Units Percent Carbon 002E 046 FP R W 0 02 to 0 350 Value Percent Hydrogen 0022 034 FP R W 1 to 99 H2 200 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 7 5 Output Algorithms Table 10 13 lists all the register addresses and ranges or selections for the function parameters in Set up Group Output Table 10 13 Set up Group Output Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Output 00A0 160 INT R W 0 Time Simplex Algorithm 1 Current Simplex 2 Three Position Step or Position Proportioning 3 Time Duplex 4 Current Duplex 5 Current Time Duplex 6 Time Current Duplex Relay Cycle OOBE 190 INT R W 0 1 second increments Time 1 1 3 second increments Increments Motor Time for 004B 075 INT R W 5 to 1800 seconds Positional Proportional Relay Output 00F3 243 INT R W 0 1 OFF 2 OFF Action 1 1 ON 2 OFF 2 1OFF2 ON 3 10N 20N Current Range 0099 153 INT R W 0 Full 100 for Current 1 Split 50 Duplex Current Output 00F2 242 INT R W 0 Disable Auxiliary 1 Input 1 Output Mode
99. Run Hold key or Alarm 1 INCREMENT MINUTES INCREMENT allows you to increment the timer in SECONDS either minutes or seconds INPUT MATH ALGORITHMS Corntrollers with two inputs are provided with one input algorithm Unless otherwise noted these selections are provided only as part of the Math Options package Each algorithm can be configured to provide a derived calculated PV or a derived Remote Setpoint Up to three inputs may be applied to the calculation See Inputs A B and C for definitions per equation All algorithms operate in engineering units except Feedforward F FWRD which operates in percent of output units ATTENTION When the Input C configuration is set to NONE the value of Input C used in the functions is automatically set to 1 0 except for the Summer algorithm where it is set to 0 0 INP ALG1 4 08 NONE INPUT ALGORITHM 1 has the following selections from which to choose NONE No algorithm configured W AVG See Note 2 Standard feature on controllers with two analog inputs Alg1 Input A x Ratio A F FWRD Standard feature on controllers with two analog inputs WEIGHTED AVERAGE When you configure for Weighted Average the controller will compute a PV or SP for the control algorithm from the following equation Bias A K x Input B x Ratio B Bias B 1 K AlgiBias FEEDFORWARD SUMMER Feedforward uses Input A following a Ra
100. SABLE Alarm NONE SHEDTIME 30 0 Email Subj mie SHEDMODE LAST SHEDSP TO LSP UNITS PERCNT CSP RATO 1 0 CSP BIAS 0 LOOPBACK DISABLE 4 08 UDC3200 Universal Digital Controller Product Manual 95 Monitoring and Operating the Controller 4 Monitoring and Operating the Controller 4 1 Overview Introduction This section gives you all the information necessary to help you monitor and operate your controller including an Operator Interface overview how to lockout changes to the controller entering a security code and monitoring the displays What s in this section The following topics are covered in this section 4 7 Control Modes 105 4 8 Setpoints 106 4 9 Timer 107 4 10 Accutune 109 4 11 Fuzzy Overshoot Suppression 116 4 12 Using Two Sets Of Tuning Constants 116 4 13 Alarm Setpoints 118 4 14 Three Position Step Control Algorithm 120 4 15 Setting A Failsafe Output Value For Restart After A Power Loss 121 4 16 Setting Failsafe Mode 122 4 17 Setpoint Rate Ramp Program Overview 122 4 18 Setpoint Rate 123 4 19 Setpoint Ramp 123 4 20 Setpoint Ramp Soak Programming 125 96 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 2 Operator Interface Introduction Figure 4 1 is a view of the Operator Interface Figure 4 1 Operator Interface 4 3 Entering a Security Code Introduction The level of keyboard lockout may be changed in the Set Up mode However knowle
101. TCP IP protocol Introduction A controller with a communications option looks for messages from the host computer If these messages are not received within the configured shed time the controller will SHED from the communications link and return to stand alone operation You can also set the SHED output mode and setpoint recall and communication units Up to 99 addresses can be configured over this link The number of units that can be configured depends on the link length with 31 being the maximum for short link lengths and 15 drops being the maximum at the maximum link length Function Prompts Table 3 13 Communications Group Function Prompts Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition Com ADDR 1 to 99 COMMUNICATIONS STATION ADDRESS This is a number that is assigned to a controller that is to be used with the communications option This number will be its address ComSTATE DISABLE MODBUS COMMUNICATIONS SELECTION DISABLE Disables RS 485 communications option MODBUS Enables RS 485 Modbus RTU communication port IR ENABLE DISABLE ENABLE IR ENABLE Disable Enables IR communications port ATTENTION If there are no IR communications transactions for four minutes then the IR port automatically shuts down It can be re enabled by pressing any key on the front panel BAUD 4800 9600 19200 38400
102. TION The keyboard takes priority over the external switch for the RUN HOLD function Reopening the HOLD switch runs the program Upper Display PV value Lower Display XXRAHH MM for Ramps or XXSKHH MM for Soaks Time remaining in the SEGMENT in hours and minutes XX The segment number 1 to 12 continued UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Viewing the number of cycles left in the program Upper Display PV value Lower Display RECYC XX until yousee Number of cycles remaining in the setpoint program X 0 to 99 End Program When the final segment is completed the R in the upper display either changes to H if configured for HOLD state or disappears if configured for disable of setpoint programming The controller then either operates at the last setpoint in the program or goes into manual mode failsafe output depending upon the LAST configuration Disable Program See Section 3 Configuration Group SP PROG for details Power outage ATTENTION If power is lost during a program upon power up the controller will be in hold and the setpoint value will be the setpoint value prior to the beginning of the setpoint program The program is placed in hold at the beginning The mode will be as configured under PWR UP in the CONTROL group Digital input remote switch operation 4 0
103. Table 7 3 Background Tests Lower Reason for Failure How to Correct the Problem Display EE FAIL Unable to write to non volatile memory 1 Check the accuracy of the parameter and re enter pda ade AL and itis 2 Try to change something in configuration a cid oi i 3 Run through Read STATUS tests to re write to EEPROM FAILSAFE This error message shows whenever the 1 Run through STATUS check to determine the controller goes into a failsafe mode of reason for the failure operation This will happen if 2 Press the SET UP key until STATUS appears in a test ie bis the lower display e Configuration test faile bion test failed 3 Press the FUNCTION key to see whether the tests Burnout configured for none and pass or fail then E e STATUS codes a the input failed second time to see if the error cleared INP1 RNG Input 1 out of range The process input is 1 Make sure the range and actuation are configured outside the range limits properly 2 Check the input source 3 Restore the factory calibration See Subsection 5 6 4 Field calibrate See Section 5 Input Calibration INP1FAIL Two consecutive failures of input 1 1 Make sure the actuation is configured correctly integration i e cannot make analog to See Section 3 Configuration digital conversion This will happen if 2 Make sure the input is correct and that it has not Upscale or Downscale burnout is burned out opened selected and the input is open 3 Check f ith ii
104. Thermocouple Source 1 Connect the thermocouple extension wires to the terminals for Input 1 as shown in Figure 5 3 22 R 23 Input 2 R 24 W 25 Thermocouple K 26 Input 1 Source K 27 Thermocouple Extension Wire E Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source 5 4 3 RTD Inputs Refer to Figure 5 4 and wire the controller according to the procedure given in Table 5 5 Table 5 5 Set Up Wiring Procedure for RTD Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 4 22R 23 Input 2 24 a Lot ee Resistance 29 26 Input 1 AA FIN r S Copper Leads Equal Length XXXX Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device 4 08 UDC3200 Universal Digital Controller Product Manual 137 Input Calibration 5 4 4 Radiamatic Millivolts Volts or Thermocouple Differential Inputs Refer to Figure 5 5 and wire the controller according to the procedure given in Table 5 6 Table 5 6 Set Up Wiring Procedure for Radiamatic Millivolts Volts or Thermocouple Differential Inputs Except 0 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 5 2 Place current voltage source at zero before switching on 3 Do not switch current voltage source ON OFF while connected to the instrument ATTENTION For Radiamatic inputs only set Emissivity value to 1 0 See Su
105. UTPUT LEVEL Determines the mode of local control you want when the controller is shed from the communications link LAST SAME MODE AND OUTPUT The controller will return to the same mode manual or automatic at the same output level that it had before shed TO MAN MANUAL MODE SAME OUTPUT The controller will return to manual mode at the same output level that it had before shed FSAFE MANUAL MODE FAILSAFE OUTPUT The controller will return to manual mode at the output value selected at Control prompt FAILSAFE TO AUTO AUTOMATIC MODE LAST SP The controller will return to the automatic mode and the last setpoint used before shed 4 08 UDC3200 Universal Digital Controller Product Manual 85 Configuration DISABLE ENABLE Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display SHED SP SHED SETPOINT RECALL Note If SHEDENAB DISABLE this prompt will not be configurable TO LSP TO LSP Controller will use last local or remote setpoint used TO CSP TO CSP When in slave mode the controller will store the last host computer setpoint and use it at the Local setpoint When in monitor mode the controller will shed to the last instrument Local or Remote setpoint used and the LSP is unchanged UNITS COMPUTER SETPOINT UNITS ENG ENG Engineering units PERCENT PERCENT Percent of PV range CSP RATO 20 0 to 20 0 COMPUTER SET
106. Universal Digital Controller Product Manual 93 Configuration 3 16 Configuration Record Sheet Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured Group Function Value or Factory Group Function Value or Factory Prompt Prompt Selection Setting Prompt Prompt Selection Setting TUNING PROP BD ALGORTHM CONT ALG PIDA or TIMER DISABLE GAIN 1 000 PERIOD 0 01 or START KEY GAINVALn Read Only LOW DISP TI REM RATE MIN 0 00 RESET KEY RSET MIN 1 00 INCREMENT MINUTES or INP ALG1 NONE RSET RPM MATH K 1 0 MAN RSET 0 CALC HI PROPBD2 CALC LO or ALG1 INA INPUT 1 GAIN 2 1 000 ALG1 INB INPUT 2 RATE2MIN 0 00 ALG1 INC NONE RSET2MIN 1 00 ALG1BIAS 0 000 or PCT CO 0 200 RSET2RPM a OUT ALG CYC SEC 20 or OUT ALG NOTE 1 CYC SX3 20 RLYSTATE 10F 20N CYC2 SEC 20 RLY TYPE MECHAN or MOTOR TI 30 CYC2 SX3 20 CUR OUT DISABLE SECURITY 0 CO RANGE 4 20mA LOCKOUT CALIB LOW VAL 0 0 AUTO MAN ENABLE HIGH VAL 100 0 RUN HOLD ENABLE SP SEL ENABLE SP RAMP SP RAMP DISABLE INPUT 1 IN1 TYPE 0 10mV TIME MIN 3 XMITTER1 LINEAR FINAL SP 1000 IN1 HIGH 1000 SP RATE DISABLE IN1 LOW 0 EU HR UP 0 RATIO 1 1 00 EU HR DN 0 BIAS IN1 0 HOTSTART DISABLE FILTER 1 1 SP PROG DISABLE BURNOUT1 NONE EMMISIV1 0 00 ACCUTUNE FUZZY DISABLE INPUT 2 IN2 TYPE 0 10mV ACCUTUNE DISABLE XMITTER2 LINEAR DUPLEX MANUAL IN2 HIGH 1000 ATERROR Read Only NONE IN2 LOW 0 RATIO 2 1
107. Use these values when calibrating your controller Table 5 1 Voltage Milliamp and Resistance Equivalents for Input Range Values Sensor Type PV Input Range Range Values Thermocouples per ITS 90 B O to 3300 18 to 1816 0 100 mV 13 769 mV ETCH 454 to 1832 270 to 1000 9 835 mV 76 373 mV ETCL 200 to 1100 129 to 593 6 472 mV 44 455 mV JTCH 0 to 1600 18 to 871 0 886 mV 50 060 mV J TC M 20 to 900 7 to 482 0 334 mV 26 400 mV JTCL 20 to 550 7 to 288 0 334 mV 15 650 mV KTCH 0 to 2400 18 to 1316 0 692 mV 52 952 mV KTCM 20 to 1200 29 to 649 1 114 mV 26 978 mV KTCL 20 to 750 29 to 399 1 114 mV 16 350 mV NNM H 32 to 2500 0 to1371 0 000 mV 71 773 mV NNM L 32 to 1260 0 to 682 0 000 mV 31 825 mV NIC H 0 to 2372 18 to1300 0 461 mV 47 513 mV NIC L 0 to 1472 18 to 800 0 461 mV 28 455 mV RTC 0 to 3100 18 to1704 0 090 mV 20 281 mV 4 08 UDC3200 Universal Digital Controller Product Manual 133 Input Calibration Sensor Type PV Input Range Range Values STC 0 to 3100 18 to1704 0 092 mV 17 998 mV TTCH 300 to 700 184 to 371 5 341 mV 19 097 mV TTCL 200 to 500 129 to 260 4 149 mV 12 574 mV WTCH 0 to 4200 18 to 2315 0 234 mV 37 075 mV WTCL 0 to 2240 18 to 1227 0 234 mV 22 283 mV Thermocouple 50 to 150 46 to 66 1 54 mV 4 62 mV Differential Honeywell Radiamatic Type RH 0 to 3400 18 to
108. V 31 0 5 Vdc 32 1 5 Vdc 33 0 10 Vdc 34 Unused 35 Carbon 36 Oxygen 37 Thermocouple Differential ATTENTION Changing the Input Type will result in the loss of Field Calibration values and will restore the Factory Calibration values 4 08 UDC3200 Universal Digital Controller Product Manual 203 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 1 00A9 169 INT R W 0 BTC Transmitter 1 ETCH Characterization 2 ETCL 3 JTCH 4 JTCM 5 JTCL 6 K TC H 7 K TC M 8 K TC L 9 NNM H 10 NNML 11 Nicrosil H TC 12 Nicrosil L TC 13 RTC 14 STC 15 TTCH 16 TTCL 17 WTCH 18 WTCL 19 100 PT RTD 20 100 PT LO RTD 21 200 PT RTD 22 500 PT RTD 23 Radiamatic RH 24 Radiamatic RI 25 Linear 26 Square Root Input 1 High 001D 029 FP R W 999 to 9999 Engineering Range Value Units Linear types only Input 1 Low 001E 030 FP R W 999 to 9999 Engineering Range Value Units Linear types only Input 1 Ratio 006A 106 FP R W 20 00 to 20 00 Input 1 Bias 006B 107 FP R W 999 to 9999 Engineering Units Input 1 Filter 002A 042 FP R W 0 to 120 seconds 204 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes Parameter Regis
109. ach time a transfer is made Only available if no tracking is selected DISABLE Disables auto bias ENABLE Enables auto bias SP TRACK NONE PV RSP SETPOINT TRACKING The local setpoint can be configured to track either PV or RSP as listed below Not configurable when Auto Bias is set ATTENTION For selections other than NONE LSP is stored in nonvolatile memory only when there is a mode change i e when switching from RSP to LSP or from Manual to Automatic If power is lost then the current LSP value is also lost NO TRACKING TIf local setpoint tracking is not configured the LSP will not be altered when transfer from RSP to LSP is made PV Local setpoint tracks the PV when in manual RSP Local setpoint tracks remote setpoint when in automatic When the controller transfers out of remote setpoint the last value of the remote setpoint RSP is inserted into the local setpoint PWR MODE 4 08 MANUAL ALSP POWER UP CONTROLLER MODE RECALL This selection determines which mode and setpoint the controller will use when the controller restarts after a power loss MANUAL LSP At power up the controller will use manual mode with the local setpoint displayed AUTOMATIC MODE LAST LSP At power up the controller will use automatic mode with the last local setpoint used before power down displayed UDC3200 Universal Digital Controller Product Manual 73 Configurat
110. addresses and ranges or selections for the function Modbus Read Write and Override Parameters plus Exception Codes prompts in Set up Group Control Table 10 16 Set up Group Control Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal PV Source 0085 133 INT R W 0 Input 1 1 Input 2 2 Input Algorithm 1 Tuning OOAC 172 INT R W 0 One set only Parameter 1 2 sets keyboard selected Selection 2 2 sets with PV automatic switchover 3 2 sets with setpoint SP automatic switchover Automatic 0038 056 FP R W Within the PV Range in Switchover engineering units Value used with 172 selection 2 or 3 Local Setpoint 00AD 173 INT R W 0 One Local Setpoint Source Number 1 Two Local Setpoints of LSPs 2 Three Local Setpoints Power Up Mode 0082 130 INT R W Control Setpoint Recall Mode Mode 0 MAN LSP 1 AUTO LSP 2 AUTO Last RSP 3 LAST Last SP 4 LAST Last Local SP RSP Source 0083 131 INT R W 0 None 1 Input 2 Setpoint 008A 138 INT R W 0 None Tracking 1 LSP PV when in Manual 2 LSP RSP when switched Auto Bias 0089 137 INT R W 0 Disable 1 Enable 4 08 UDC3200 Universal Digital Controller Product Manual 209 Modbus Read Write and Override Parameters plus Exception Codes Data Type Parameter Register Description Address Hex Decimal Control Setpoin
111. air Category 5 STP CAT5 Ethernet cable G Use Switch rather than Hub to maximize performance Figure 2 16 Ethernet Communications Option Connections Figure 2 16 and Table 2 7 shows how to connect a UDC to a MDI Compliant Hub or Switch utilizing a straight through cable or for connecting a UDC to a PC utilizing a crossover cable 4 08 UDC3200 Universal Digital Controller Product Manual 33 Installation Table 2 7 Terminals for connecting a UDC to a MDI Compliant Hub or Switch UDC Terminal UDC Signal Name RJ45 Socket Pin Switch Signal Name Position 14 Shield Shield Shield Position 15 RXD 6 TXD Position 16 RXD 3 TXD Position 17 TXD 2 RXD Position 18 TXD 1 RXD Table 2 8 shows how to connect a UDC directly to a PC utilizing a straight through cable wiring the UDC cable this way makes the necessary cross over connections Table 2 8 Terminals for connecting a UDC directly to a PC utilizing a straight through cable UDC Terminal UDC Signal Name RJ45 Socket Pin PC Signal Name Position 14 Shield Shield Shield Position 15 RXD 2 TXD Position 16 RXD 1 TXD Position 17 TXD 6 RXD Position 18 TXD 3 RXD Auxiliary Output Auxiliary Load 0 1000 Q Connect shield to ground at one end only Digital Inputs O Digital Input 1 Digital Input 2 T Connect shield to ground at one end only Auxiliary O
112. al 4 08 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 2 OOAB 171 INT R W 0 B TC Transmitter 1 ETCH Characterization 2 ETCL 3 JTCH 4 JTCM 5 JTCL 6 K TC H 7 K TC M 8 K TC L 9 NNM H 10 NNML 11 Nicrosil H TC 12 Nicrosil L TC 13 RTC 14 STC 15 TTCH 16 TTCL 17 WTCH 18 WTCL 19 100 PT RTD 20 100 PT LO RTD 21 200 PT RTD 22 500 PT RTD 23 Radiamatic RH 24 Radiamatic RI 25 Linear 26 Square Root Input 2 High 0023 035 FP R W 999 to 9999 Engineering Range Value Units Input 2 Low 0024 036 FP R W 999 to 9999 Engineering Range Value Units Input 2 Ratio 0025 037 FP R W 20 00 to 20 00 Input 2 Bias 0026 038 FP R W 999 to 9999 Engineering Units Input 2 Filter 002B 043 FP R W 0 to 120 seconds Input 2 002C 044 FP R W 0 01 to 1 00 Emmissivity 4 08 UDC3200 Universal Digital Controller Product Manual 207 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 2 Burnout 00A5 0165 INT RW 0 None 1 Up 2 Down 3 No Failsafe 208 UDC3200 Universal Digital Controller Product Manual 4 08 10 7 8 Control Table 10 16 lists all the register
113. al 49 Configuration 3 7 Algorithm Set Up Group Introduction This data deals with various algorithms in the controller and Timer functions The Timer section allows you to configure a time out period and to select the timer start by either the keyboard RUN HOLD key or Alarm 2 An optional digital input can also be configured to the start the timer The timer display is selectable as either time remaining see TI REM or elapsed time see E TIME Alarm 1 is activated at the end of the time out period When the timer is enabled it has exclusive control of the alarm 1 relay any previous alarm 1 configuration is ignored At time out the timer is ready to be activated again by whatever action has been configured Function Prompts Table 3 7 ALGORTHM Group Function Prompts 50 Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display CONT ALG The CONTROL ALGORITHM lets you select the type of control that is best for your process ON OFF ON OFF is the simplest control type The output can be either ON 100 or OFF 0 The Process Variable PV is compared with the setpoint SP to determine the sign of the error ERROR PV SP The ON OFF algorithm operates on the sign of the error signal In Direct Acting Control when the error signal is positive the output is 100 and when the error signal is negative the output is 0 If the control action is revers
114. al Controller Product Manual 65 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition FILTER 1 0 to 120 seconds No filter 0 FILTER FOR INPUT 1 A software digital filter is provided for Input 1 to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter 0 BURNOUT NONE UP DOWN NO FS BURNOUT PROTECTION SENSOR BREAK provides most input types with upscale or downscale protection if the input fails NO BURNOUT Pre configured Failsafe output selected in the CONTROL Set up Group applied if failed input is detected does not apply for an input out of range Diagnostic message IN1 FAIL is intermittently flashed on the lower display UPSCALE BURNOUT will force the Input 1 signal to the full scale value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 1 signal developed by the Burnout circuitry DOWNSCALE BURNOUT will force the Input 1 signal to the lower range value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the lower
115. ameters such as Output Setpoints Inputs Deviation active Tuning Parameter Set Timer Status or minutes remaining in a setpoint ramp 4 digits During configuration the lower display provides guidance for the operator through prompts 8 characters Indicates Alarm 1 and or Alarm 2 conditions exist Indicates Digital Input 1 and or 2 on Indicates Control Relay 1 and or 2 on Or Indicates either degrees Fahrenheit or fa Centigrade Or Indicates either Manual or Auto mode Indicates Local Setpoint 1 Also a bar is lighted when the setpoint being used is shown on the lower display Keys and Functions 9 0 KE KE BOE Selects functions within each configuration group Scrolls through the configuration groups Returns Controller to normal display from Set Up mode Toggles various operating parameters for display Increases setpoint or output value Increases the configuration values or changes functions in Configuration mode groups Infrared transceiver Pa E f EJ K a EJ z kE Selects Manual or Auto mode Hold key down to cycle through configured setpoints Enables Run Hold of the SP Ramp or Program plus Timer start Decreases setpoint or output value Decreases the configuration values or changes functions in Configuration mode groups NEMA4X and IP66 screw attachment each corner o UDC3200 Universal Digital Controller Product Manual 4 08 Introd
116. and also the specific parameters Function prompts associated with each group Table 3 1 shows an overview of the prompt hierarchy as it appears in the controller What s in this section 36 The following topics are covered in this section Table 3 1 Configuration Topics 3 8 OutputSetUpGroup 3 10 Input2SetUpGroup 3 16 Configuration Record Sheet UDC3200 Universal Digital Controller Product Manual 4 08 Configuration 3 2 Configuration Prompt Hierarchy Table 3 2 Configuration Prompt Hierarchy Set Up Group Function Prompts TUNING gt f Foren RSET2MIN or GAIN or or or RSET RPM GAIN 2 RSET2RPM CYC SX3 bin or or CYC2 SX3 SPRAMP seme Corea car SFE Com eo E en x 1to 12 Program concludes after segment 12 or SEGRATE ACCUTUNE ALGORTHM contac mmer _ Perion start towoise reser menement mP arca ema eMe EAE aora AUT ACCT Pere CT ALGORTHM contae mmer Perio srant towbise wP arci mark caucus O emco morma ALTE sine Perco PET as MEE O INPUT2 PDE me wena wetow Chavo msm ruven euo EmA o o a o O TaN a o a FAIWODE Ly aim our ATO OUT Paor6aN non 4 08 UDC3200 Universal Digital Controller Product Manual 37 Configuration COM gt Co UMS sra ESPNS room 38 ALARMS DISPLAY CALIB gt USED FOR FIELD CALIBRATION STATUS version UDC32
117. as HEAT Rate on Duplex models for variations of Heat Cool applications 40 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition RSET MIN or RSET RPM 0 02 to 50 00 RSET MIN Reset in Minutes per Repeat RSET RPM Reset in Repeats per Minute RESET or Integral Time adjusts the controller s output in accordance with both the size of the deviation SP PV and the time that it lasts The amount of the corrective action depends on the value of Gain The Reset adjustment is measured as how many times proportional action is repeated per minute or how many minutes before one repeat of the proportional action occurs Used with control algorithm PID A or PID B Also defined as HEAT Reset on Duplex models for variations of Heat Cool applications ATTENTION The selection of whether Minutes per Repeat or Repeats per Minute is used is made in the CONTROL parameters group under the prompt MINorRPM MAN RSET 100 to 100 in output MANUAL RESET is only applicable if you use control algorithm PD WITH MANUAL RESET in the Algorithm Set Up group Because a proportional controller will not necessarily line out at setpoint there will be a deviation offset from setpoint This eliminates the offset and lets the PV line out at setpoint ATTENTION Bias is shown on
118. as A1S1 VAL A2S1 VAL Value in engineering units ALARM 2 SETPOINT 1 VALUE This is the value at which you want the alarm type chosen in prompt A2S1TYPE to actuate The details are the same as A1S1 VAL A2S2 VAL Value in engineering units ALARM 2 SETPOINT 2 VALUE This is the value at which you want the alarm type chosen in prompt A2S2TYPE to actuate The details are the same as A1S1 VAL 4 08 UDC3200 Universal Digital Controller Product Manual 87 Configuration 88 Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display A1S1TYPE ALARM 1 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 1 to represent It can represent the Process Variable Deviation Input 1 Input 2 Output and if you have a model with communications you can configure the controller to alarm on SHED If you have setpoint programming you can alarm when a segment goes ON or OFF NONE NO ALARM INPUT 1 INPUT 1 INPUT 2 INPUT 2 PV PROCESS VARIABLE DEV DEVIATION OUTPUT OUTPUT NOTE 1 SHED SHED FROM COMMUNICATIONS EV ON EVENT ON SP PROGRAMMING EV OFF EVENT OFF SP PROGRAMMING MANUAL ALARM ON MANUAL MODE NOTE 2 REM SP REMOTE SETPOINT F SAFE FAILSAFE PV RATE PV RATE OF CHANGE DIG INP 1 DIGITAL INPUT 1 ACTUATED NOTE 7 DIG INP 2 DIGITAL INPUT 2 ACTUATED NOTE 7 DEV 2 DEVIATION FROM LSP 2 NOTE 3 BREAK LOOP BREAK NOTE 4 TCWARN THERMOCOU
119. ata Description Function code 20 14 Hex is used in this instrument to read information stored in its configuration database Each configuration item is explicitly addressed by a file number and register address IEEE 32 bit floating point and 16 bit integer formats are supported Request and Response Formats The Request and Response formats for Function code 20 14 Hex are shown below Details for each block reference follow Request Message Format Slave Function Byte Reference File Register Register es Address Code 14 Count Type Number Address Count Reference File Register Register CRC CRC Type Number Address Count Data Data Response Message Format Data Slave Function Byte Reference Address Code 14 Count Byte Type Data Data Data Count Data Reference See Data Byte Type Data Data Data Data cece Count yp CRC CRC Data Data Byte Count The Byte Count equals the number of bytes transmitted in either the request or response message and will be the minimum number required to transmit all requested data Data Byte Count The Data Byte Count is the number of data bytes of the sub response including the Reference Type but not including itself A floating point sub response has four bytes of data and one byte representing the reference type making the data byte count equal to five 178 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus RTU Function Codes Reference Type Definitions
120. ation device to an output signal equal to the 0 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 0 range values e Wait 15 seconds then go to the next step 140 UDC3200 Universal Digital Controller Product Manual 4 08 Input Calibration CC O 3 Calibrate 100 Function You will see SS Upper Display APPLY Lower Display INn SPAN n 1 or 2 e Adjust your calibration device to an output signal equal to the 100 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 100 range values e Wait 15 seconds and lf Then you are calibrating a Thermocouple input go to step 4 you are calibrating other than a go to step 5 Thermocouple input 4 Check the Cold Function The calculations for zero and span are now stored and you Junction N A will see Temperate Upper Display The cold junction temperature at the rear terminals Lower Display CJTEMP The value in the upper display is in tenths of a degree It is the current reading of the temperature as measured at the thermocouple terminals and recognized by the controller You can change this value if it is in error using the Mor keys WARNING The accuracy of the controller is directly affected by the accuracy of this value Itis recommended that this value not be changed under normal circumstances 5 Exit the Function The cont
121. atus is used in close proximity the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment WARNING If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 4 08 UDC3200 Universal Digital Controller Product Manual 9 2 Installation 2 1 Overview Introduction Installation Installation of the UDC3200 consists of mounting and wiring the controller according to the instructions given in this section Read the pre installation information check the model number interpretation Subsection 2 3 and become familiar with your model selections then proceed with installation What s in this section 4 08 The following topics are covered in this section TOPIC 2 1 Overview 2 2 Condensed Specifications 2 3 Model Number Interpretation 2 4 Control and Alarm Relay Contact Information 2 5 Mounting 2 6 Wiring 2 7 Wiring Diagrams Composite Wiring Diagram AC Line Voltage Input 1 Connections Input 2 Connections Relay Output Electromechanical Solid State Open Collector Dual Electromechanical Relay Current Output Connections Three Position Step Control Connections w o Dual Relay Three Position Step Control Connections with Dual Relay RS 422 485 Communications Option Ethernet Communications Option Auxiliary Output and Digital Inputs Option Transmitter Power using Open Collector O
122. ay Selections or Range of Setting Upper Display Parameter Definition 4 08 TO HOLD TO PID2 PV 2IN RERUN TO RUN ToBEGIN STOP MAN FS TO LOCK TO HOLD Contact closure suspends Setpoint Program or Setpoint Ramp When contact reopens the controller starts from the Hold point of the Ramp Program unless the Ramp Program was not previously started via the EZSlkey This selection applies to either loop TO PID2 Contact closure selects PID Set 2 PV INPUT 2 Contact closure selects PV Input 2 RERUN Allows the Setpoint Programmer to be reset to the initial segment of its current cycle unit stays in previous mode RUN Contact closure starts a stopped SP Ramp or Program Upper left character blinks R Reopening the contact puts controller in HOLD mode This selection applies to either loop EXTERNAL SP PROGRAM RESET Contact closure resets SP Program back to the beginning of the first segment in the program and places the program in the HOLD mode Program cycle number is not affected Reopening switch has no effect This selection applies to either loop ATTENTION Once the last segment of the setpoint program has timed out the controller enters the mode of action specified in the configuration data and the program cannot be reset to the beginning of the first segment by digital input closure INHIBIT INTEGRAL RESET Contact closure disables PID Integral
123. ay SPAN VAL When the motor stops the display should stop counting then go to Step 8 You will see Upper Display the existing zero calibration value in counts Lower Display ZERO VAL UDC3200 Universal Digital Controller Product Manual 149 Output Calibration Step Description Press Action AXNorw Set 100 Function Set 100 value AX orw 7 Exit the Calibration Mode JE 4 NE E E 3 NE until the desired zero value is reached in the upper display Upper Display the desired zero calibration value Lower Display ZERO VAL The controller will store the 0 value and you will see Upper Display the existing span calibration value in counts Lower Display SPAN VAL until the desired span value is reached in the upper display Upper Display the desired span calibration value Lower Display SPAN VAL For manual calibration the motor does not move from its position prior to the start of Position Proportional calibration The controller will store the 100 value To exit the calibration mode 150 UDC3200 Universal Digital Controller Product Manual 4 08 Output Calibration 6 5 Restore Output Factory Calibration Introduction The factory calibration constants for the Current and Auxiliary Outputs are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for those outputs by simply changing the CO RANGE setting for
124. ble You can now duplicate an instrument s configuration upload or download a new configuration in a matter of seconds just by pointing your Pocket PC in the direction of the instrument It takes just a few seconds to upload a configuration from an instrument You can then save the configuration file onto your PC or pocket PC for review modification or archiving Furthermore this software also gives you important maintenance information on the controller instantly get information on the current operating parameters digital inputs and alarm status identify internal or analog input problems Question What if I have several controllers on the same panel How can I be sure I am communicating with the correct one Answer The infrared port of the controller is normally off You activate the infrared port by pressing any controller s key You can now communicate After 4 minutes the port will be shut down again Each controller may also be assigned a different communications address Figure 1 3 Depiction of infrared communications 1 4 CE Conformity Europe This product is in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed Product Classification Class I Permanently connected panel mounted Industrial Control Equipment wi
125. bove 50 4 08 UDC3200 Universal Digital Controller Product Manual 113 Monitoring and Operating the Controller sep Operation press ren 3 Switch to Automatic Mode 4 Show Tuning Prompt 5 Initiate Tuning 6 Tuning in operation Until the A indicator is lighted on controllers with Manual option Until TUNE OFF is shown on lower display Select DO SLOW or DO FAST in lower display Upper display will show a T as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NO TUNE prompt Table 4 14 Procedure for Using MANUAL TUNE for Cool side of Duplex Control sp Operation press re Piou 1 Configure LSP2 2 3 Switch to Automatic Mode 4 Show Tuning Prompt 5 Initiate Tuning 6 Tuning in operation Until 2SP Local Setpoint 2 shows in the lower display Until LSP2 is a value within the Cool Zone output below 50 Until the A indicator is lighted on controllers with Manual option Until TUNE OFF is shown on lower display Select DO SLOW or DO FAST in lower display Upper display will show a T as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NO TUNE prompt 114 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operatin
126. bsection 3 9 Configuration Set Up prompt INPUT 1 function prompt EMISSIV 1 Subsection 3 10 Configuration Set Up prompt INPUT 2 function prompt EMISSIV 2 22 23 Input 2 24 25 26 Input 1 27 ioi m4 toy Wa a lie Daa WSIS 74 2 DN 4 A Millivolt or ORO KA 75 X SSi Volt Source XXXX Figure 5 5 Wiring Connections for Radiamatic Thermocouple Differential Millivolts or Volts Except 0 to 10 Volts 138 UDC3200 Universal Digital Controller Product Manual 4 08 Input Calibration 5 4 5 0 to 10 Volts Refer to Figure 5 6 and wire the controller according to the procedure given in Table 5 7 Table 5 7 Set Up Wiring Procedure for 0 to 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 6 Place voltage source at zero before switching on Do not switch voltage source ON OFF while connected to the instrument Input 2 Input 1 Voltage Source Figure 5 6 Wiring Connections for 0 to 10 Volts 5 4 6 Milliamperes Refer to Figure 5 5 and wire the controller according to the procedure given in Table 5 6 Table 5 8 Set Up Wiring Procedure for Milliampere Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 7 Place current source at zero before switching on Do not switch current source ON OFF while connected to the instrument 22 23 Input 2 24
127. can be shown TEMP UNIT TEMPERATURE UNITS This selection will affect the indication and operation DEG F DEG F Degrees Fahrenheit Degrees F Annunciator lighted DEG C DEG C Degrees Centigrade Degrees C Annunciator lighted NONE NONE No temperature annunciators lighted Upper and Lower Displays will show temperature in Degrees Fahrenheit when inputs are configured for Thermocouple or RTD types PWR FREQ 60 HZ POWER LINE FREQUENCY Select whether your 50 HZ controller is operating at 50 or 60 Hertz ATTENTION For controllers powered by 24 Vdc this configuration should be set to the AC line frequency used to produce the 24 Vdc supply Incorrect setting of this parameter may cause normal mode noise problems in the input readings RATIO 2 INPUT 2 RATIO This enables the Ratio for Input 2 to be set from the front panel Input 2 must be installed and enabled for this configuration to operate DISABLE DISABLE Disables setting Ratio 2 from front panel 92 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display ENABLE ENABLE Allows the Ratio for Input 2 to be set through the keyboard LANGUAGE LANGUAGE This selection designates the prompt language ENGLISH ENGLISH FRENCH FRENCH GERMAN GERMAN SPANISH SPANISH ITALIAN ITALIAN 4 08 UDC3200
128. cated anywhere between the thermocouples and the instrument terminals it does not need to be close to the other thermocouple junctions Both thermocouples must be of the same type For best accuracy the two thermocouples should be matched or preferably made from the same batch of wire This controller does not produce a steady current for burnout detection For that reason when a thermocouple is used in parallel with another instrument it may be desirable to configure the burnout selection for this controller to NOFS and use the burnout current from the other instrument to also drive this controller The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450 F 232 C Figure 2 6 Input 1 Connections UDC3200 Universal Digital Controller Product Manual 4 08 4 08 Installation Input 2 Thermocouple Millivolt or Volts except 0 10 Volts Use Thermocouple extension wire only 0 10 Volts Milliamps Use Thermocouple extension wire only Po wer Supply Slidewire Input for Position Proportional Control or Three Position Step Control The 250 ohm resistor for milliamp inputs or the voltage divider for 010 Volt inputs are supplied with the controller when those inputs are specified These items must be installed prior to start up when the controller is wired For 0 20 mA applications the resistor sh
129. cations Standard Type Serial Infrared SIR Length of Link 3 ft 1 m maximum for IrDA 1 0 compliant devices Baud Rate 19 200 or 38 400 baud selectable Power Consumption 20 VA maximum 90 to 264 Vac 15 VA maximum 24 Vac dc Power Inrush Current 10A maximum for 4 ms under operating conditions reducing to a maximum of 225 mA 90 to 264 Vac operation or 750 mA 24 Vac dc operation after one second CAUTIOR When applying power to more than one instrument make sure that sufficient power is supplied Otherwise the instruments may not start up normally due to voltage drop from the inrush current Weight 3 Ibs 1 3 kg Environmental and Operating Conditions Parameter Reference Rated Operative Transportation and Storage Limits Ambient Temperature 25 3 C 15 to 55 C 0 to 55 C 40 to 66 C 7745 58 to 131 F 32 to 131 F 40 to 151 F Relative Humidity 10 to 55 10 to 90 5 to 90 5 to 95 Vibration Frequency Hz 0 0 to 70 0 to 200 0 to 200 Acceleration g 0 0 4 0 6 0 5 Mechanical Shock Acceleration g 0 1 5 20 Duration ms 0 30 30 30 Line Voltage Vdc 24 1 22 to 27 20 to 30 He Line Voltage Vac 90 to 240 Vac 120 1 90 to 240 90 to 264 240 2 24 Vac 24 1 20 to 27 20 to 27 Frequency Hz 50 0 2 49 to 51 48 to 52 For Vac 60 0 2 59 to 61 58 to 62 The maximum moisture rating only applies up to 40 C 104
130. ccsssseeeesssseeeeenes 96 AY OVINA A A A AD tidad eii 96 4 2 Operator Interface von a astilla 97 4 3 Entering a Security Code niinen nirani iiion ni ae astas iien Erai raaa i 97 44 Lockout Featire Ad A A a a a 98 4 5 Monitoring Your Controller nisser orsin anain Ra RAA a A 100 TS O RE 100 4 5 2 Viewing the operating parameters ccccccescceseceseceseceeeceeeeeseecseecsaecaeceseceseeeeeeseeeseeeeaes 101 4 3 3 Diagnostic Messages ai la dalla deis 102 4 6 Start Up Procedure for Operation ooococonocononnnonnnonnnooncnnnconccon nono nono noco nono nn nan n naar rra n anna rnrrnnrrnn rin 104 AT Control Mode A A conten as 105 Adol Mode Detinitions accan eee A e EEE AE E EES 105 4 7 2 What happens when you change MOdeS ccccesscesseesseeeceeseeceecsaecnseceseceseeneeeeeeeseeeeees 106 AO SOM id e IEA aaa casts as Aas oe 106 O O TO 108 ALO Accutane acidos 109 4 10 1 Tune for Simplex Outputs ssnin n a a a a a a a aE 110 4 10 2 Tune for Duplex Heat Cool iceren irisi a ai a 111 4 10 3 Using AUTOMATIC TUNE at start up for Duplex Heat CooOl ooooonocinccnococoncconono 112 4 10 4 Using BLENDED TUNE at start up for Duplex Heat Co0l oooooocinnnnnccnoncnonnconocononos 113 4 10 5 Using MANUAL TUNE at start up for Duplex Heat Cool oooonooninnninocioncnonnconocononos 113 4 10 6 lEI a COGS ek ia Rica EE A OES AEAN 115 4 11 Fuzzy Overshoot Suppression eee ea e E e E E E E E E T rin 116 4 12 Using Two Sets of Tuning Constants
131. cedure for Identifying the Software Version Procedure for Displaying the Status Test Results Background Tests Controller Failure Symptoms Troubleshooting Power Failure Symptoms Troubleshooting Current Output Failure Troubleshooting Position Proportional Output Failure Troubleshooting Time Proportional Output Failure Troubleshooting Current Time or Time Current Proportional Output Failure Troubleshooting Alarm Relay Output Failure Troubleshooting a Keyboard Failure Troubleshooting a RS 485 Communications Failure Troubleshooting an Ethernet Communications Failure Troubleshooting Auxiliary Output Failure Restoring Factory Configuration Software Upgrades Parts Identification Parts Not Shown Software Upgrades see Section 7 9 Integer Parameter Type Floating Point Parameter Type Register Address Format for Function Code 20 Register Address Format for Function Code 21 Control Data Parameters Option Status Miscellaneous Read Onlys SetPoint Program Read Only Information Setpoint Code Selections Setpoint Associated Parameters Computer Setpoint Selection Computer Setpoint Associated Parameters Set up Group Tuning 0 Set up Group Setpoint Ramp Rate UDC3200 Universal Digital Controller Product Manual 138 139 139 140 142 144 145 146 147 148 151 155 156 157 159 161 161 162
132. cintas patita 156 Stray Rejection oooooooconncnnoniconoonconnonononnnonnonononos 12 Summer With Ratio And Bias eee 54 Suppression Devices ccscceseesteeseeeneeeeeeeeeees 21 Switch Between Two Sets Via Keyboard 118 Switching Between Setpoints 0 0 eee 107 T Temperature UniS vc idas 92 Test Failures iii 156 Thermocouple Health ooooonoonnncnnncnnnnincnincconcoo 2 Thermocouple Inputs Using A Thermocouple Uta ir acho 137 Thermocouple Inputs Using An Ice Bath 136 Three Position Control Step Output Start Up Mode ioerectec lotic EEN 74 Three Position Step cooooconoonocnnonnconccnnconnonnnonnos 52 Three Position Step Control c cece 148 Three Position Step Control Algorithm 120 Three Position Step Control Connections 32 Three Position Step Test Failures 156 Time Current DupleX oooooonicnncnincnincnnncnnnonnos 61 Time Duplicador deso 61 Time Proportional OUtpUt ooooonccnnnnincnnncinnon s 60 Time Proportional Output Failure 163 Time Remaining ocooococcnoninnccononnnononinnnonnonanonos 108 A e a a 60 TimeOut sieti e eaS 109 Timro ds 4 108 Time icnn is 52 Transmitter Characterization 000 65 69 Transmitter POWOT oooononionococnnoncnnconcnnnonononinnonos 3 Transmitter Power For 4 20 Ma 34 35 Troubleshooting Aids ooooooncciocinoniccnccncnnnnnos 154 Troubleshooting Procedures oo ooonoon 160 T
133. circuits e Low voltage wiring to open collector type control circuits 4 08 UDC3200 Universal Digital Controller Product Manual 21 Installation 2 7 Wiring Diagrams Identify Your Wiring Requirements To determine the appropriate diagrams for wiring your controller refer to the model number interpretation in this section The model number of the controller is on the outside of the case Universal Output Functionality and Restrictions 22 Instruments with multiple outputs can be configured to perform a variety of output types and alarms For example an instrument with a current output and two relays can be configured to perform any of the following 1 Current Simplex with two alarm relays 2 Current Duplex 100 with two alarm relays 3 Time Simplex with one alarm relay 4 Time Duplex with no alarm relays or 5 Three Position Step Control with no alarm relays These selections may all be made via the keyboard and by wiring to the appropriate output terminals there are no internal jumpers or switches to change This flexibility allows a customer to stock a single instrument which is able to handle a variety of applications Table 2 6 shows what control types and alarms are available based upon the installed outputs In this table when Duplex Control and Reverse Action are configured Output 1 is HEAT while Output 2 is COOL When Three Position Step Control is configured Output 1 is OPEN while Output 2
134. concnincnnnnninnon s 75 Controller Failure Symptoms 0 0 159 Controller Grounding oooooococonocononccononnnonnnonnss 20 Controller Output Typ8S ooooconoconocococcioninnnonnss 13 Current Duplex c oooconncniccnonnconcconcconccnncnnnonnnonnos 61 Current OUIPUL incendio distin 31 Current Output atan 63 Current Output 2 vis ccccsseciseccesssesscveecenscvenessenveves 78 Current Output Failure Symptoms 161 Current Outputs ccoooccocccconccconcccononnonccnnnncnanccnnno 13 Current Proportional Output Calibration 144 Current SimpleX sanieren 60 Current Time DupleX oooonccnocnnonnnonninncnnnocnnonos 61 Current Time Or Time Current Proportional Output Failure ooooooncnnncincnnnnnncniccnonnnnnnonos 164 Customer SUPPOTt coooccccnoccconcnononcconanononacannnonn 155 Cycle NuMbeL cooooococcoccconononcconononononinncnnonanonos 188 Cycle Time Colima 42 Cycle Time H at ancianas 42 Cycles Remaining ccccccsseeseesseeteeereeeseees 188 D Data Security 2 24 Seen h loti eee he ec aes 4 Data Transfer iii 185 Deadbaind ii secretas 75 Decimal Point Location oooonconnononnnnoncnonncnnnnon 92 Declaration Of ConforMitY ooocoociccnoccconccononnnonnss 9 Demand Tuning enecens 48 US insiren 55 DiagnoStiC ooooconocciononononononnnonn nono nonnnnnnconocnnonnnoo 91 Diagnostic AlatM oooonnccnnncnncnnccnnonnocnconnconoconooo 91 Diagnostic Messages oooocooonoccconccnnccnnocnnonnnonos 102 Diagnostic Failsaf
135. dge of a security code number 0 to 9999 may be required to change from one level of lockout to another When a controller leaves the factory it has a security code of 0 which permits changing from one lockout level to another without entering any other code number Procedure If you require the use of a security code select a number from 0001 to 9999 and enter it when the lockout level is configured as NONE Thereafter that selected number must be used to change the lockout level from something other than NONE ATTENTION Write the number on the Configuration Record Sheet in the configuration section so you will have a permanent record 4 08 UDC3200 Universal Digital Controller Product Manual 97 Monitoring and Operating the Controller Table 4 1 Procedure to Enter a Security Code step Operation ess A OOO 1 Enter Set Up C setup Upper Display SET UP Mode A Lower Display TUNING 2 Select any Set Function Upper Display 0 Up Grou i SS Lower Display SECUR 3 Security Code Axor To enter a four digit number in the upper display Entry 0001 to 9999 This will be your security code 4 4 Lockout Feature Introduction The lockout feature in the UDC3200 is used to inhibit changes via keyboard of certain functions or parameters by unauthorized personnel Lockout levels There are different levels of Lockout depending on the level of security required These levels are e NONE No Lockout All g
136. display will show NO TUNE prompt ATTENTION The Accutune process may be aborted at any time by changing the lower display back to NoTUNE or by switching the controller into Manual Mode 4 10 2 Tune for Duplex Heat Cool Accutune for applications using Duplex Heat Cool control The controller must be configured to have two local setpoints unless Blended Tuning is desired see below See Subsection 3 11 Control Set Up Group for details on configuring two local setpoints During tuning the Accutune III process assumes that Local Setpoint 1 will cause a Heating demand output above 50 and the tuning parameters calculated for that setpoint are automatically entered as PID SET 1 Likewise Accutune III assumes that Local Setpoint 2 will cause a Cooling demand output less than 50 and the tuning parameters calculated for that setpoint are automatically entered as PID SET 2 Configuration Check for Duplex See Subsection 3 6 Accutune Set Up Group for details Make sure e TUNE has been enabled e DUPLEX has been configured to Manual Automatic or Disabled 4 08 UDC3200 Universal Digital Controller Product Manual 111 Monitoring and Operating the Controller 4 10 3 Using AUTOMATIC TUNE at start up for Duplex Heat Cool Used when DUPLEX has been configured for AUTOMATIC This is the preferred selection for most Heat Cool applications when tuning a new chamber This selection will sequentially perform both Heat and
137. e Lower Display FSMODE 3 Select a value To select a failsafe mode in the upper display 4 Return to Normal At power up the output will go to the value set Display 4 17 Setpoint Rate Ramp Program Overview Introduction The Setpoint Ramp configuration group lets you enable and configure any of the following e SP RATE a specific rate of change for any local setpoint change Subsection 4 18 e SP RAMP a single setpoint ramp that occurs between the current local setpoint and a final local setpoint over a time interval of 1 to 255 minutes Subsection 4 19 e SP PROG a ramp soak profile in a 12 segment program Subsection 4 20 This section explains the operation of each selection and configuration reference where necessary PV Hot Start This is a standard feature At power up the setpoint is set to the current PV value and the Rate or Ramp or Program then starts from this value 122 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller RUN HOLD key You can start or stop the Ramp or Program using the RUN HOLD key 4 18Setpoint Rate Introduction When you have configured a SETPOINT RATE it will apply immediately to local setpoint change Configuration check Make sure e SPRATE is enabled e A Rate Up EUHRUP or Rate Down EUHRDN value has been configured in Engineering units per hour ATTENTION A value of 0 will imply an immediate change in setpoint that
138. e For example if SP 1500 and the SP HiLIM is changed to 1200 the new local setpoint will be 1200 NOTE 1 Does not apply to Three Position Step Control NOTE 2 If controller is in Manual mode when a failure occurs then the output will maintain its value NOTE 5 Reset limits and Dropoff are not displayed when Three Position Step Control is configured 4 08 UDC3200 Universal Digital Controller Product Manual 77 Configuration 3 12 Options Group Introduction The Options group lets you configure the remote mode switch Digital Inputs to a specific contact closure response or configure the Auxiliary Output to be a specific selection with desired scaling Function Prompts Table 3 12 OPTION Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display AUX OUT AUXILIARY OUTPUT SELECTION ATTENTION This selection provides an mA output representing Prompts for the one of several control parameters The display for Auxiliary Output auxiliary output viewing will be in engineering units Selection appear only for all but output Output will be displayed in percent if one of the Auxiliary Output boards is ATTENTION Other prompts affected by these installed selections 4mA VAL and 20mA VAL ATTENTION Output cannot be configured when Three Position Step Control is used DISABLE NO AUXILIARY OUTPUT INPUT 1 INPUT 1 This r
139. e if the controller does not have a current output then none of the prompts for Output Algorithms that need a current output will appear Likewise if the controller does not have a relay output then none of the prompts that need a relay output will appear ATTENTION For all Duplex Output forms PID heat parameters apply for controller output greater than 50 PID cool parameters apply for controller output less than 50 TIME SIMPLEX This output algorithm uses Digital Output 1 for Time Proportional Control The output is updated per the Loop sampling rate selection Time Proportional Output has a resolution of 4 44 msec Cycle Time is adjustable from 1 to 120 seconds CURRENT SIMPLEX Type of output using one 4 mA to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 1000 ohms This signal can easily be configured for 4 20 mA or 0 20 mA operation via the CO RANGE configuration below POSITION PROPORTIONAL Type of output using two relays and a motor that has a 100 to 1000 ohms feedback slidewire This output algorithm selection forces Input 2 to the SLIDEW selection when the Control Algorithm is any selection other than 3PSTEP ATTENTION Other prompts affected DEADBAND IN2 TYPE UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition
140. e the opposite is true An adjustable overlap Hysteresis Band is provided between the on and off states ATTENTION Other prompts affected OUT HYST DUPLEX ON OFF is an extension of this algorithm when the output is configured for a Duplex control algorithm It allows the operation of a second ON OFF output There is a deadband between the operating ranges of the two inputs and an adjustable overlap hysteresis of the on and off states of each output Both Deadband and Hysteresis are separately adjustable With no relay action the controller will read 50 ATTENTION Other prompts affected OUT HYST and DEADBAND UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display PIDA PID A is normally used for three mode control This means that the output can be adjusted somewhere ATTENTION PIDA between 100 and 0 It applies all three control should not be used for Proportional only action i e no integral reset action Instead use PD MR with rate set to 0 PIDB PD MR actions Proportional P Integral I and Derivative D to the error signal Proportional Gain Regulates the controller s output in proportion to the error signal the difference between Process Variable and Setpoint Integral Reset Regulates the controllers output t
141. e 00B8 184 INT R W 0 Motor goes to closed Output position 0 1 Motor goes to open position 100 Manual Output 0071 113 FP R W 0 to 100 Automatic 0072 114 FP R W 0 to 100 Output Proportional 0094 148 INT R W 0 Gain Band Units 1 Proportional band Reset Units 0095 149 INT R W 0 Minutes 1 RPM 4 08 UDC3200 Universal Digital Controller Product Manual 211 Modbus Read Write and Override Parameters plus Exception Codes 10 7 9 Options Table 10 18 lists all the register addresses and ranges or selections for the function parameters in Set up Group Options Table 10 17 Set up Group Options Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Auxiliary 0086 134 INT R W 0 None Output 1 Input 1 2 Input 2 3 PV 4 Deviation 5 Output 6 Setpoint 7 LSP 8 RSP 9 Input Algorithm 1 Low Scaling 0031 049 FP R W Within the range of the Factor selected variable in ID 134 High Scaling 0032 050 FP R W Within the range of the Factor selected variable in ID 134 Auxiliary 00EB 236 INT R W 0 4 20 mA Output Range 1 0 20 mA 212 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Digital Input 00B
142. e Outputs 0 0 0 cceeeeseerteeeee 4 Digital Input Remote Operation 131 Digital Input Combinations coooonoonccnonicnicccnnon 83 4 08 UDC3200 Universal Digital Controller Product Manual Index Digital Input Selecti0NS oocononnninnnnnncnnmmm 80 Digital Inp ts scesero tierces 2 12 Digital Inputs Option Connections 34 Digital Output Status o ooonccicnnnnnonoccnacnononannninnon 62 DIMENSIONS 22 cotos ida bala 18 Direct Acting Control oooooccnnnnnniocnnncconncnnnonnss 74 Display IndicatofS ooooncncnnnnnonnnononnnecenccnnnos 6 Dual Electromechanical Relay Option Output 31 E Elapsed Tie iii ii 108 Electrical ConsideratiODS oooonccicnnnnonnnnnennnnn 20 Electrical Noise Precauti0NS oocoonccnnninnninmo o 20 Electromechanical Relay Output 28 Electromechanical Relays ooooonnonnnnnnninninn o o 13 Emc Classification 9 Emissivity ici ica 67 70 Enclosure Rating ooonooncccncnnonnnocncononononnnonnonnnnnos 9 End Segment Number cccsscesseeteeeeees 126 Environmental And Operating Conditions 14 Equipment You Will Need To Calibrate 135 Error Code csi 115 Error Messages cccsscceesceceseeeeneeceseeeeneeeeeees 102 Estimated Motor Position ceseeeeeee 120 Ptherne ten eee Bsttha esti a a 7 Ethernet Communications Failure 168 Ethernet Tep lP oooconccncinnninonnncnicnonnonnnnnnnnos 2
143. e external equipment when preset alarm setpoints are reached Each of the two alarms can be set to monitor two independent setpoints Each alarm setpoint can be either high or low alarm The alarm type can be selected to be either of the inputs the Process Variable Deviation Output Shed from communications PV rate of change or to alarm on manual mode activation or a Current Output Open failure It can also be used as an On or Off event at the beginning or end of a Ramp Soak segment The alarm hysteresis is configurable from 0 to 100 of range e Alarms can be configured as latching or non latching e Alarm blocking is also available which allows start up without alarm energized until after it first reaches the operating region e PV rate of change alarm e Loop break alarm e Timer output reset e Diagnostic Alarm Communications A communications link is provided between the UDC3200 and a host computer or PLC via the RS422 485 Modbus RTU or Ethernet TCP IP communications option An infrared communication link is also available allowing a non intrusive configuration of the instrument Miscellaneous Features 4 08 Auxiliary Output optional Either or both of the two current outputs can function as an Auxiliary Output which can be scaled from 4 20 ma for 0 to 100 for any range It can be configured to represent Input 1 Input 2 PV active Setpoint Local SP1 Deviation or the Control Output Transmitter Power This outpu
144. e two options of where to install the mounting clips 1 Insert the prongs of the clips into the two holes on the left and right side of the top and bottom of the case or 2 on the center on each of the four sides e Tighten screws to 2 lb inch 22 Necm to secure the case against the panel CAUTION Over tightening will cause distortion and the unit may not seal properly 4 For water protected installation install four screws with washers into the four recessed areas in the corners of the front bezel Figure 2 3 Push the point of the screw through the center piercing the elastomeric material and then tighten screws to 5 Ib in 56 Necm 4 08 UDC3200 Universal Digital Controller Product Manual 19 Installation 2 6 Wiring 2 6 1 Electrical Considerations Line voltage wiring This controller is considered rack and panel mounted equipment per EN61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements Conformity with 72 23 EEC the Low Voltage Directive requires the user to provide adequate protection against a shock hazard The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals Mains Power Supply This equipment is suitable for connection to 90 to 264 Vac or to 24 Vac dc 50 60 Hz power supply mains It is the user s responsibility to provide a switch and non time delay North America quick acting high breakin
145. ections for Calibrating Auxiliary Output 146 Figure 8 1 UDC3200 Exploded View 173 Figure 10 1 Software Option Status Information 187 4 08 UDC3200 Universal Digital Controller Product Manual Introduction 1 Introduction 1 1 Overview Function The UDC3200 is a microprocessor based stand alone controller It combines a high degree of functionality and operating simplicity in a 1 4 DIN size controller This instrument is an ideal controller for regulating temperature and other process variables in numerous heating and cooling applications as well as in metal working food pharmaceuticals semiconductor testing and environmental work The UDC3200 monitors and controls temperatures and other variables in applications such as environmental chambers plastic processing machines furnaces and ovens and packaging machinery Features Oo Oo 2 Universal Analog Inputs 0 20 Accuracy Fast scanning rate 166ms Up to 5 Analog and Digital Output Types 2 Digital Inputs Math Functions Ethernet and Modbus communication Infrared PC amp Pocket PC configuration NEMAAX and IP66 front face protection Multilanguage prompts Ya DIN Size Jumper free configuration Easily Field Upgradable Easy to read displays Bright dual displays with multi language prompts in English French German Spanish or Italian make the operator interface easy to read understand and operate Simple keystrokes let you set operating parameters that meet y
146. edge of the process is required at start up The operator simply initiates the tuning while in the automatic mode Once Accutune III has been enabled in the TUNE setup group either SLOW or FAST tuning may be used Which one is used is selected via the lower display during normal operation For the SLOW selection the controller calculates conservative tuning constants with the objective of minimizing overshoot If the controller determines that the process has appreciable dead time it will automatically default to use Dahlin Tuning which produces very conservative tuning constants The SLOW selection may be useful for TPSC and Position Proportional applications as it reduces hunt problems for the motor This selection is also recommended for applications that have significant deadtimes For the FAST selection the controller calculates aggressive tuning constants with the objective of producing quarter damped response Depending upon the process this selection will usually result in some overshoot For this reason it may be desireable to enable the FUZZY tune selection See Section 4 11 When Fuzzy tune is enabled it will work to suppress or eliminate any overshoot that may occur as a result of the calculated tuning parameters as the PV approaches the setpoint This selection is best suited for processes with a single lag or for those that do not have any appreciable deadtime FUZZY tuning does not work well for processes that
147. en for a click from the relay when the OUT1 indicator changes state 4 Check the Current Proportional Put the controller into Manual mode and change Output the output from 0 to 100 4 20 mA Use a DC milliammeter at the rear terminals to verify the output 5 Recalibrate the controller Refer to Section 6 Output Calibration for details 6 Change MCU and or Current Output Installation instructions supplied with new board boards UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service Procedure 6 Table 7 10 explains how to troubleshoot Alarm Relay Output failure Table 7 10 Troubleshooting Alarm Relay Output Failure Step What to do How to do it 1 Check the alarm configuration Reconfigure if necessary data If it is correct check the Refer to Section 3 Configuration for field wiring details 2 Check that the applicable alarm If the alarm type is set for PV place the relay actuates properly controller in manual mode Vary the input depending on what you have set to raise and lower the PV around the at prompt AxSxTYPE setpoint Listen for a click from the relay i as the PV moves in either direction and If it does check the field wiring note that the proper ALM1 or ALM2 is lit EXAMPLE If the alarm is set for MAN put the controller into manual mode The alarm light is ON Put the controller into automatic mode and the alarm light is OFF 3 Check the contacts Make
148. en in the Display Set up group 4 08 UDC3200 Universal Digital Controller Product Manual 127 Monitoring and Operating the Controller Ramp soak profile example Before you perform the actual configuration we recommend that you draw a Ramp Soak profile in the space provided on the Program Record Sheet Figure 4 4 and fill in the associated information An example of a Ramp Soak Profile is shown in Figure 4 3 Start setpoint is at 200 degrees F Setpoint 5 200 oo HHH HHH HHH HH HH HHH ttt TT AE EEE EENE EN ASA A HT TT gte TTT TTT NV TTT I YIT TTT tT tee T TT TT TT TTT T T T 1 NSE 12 TST AT TT TTT TT ETT O O O OS O O O O TTT Time Hours O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20765 Figure 4 3 Ramp Soak Profile Example Ramp Soak Profile Example STRT SEG Start Seg 1 SEG4TIME Soak Time 4 1 hr END SEG End Seg 12 SEG5RAMP Ramp Time 5 1 hr 30 min RAMP UNIT Engr Unit for TIME SEG6 SP Soak SP 6 250 Ramp RECYCLES Number of 2 SEG6TIME Soak Time 6 3 hr 0 min Recycles SOAK DEV Deviation 0 SEG7RAMP Ramp Time 7 2 hr 30 min Value PROG END Controller LAST SP SEG8SP Soak SP 8 500 Status STATE Controller HOLD SEG8TIME Soak Time 8 0 hr 30 min State at end KEYRESET Reset SP DISABLE SEG9RAMP Ramp Time 9 0 Program HOTSTART PV Hot Start DISABLE SG10SP Soak SP 10 400 Program Initialization or power
149. epresents the configured range of input 1 FOR EXAMPLE Type J Thermocouple 0 F to 1600 F 0 F display 0 output 1600 F display 100 output INPUT 2 INPUT 2 represents the value of the configured range of input 2 PV PROCESS VARIABLE Represents the value of the Process Variable PV Input XxRatioX BiasX Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition DEV OUTPUT SP LSP 1 RSP IN ALG1 DEVIATION PROCESS VARIABLE MINUS SETPOINT Represents 100 to 100 of the selected PV span in engineering units Zero deviation will produce a center scale 12 mA or 50 output A negative deviation equal in magnitude to the Auxiliary Output High Scaling Factor will produce a low end output 4 mA or 0 output A positive deviation equal in magnitude to the Auxiliary Output Low Scaling Factor will produce a high end output 20 mA or 100 FOR EXAMPLE Input 1 Type T High Thermocouple PV range 300 F to 700 F PV span 1000 F Deviation Range 1000 F to 1000 F Auxiliary Output Low Scale Value 0 0 Auxiliary Output High Scale Value 1000 If PV 500 F and SP 650 F then Deviation Display 150 F which is 7 5 of the Deviation Range so Auxiliary Output 50 7 5 42 5 OUTPUT Represents the displayed controller output in percent Cannot be used with Three Position Step Control
150. ersal Digital Controller Product Manual 129 Monitoring and Operating the Controller Run Monitor the program Prior to running the program make sure all the SP PROG function prompts under the Set Up group SP RAMP have been configured with the required data H appears in the upper display indicating that the program is in the HOLD state ATTENTION SP Program parameter cannot be changed during RUN state the unit must be in the HOLD state in order to change parameters Run Monitor functions 130 Table 4 25 lists all the functions required to run and monitor the program Table 4 25 Run Monitor Functions Set the Local Setpoint Run State Hold State PY External Hold Viewing the present ramp or soak segment number and time until you see Upper Display PV value Lower Display SP To set the Local Setpoint value to where you want the program to start out Initiates the setpoint program R appears in the upper display indicating that the program is running Holds the setpoint program H appears in the upper display indicating that the program is in the HOLD state The setpoint holds at the current setpoint If one of the Digital Inputs is programmed for the HOLD function then contact closure places the controller in the HOLD state if the setpoint program is running The upper display will periodically show H while the switch is closed ATTEN
151. ese features you wish to use Make the Options Set UP group function prompt CRANGE 4 20 or 0 20 per your application Refer to Section 3 Configuration Output impedance must be less than or equal to 1000 ohms Change the AUX OUT selection to OUTPUT Put the controller into Manual mode and change the output from 0 to 100 4 20 mA Use a DC milliammeter at the rear terminals to verify the output Refer to Section 6 Output Calibration for details Installation instructions provided with new board UDC3200 Universal Digital Controller Product Manual 169 Troubleshooting Service 7 8 Restoring Factory Configuration Introduction 170 This procedure restores the configuration of the instrument back to the Factory Settings per Section 3 16 ATTENTION Restoring the factory configuration overwrites all user entered configuration changes This procedure cannot be undone it is a one way process Table 7 15 explains how to restore Factory Configuration Table 7 15 Restoring Factory Configuration Step What to do 1 Turn off the power to the instrument for at least five seconds 2 Turn the power back on and simultaneously press the FUNCTION and A keys This must be done while TEST DONE is being displayed 3 If step 2 was performed correctly the instrument will now display UDC Upper UPDATE Lower 4 Press the Function Key The instrument will now display DIS
152. fective unit Do not return your controller without authorization from Honeywell s Technical Assistance Center or until the replacement has been received Check out Honeywell s web site at http www honeywell com imc Determining the software version Table 7 1 lists the procedure for identifying the software version number Table 7 1 Procedure for Identifying the Software Version sep Operation Press Rem STATUS m C setup ae Disoley STATUS 2 Read the software Function You will see Version SS Upper Display Software version number 32xx Lower Display VERSION Please give this number to the Customer Support person It will indicate which version of UDC3200 you have and help them determine a solution to your problem 4 08 UDC3200 Universal Digital Controller Product Manual 155 Troubleshooting Service 7 3 Power up Tests What happens at power up When power is applied the controller will run three diagnostic tests After these tests are completed TEST DONE is displayed Failsafe Failures If one or more of these tests fail the controller will go to the Failsafe Manual Mode and FAILSF will flash in the lower display and a message indicating which test failed will appear in the lower display Then DONE will appear in the lower display Three Position Step test failures For controller configured for Three Position Step Control with motor position indication and Auto cal has never been d
153. for Three Position Step Control applications 56 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display PCT CO 0 020 to 0 350 fractional PERCENT CARBON is only applicable when percent of CO Carbon Potential is selected Enter the value in percent carbon monoxide that is applicable for the enriching gas used in fractional form FOR EXAMPLE Natural Gas 20 0 CO then setting is 0 200 Propane Gas 23 0 CO setting is 0 230 ALG1 BIAS 999 to 9999 floating in INPUT ALGORITHM 1 BIAS Does not apply to engineering units selections FFWRD FFWDMU HISEL or LOSEL PCT H2 1 0 to 99 0 Ho HYDROGEN CONTENT FOR DEWPOINT is only applicable when Dewpoint is selected Enter a value for the percentage of Hydrogen content that is applicable Math Algorithm Notes 1 Calculation ranges for the Math Algorithms are set via CALC HI and CALC LO parameters and are between 999 and 9999 The SP High and Low values SP Range are independent of these settings and can be any value between 999 and 9999 2 The CALC HI and CALC LO values determine the range limits for the SP High and Low values for the Weighted Average Summer Hi Select and Low Select algorithms 3 Ifthe Ratio for Input 2 is set to 0 0 then a constant value may be used for the Input 2 value via the Input 2 Bias setting For this
154. g capacity Type F Europe 1 2A 250V fuse s or circuit breaker for 90 264 Vac applications or 1 A 125 V fuse or circuit breaker for 24 Vac dc applications as part of the installation The switch or circuit breaker shall be located in close proximity to the controller within easy reach of the OPERATOR The switch or circuit breaker shall be marked as the disconnecting device for the controller Applying 90 264 Vac to an instrument rated for 24 Vac dc will severely damage the instrument and is a fire and smoke hazard When applying power to multiple instruments make certain that sufficient current is supplied Otherwise the instruments may not start up normally due to the voltage drop caused by the in rush current Controller Grounding PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes To minimize electrical noise and transients that may adversely affect the system supplementary bonding of the controller enclosure to a local ground using a No 12 4 mm copper conductor is recommended Control Alarm Circuit Wiring The insulation of wires connected to the Control Alarm terminals shall be rated for the highest voltage involved Extra Low Voltage ELV wiring input current output and low voltage Control Alarm circuits shall be separated from HAZARDOUS LIVE gt 30 Vac 42 4 Vpeak or 60 Vdc wiring per Permissible Wiring Bund
155. g the Controller 4 10 6 Error Codes Table 4 15 Procedure for Accessing Accutune Error Codes step operation press mea 1 Select Accutune C setup Upper Display SETUP Set up Group NE Lower Display ACCUTUNE 2 Go to Error Code Function Upper Display an error code Prompt NA Lower Display AT ERROR Table 4 16 lists all the error codes definitions and fixes Table 4 16 Accutune Error Codes Error Code Upper Display Definition RUNNING ACCUTUNE RUNNING The Accutune process is still active Read Only NONE NO ERRORS OCCURRED None DURING LAST ACCUTUNE PROCEDURE ID FAIL PROCESS IDENTIFICATION Illegal Values FAILURE try Accutune again Autotune has aborted e untunable process contact local application because an illegal value of engineer GAIN RATE or reset was calculated ABORT CURRENT ACCUTUNE Try Accutune again PROCESS ABORTED caused by the following conditions a Operator changed to Manual mode b Digital Input detected c In Heat region of output and a Cool output calculated or vice versa SP2 LSP2 not enabled or LSP1 or Enable LSP2 and configure the desired LSP1 and LSP2 not in use only applies LSP2 setpoints See Section 4 10 to Duplex Tuning Aborting Accutune To abort Accutune and return to the last previous operation SP or output level press MAN AUTO key to abort the Accutune process or increment from the DO SLOW or DO FAST prompt to the TUNE OFF prompt
156. gly Use Fast Blo fuses only Figure 2 9 Solid State Relay Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 4 08 UDC3200 Universal Digital Controller Product Manual 29 Installation Time Simplex Customer Supplied Electromechanical relay N C Alarm 2 Customer Supplied e o o Relay Load 165 E Relay 2 Solid State relay Power A Sia pare or N C Alarm Relay 1 N O Load Supply pie Power A a To terminal 70r9 Customer Supplied Electromechanical relay Customer Supplied Electromechanical relay lt f S 2 Customer Supplied Solid State relay 3f ae e Qo Customer Supplied Solid State relay a N C Alarm Relay 1 N O To terminal Power ee ai 7or9 O CAUTION Open collector outputs are internally powered at 30 Vdc Connecting an external power supply will damage the controller O Alarm 2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay option is used O Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 10 Open Collector Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 30 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Time Duplex with a Dual Relay Board Load Supply Power 1 Out Relay 2C N O 3 L1 ou Relay 1 Pg
157. gnal to the full scale value when the sensor fails Diagnostic message IN2 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 2 signal developed by the Burnout circuitry DOWNSCALE BURNOUT will force the Input 2 signal to the lower range value when the sensor fails Diagnostic message IN2 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the lower range Input 2 signal developed by the Burnout circuitry NO FAILSAFE T his selection does not provide input failure detection and should only be used when a thermocouple input is connected to another instrument which supplies the Burnout current For this selection no burnout signal is sent to the sensor ATTENTION For Burnout to function properly on a 0 20 mA input type or a 0 5V type that uses a dropping resistor the dropping resistor must be remotely located across the transmitter terminals Otherwise the input at the instrument terminals will always be 0 mA i e within the normal operating range when the 0 20 mA line is opened EMISSIV2 0 01 to 1 00 EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be em
158. has been configured MANUAL Tune manually using LSP 1 and LSP 2 values LSP 1 is used to derive tuning parameters associated with HEAT output gt 50 LSP 2 is used to derive tuning parameters associated with COOL output lt 50 AUTOMATIC Tuning is performed automatically on both HEAT and COOL sequentially LSP 1 is used for HEAT tuning and LSP 2 is used for COOL tuning To initiate tuning either LSP 1 or LSP 2 must be in use DISABLE The current SetPoint is used to derive a single set of blended tuning parameters This tuning is performed over the range of the output limits similar to Simplex Tuning The Tuning Parameters derived are placed into both the HEAT and COOL tune sets PID 1 and PID 2 AT ERROR Read Only NONE RUNNING ABORT SP2 ACCUTUNE ERROR STATUS When an error is detected in the Accutune process an error prompt will appear NONE No errors occurred during last Accutune procedure RUNNING An Accutune process is still active checking process gain even though T is not lit It does not affect keyboard operation CURRENT ACCUTUNE PROCESS ABORTED Caused by one of the following conditions e changing to manual mode e digital input detected e in heat region of output but a cool output was calculated or vice versa SP2 LSP2 not configured or a Setpoint other than LSP1 or LSP2 is in use 4 08 UDC3200 Universal Digital Controller Product Manu
159. have appreciable deadtime The Accutune III tuning process will cycle the controller s output two full cycles between the low and high output limits while allowing only a very small Process Variable change above and below the SP during each cycle A T shows in the upper display until tuning is completed At the end of the tuning process the controller immediately calculates the tuning constants and enters them into the Tuning group and begins PID control with the correct tuning parameters This works with any process including integrating type processes and allows retuning at a fixed setpoint 4 10 1 Tune for Simplex Outputs After TUNE has been enabled you can start Accutune as shown in Table 4 10 Table 4 10 Procedure for Starting TUNE see Operation press re 1 Configure LSP1 Until SP Local Setpoint 1 shows in the lower display 2 Until LSP1 is to the desired value 3 Switch to Pa Until the A indicator is lighted on Automatic Mode adh controllers with Manual option 110 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Until TUNE OFF is shown on lower display 4 Show Tuning Prompt Select DO SLOW or DO FAST in lower display 5 Initiate Tuning 6 Tuning in operation Upper display will show a T as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower
160. he control outputs energize and the value at which they de energize Only applicable for ON OFF control 4 08 UDC3200 Universal Digital Controller Product Manual 75 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition FAILMODE NoLATCH LATCH FAILSAFE MODE NON LATCHING Controller stays in last mode that was being used automatic or manual If unit was in Automatic mode then the output goes to the failsafe value NOTE 1 NOTE 2 LATCHING Controller goes to manual mode If unit was in Automatic mode then the output goes to the failsafe value NOTE 2 FAILSAFE 0 to 100 FAILSAFE OUTPUT VALUE The value used here will also be the output level when you have Communications SHED set to failsafe or when NO BURNOUT is configured and Input 1 fails ATTENTION Applies for all output types except Three Position Step Control 0 PCT 100 PCT THREE POSITION STEP FAILSAFE OUTPUT 0 PCT Motor goes to closed position 100 PCT Motor goes to open position SW FAIL 0 PCT 100 PCT Position Proportional motor position when slidewire fails 0 PCT Motor goes to closed position 100 PCT Motor goes to open position ATTENTION PWR OUT must be configured for FSAFE MAN OUT 0 to 100 POWER UP PRESET MANUAL OUTPUT At power up the controller will go to manual and the output to
161. he cycle time in the COOL zone of Heat Cool applications or for the second set of PID constants CYC2 SEC Electromechanical relays CYC2 SX3 Solid state relays ATTENTION Cycle times are in either second or 1 3 second increments depending upon the configuration of RLY TYPE in the Output Algorithm Set Up group SECURITY 0 to 9999 SECURITY CODE The level of keyboard lockout may be changed in the Set Up mode Knowledge of a security code may be required to change from one level to another This configuration should be copied and kept in a secure location NOTE The Security Code is for keyboard entry only and is not available via communications ATTENTION Can only be changed if LOCKOUT selection is NONE LOCKOUT 42 NONE CALIB CONF VIEW LOCKOUT applies to one of the functional groups Configuration Calibration Tuning Accutune DO NOT CONFIGURE UNTIL ALL CONFIGURATION IS COMPLETE NONE No lockout all groups are read write CALIB All groups are available for read write except for the Calibration and Keyboard Lockout groups CONF Tuning SP Ramp and Accutune groups are read write All other groups are read only Calibration and Keyboard Lockout groups are not available VIEW Tuning and Setpoint Ramp parameters are read write No other parameters are viewable UDC3200 Universal Digital Controller Product Manual 4 08 Configuration
162. hoot an Ethernet Communications failure Table 7 13 Troubleshooting an Ethernet Communications Failure Step What to do How to do it 1 Check the IP address Subnet See the PIE Tool Manual Mask address and Gateway address settings 2 Check if the Ethernet Connection Looking into the instrument there should be steady is active green LED If this is not present then the instrument is not seeing a valid Ethernet connection See Section 2 7 for wiring diagrams A second green LED will blink during actual Ethernet transactions 3 Change Ethernet Installation instructions provided with new Communications board board 4 Change Controller 168 UDC3200 Universal Digital Controller Product Manual 4 08 Procedure 10 Table 7 14 explains how to troubleshoot Auxiliary Proportional Output failure symptoms 4 08 1 Troubleshooting Service Table 7 14 Troubleshooting Auxiliary Output Failure Step What to do How to do it Make sure the controller is configured for Auxiliary Output and the proper range 4 to 20 or 0 to 20 is configured Check the field wiring Check the output Recalibrate the Auxiliary output Change Auxiliary Output board Change Controller Make Options Set Up group function prompt AUX OUT any selection other than NONE If this prompt does not show up check if DIG IN 2 is enabled If so then as Auxiliary Ouptut and Digital Input 2 are mutually exclusive you must chose which one of th
163. igured To perform a Duplex Tune Two Local Setpoints must be configured per the Control Group in Section 3 11 Function Prompts Table 3 6 ACCUTUNE Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display FUZZY FUZZY OVERSHOOT SUPPRESSION Can be enabled or disabled independently of whether Demand Tuning or SP Tuning is enabled or disabled DISABLE DISABLE Disables Fuzzy Overshoot Suppression ENABLE ENABLE The instrument uses Fuzzy Logic to suppress or minimize any overshoot that may occur when PV approaches SP It will not recalculate any new tuning parameters 48 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition ACCUTUNE DISABLE TUNE ACCUTUNE lll DISABLE Disables the Accutune function DEMAND TUNING If TUNE is selected and tuning is initiated through the operator interface or digital input if configured the algorithm calculates new tuning parameters and enters them into the tuning group This tuning requires no process knowledge and does not require line out for initialization DUPLEX This prompt only appears when a Duplex Control Algorithm has been configured MANUAL AUTO DISABLE DUPLEX ACCUTUNING Ill These prompts only appear when a duplex output type
164. ing Method page 19 Overall Dimensions Max panel thickness 19 1 x inches 1S 0 35 108 6 92 0 0 8 3 57 4 28 0 00 Panel 3 62 0 03 Cui n 0 00 lt gt 92 0 A 113 1 0 4 45 3 62 0 03 17 9 0 00 0 70 Figure 2 2 Mounting Dimensions not to scale Mounting Notes Before mounting the controller refer to the nameplate on the outside of the case and make a note of the model number It will help later when selecting the proper wiring configuration 18 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Mounting Method Before mounting the controller refer to the nameplate on the outside of the case and make a note of the model number It will help later when selecting the proper wiring configuration Mounting clips Attach screws and washers here for water protection Figure 2 3 Mounting Methods Mounting Procedure Table 2 4 Mounting Procedure 1 Mark and cut out the controller hole in the panel according to the dimension information in Figure 2 2 2 Orient the case properly and slide it through the panel hole from the front 3 Remove the mounting kit from the shipping container and install the kit as follows e For normal NEMA 3 IP55 installation two mounting clips are required Insert the prongs of the clips into the two holes in the top and bottom center of the case e For water protected NEMA 4X IP66 installation four mounting clips are required There ar
165. ing setpoints for the UDC3200 controller e A Single Local Setpoint e 2 Local Setpoints e 3 Local Setpoints e Upto 3 Local Setpoint and one Remote Setpoint Refer to Subsection 3 11 Control Set Up Group for configuration details 106 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Changing the Setpoints Table 4 8 Procedure for Changing the Local Setpoints A Select the Until you see Setpoint Upper Display PV Lower Display SP or 2SP or 3SP Value 2 Change the An ory To change the Local Setpoint to the value at which you want Value the process maintained The display blinks if you attempt to enter setpoint values beyond the high and low limits 3 Return to PV To store immediately or will store after 30 seconds Display Switching between setpoints You can switch Local and Remote setpoints or between two Local setpoints when configured ATTENTION The REMOTE SETPOINT value cannot be changed at the keyboard Table 4 9 Procedure for Switching Between Setpoints CE 0 APP PE Select the To switch between the Three Local Setpoints and or the Setpoint Remote Setpoint ATTENTION KEY ERROR will appear in the lower display if e the remote setpoint or additional local setpoints are not configured as a setpoint source e you attempt to change the setpoint while a setpoint ramp is enabled or e if you attempt to change
166. ion Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition A RSP AM SP AM LSP AUTOMATIC MODE LAST RSP At power up the controller will use automatic mode with the last remote setpoint used before power down displayed LAST MODE LAST SETPOINT used before power down LAST MODE LAST LOCAL SETPOINT on power down PWR OUT For Three Position Step Control Only Note 3 LAST F SAFE THREE POSITION CONTROL STEP OUTPUT START UP MODE This selection determines what position the motor will be in when powered up or in the failsafe position LAST OUTPUT At power up in automatic mode the motor position will be the last one prior to power down When the unit goes into FAILSAFE it will stay in automatic mode motor will not be driven to the configured failsafe position FAILSAFE OUTPUT At power up in manual mode the motor will be driven to either the 0 or 100 output position whichever is selected at prompt FAILSAFE For Burnout None when the unit goes into FAILSAFE it will go to manual mode motor will be driven to the configured failsafe position SP HiLIM Note 4 0 to 100 of PV span in engineering units SETPOINT HIGH LIMIT This selection prevents the local and remote setpoints from going above the value selected here The setting must be equal or less than the upper range of the PV SP LoLIM Note 4 0 to 100 of PV spa
167. ion assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC Control Products Asia Pacific Headquarters Phone 65 6355 2828 Fax 65 6445 3033 Asia Pasific Global Technical Support Field Instruments Phone 65 6580 3156 Fax 65 6445 3033 Process Instruments Phone 603 76950 4777 Fax 603 7958 8922 Australia Honeywell Limited Phone 61 7 3846 1255 FAX 61 7 3840 6481 Toll Free 1300 36 39 36 Toll Free Fax 1300 36 04 70 China PRC Beijing Honeywell China Inc Phone 86 10 8458 3280 Fax 86 10 8458 4650 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 China PRC Chengdu Honeywell China Inc Phone 86 28 8678 6348 Fax 86 28 8678 7061 China PRC Xi an Honeywell China Ltd Xi an Phone 86 29 8833 7490 Fax 86 29 8833 7489 China PRC Shenzhen Honeywell China Inc Phone 86 755 2518 1226 Fax 86 755 2518 1221 Indonesia PT Honeywell Indonesia Phone 62 21 535 8833 FAX 62 21 5367 1008 India Automation India Ltd Honeywell Ltd Phone 91 5603 9400 Fax 91 5603 9600 Japan Honeywell Inc Phone 81 3 6730 7150 Fax 81 3 6730 7228 Malaysia Honeywell Engineering Sdn Bhd Phone 60 3 7950 4776 Fax 60 3 7958 8922 4 08 New Zealand Honeywell Limited Phone 64 9 623 5052 Fa
168. itted if the target were a perfect radiator Available only for Radiamatic inputs 70 UDC3200 Universal Digital Controller Product Manual 4 08 3 11 Control Set Up Group Introduction Configuration The functions listed in this group deal with how the controller will control the process including Number of Tuning Parameter Sets Setpoint Source Tracking Power up Recall Setpoint Limits Output Direction and Limits Deadband and Hysteresis Function Prompts Table 3 11 CONTROL Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display PV SOURCE PROCESS VARIABLE SOURCE Selects the source of the Process Variable INPUT 1 INPUT 1 INPUT 2 INPUT 2 IN ALG1 INPUT ALGORITHM 1 PID SETS NUMBER OF TUNING PARAMETER SETS This selection lets you choose one or two sets of tuning constants gain rate and reset NOTE The Tuning Group is automatically configured to have two PID sets when a Duplex Control Algorithm is configured 1 ONLY ONE SET ONLY Only one set of tuning parameters is available Configure the values for Gain proportional band Rate Reset Time and Cycle Time if time proportional is used 2KEYBD TWO SETS KEYBOARD SELECTABLE Two sets of tuning parameters can be configured and can be selected at the operator interface or by using the Digital Inputs Pa Press this key until you see PID SET1 or PID SET2 then press AR
169. ivate unless the parameter being monitored has not been in an alarm condition for a minimum of one control cycle 167 ms DIAGNOST DISABLE ALARM 1 ALARM 2 DIAGNOSTIC WMonitors the Current Output and or Auxiliary Output for an open circuit condition If either of these two outputs falls below about 3 5 mA then an Alarm is activated This configuration is in addition to whatever was selected for AXSxTYPE DISABLE Disables Diagnostic Alarm ALARM 1 Alarm 1 is diagnostic alarm ALARM 2 Alarm 2 is diagnostic alarm 4 08 UDC3200 Universal Digital Controller Product Manual 91 Configuration 3 15 Display Set Up Group Introduction This group includes selections for Decimal place Units of temperature Language and Power frequency Function Prompts Table 3 15 DISPLAY Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display DECIMAL DECIMAL POINT LOCATION T his selection determines where the decimal point appears in the display NONE NONE No Decimal Place fixed no auto ranging ONE ONE One Place TWO TWO Two Places THREE THREE Three Places ATTENTION Auto ranging will occur for selections of one two or three decimal places For example should the instrument be configured for two decimal places and the PV exceeds 99 99 then the display will change to a single decimal place so that values of 100 0 and above
170. ive e The clock character has stopped moving e The Time display shows either 00 00 or the time out period depending on the configuration selection e The Timer is ready to be reset At RESET e Alarm 1 relay is inactive e The time display shows the time out period e The time out period can be changed at this time using the or W keys e The Timer is ready to be activated 4 10 Accutune Ill Introduction Accutune HI TUNE may be used for self regulating and single integrating processes This autotuning method is initiated on demand typically at initial start up There are no other requirements necessary such as prior knowledge to the process dynamics or initial or post tune process line out to setpoint or manual output Also the setpoint value is not required to change in order to initiate the tuning process but the controller must be in the Automatic mode to start tuning The process need not be in a static lined out state and may be dynamic changing with a steady output Configuration check Make sure e TUNE has been enabled see to Subsection 3 6 Accutune Set Up Group for details Tuning indicators A T will show in the leftmost alphanumeric of the upper display until tuning is completed 4 08 UDC3200 Universal Digital Controller Product Manual 109 Monitoring and Operating the Controller Operation The Accutune II algorithm provides user friendly on demand tuning in this controller No knowl
171. le adjustable full output as appropriate hysteresis is provided on alarms such that when the alarm is OFF it activates at exactly the alarm setpoint when the alarm is ON it will not deactivate until the variable is 0 0 to 100 away from the alarm setpoint Configure the hysteresis of the alarms based on INPUT signals as a of input range span Configure the hysteresis of the alarm based on OUTPUT signals as a of the full scale output range 90 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition ALM OUT1 NoLATCH LATCH LATCHING ALARM OUTPUT 1 Alarm output 1 can be configured to be Latching or Non latching NoLATCH Non latching LATCH Latching ATTENTION When configured for latching the alarm will stay active after the alarm condition ends until the RUN HOLD key is pressed BLOCK DISABLE ALARM 1 ALARM 2 ALARM12 ALARM BLOCKING Prevents nuisance alarms when the controller is first powered up The alarm is suppressed until the parameter gets to the non alarm limit or band Alarm blocking affects both alarm setpoints DISABLE Disables blocking ALARM 1 Blocks alarm 1 only ALARM 2 Blocks alarm 2 only ALARM12 Blocks both alarms ATTENTION When enabled on power up or initial enabling via configuration the alarm will not act
172. le occurs after receipt of the message and the response is returned Override Parameters e Override analog register address 007D computer setpoint is not stored in non volatile memory It can be changed as frequently as desired with no effect on non volatile memory retentivity but the controller must remain in the slave mode Digital Parameters e Whenever digital configuration register addresses 0080 through OOFA are updated via communications the non volatile memory is updated as soon as the message is received Communications Transfer Rates e Reads minimum 20mS and writes minimum 200mS Supported Function Codes e IR port 20 and 21 e RS485 and Ethernet ports 1 2 3 4 6 16 17 20 21 Communications Modes of Operation e When the Shed Timer is enabled and a write or override occurs the controller will enter Slave Mode The keypad is locked from the operator The purpose of this mode is that if communications is lost and the shed timer times out then the controller will enter a known state of operation The configuration of the Shed Mode and Output and Shed Setpoint Recall are used to configure the controller s shed state While in Slave Mode pushing the MAN AUTO key enters Emergency Manual mode The local operator then has control of the output The controller is in Monitor Mode if the Shed timer is disabled 10 2 Reading Control Data Overview The following control data can be read from the UDC3200 controller e Input
173. lection 3 Scroll through Function until the lower display rolls through the rest of the functions and Functions ban returns to Upper Display the new selection Lower Display CO RANGE 4 08 UDC3200 Universal Digital Controller Product Manual 151 sep operation poss a MW to change the range selection in the upper display back to the proper selection You will see Upper Display Original range selection Lower Display CO RANGE 4 Return to Normal to return to Normal operating mode Operation The factory calibration will be restored If the problem is not corrected contact the Honeywell Technical Assistance Center at 1 800 423 9883 USA and Canada 152 UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service 7 Troubleshooting Service 7 1 Overview Introduction Instrument performance can be adversely affected by installation and application problems as well as by hardware problems We recommend that you investigate the problems in the following order e installation related problems e application related problems e hardware and software related problems and use the information presented in this section to solve them What s in this section The following topics are covered in this section 7 2 Troubleshooting Aids e Overall Error Messages e Controller Failure Symptoms e Customer Support e Determining the Software Version Number 7 3 Power up Tests 7 4 Status Tests 7 5 Backgr
174. ling Table 2 5 Electrical Noise Precautions Electrical noise is composed of unabated electrical signals which produce undesirable effects in measurements and control circuits 20 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Digital equipment is especially sensitive to the effects of electrical noise Your controller has built in circuits to reduce the effect of electrical noise from various sources If there is a need to further reduce these effects e Separate External Wiring Separate connecting wires into bundles See Permissible Wiring Bundling Table 2 5 and route the individual bundles through separate conduit metal trays Use Suppression Devices For additional noise protection you may want to add suppression devices at the external source Appropriate suppression devices are commercially available ATTENTION For additional noise information refer to document number 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments Permissible Wiring Bundling Table 2 5 Permissible Wiring Bundling Bundle No Wire Functions OE 1 e Line power wiring e Earth ground wiring e Line voltage control relay output wiring e Line voltage alarm wiring 2 Analog signal wire such as e Input signal wire thermocouple 4 to 20 mA etc e 4 20 mA output signal wiring Digital input signals 3 e Low voltage alarm relay output wiring e Low voltage wiring to solid state type control
175. ller Setpoint Overview You can use a setpoint generated from the computer to override the setpoint being used by the controller The value generated by the computer will have ratio and bias applied by the controller Register Addresses Use the identifying code in Table 10 7 to enter the computer setpoint Table 10 7 Computer Setpoint Selection Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Computer Value from computer with Setpoint Ratio and Bias applied by the controller Within the Setpoint Range Limits in Engineering Units or Percent Shed The computer setpoint override will continue until SHED from communications occurs or the controller is placed into monitor mode through communications Doing periodic SLAVE READS within the shed time will allow the override to continue until communication is stopped and shed time elapses Does not apply to IR communications ATTENTION 0 Shed code 79 allows the override to continue indefinitely or until the reset shed timer register address 1B90 is written using function code 6 or register address 7F using function code 21 Any data value can be written because it is ignored 190 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes When SP is overridden the upper display becomes C momentarily and the lower di
176. lly inspect the into the rear of the case controller board and the inside of the case properly 3 Check the system for Brown Refer to Section 2 Installation outs heavy load switching etc and conformance to installation instructions 4 Change Power board Installation instructions supplied with new board Procedure 2 Table 7 6 explains how to troubleshoot Current Output failure symptoms Table 7 6 Troubleshooting Current Output Failure Step What to do How to do it 1 Make sure the controller is Make Output Set Up group function prompt configured for Current output OUT ALG CUR and the proper range 4 to 20 or 0 to 20 is configured Make the Output Set UP group function prompt CRANGE 4 20 or 0 20 per your application Refer to Section 3 Configuration 2 Check the field wiring Output impedance must be less than or equal to 1000 ohms 3 Check the output Put the controller into Manual mode and change the output from 0 to 100 4 20 mA Use a DC milliammeter at the rear terminals to verify the output 4 Recalibrate the Current Refer to Section 6 Output Calibration for Proportional output details 5 Change Current Output board Installation instructions provided with new board 6 Change Controller 4 08 UDC3200 Universal Digital Controller Product Manual 161 Troubleshooting Service Procedure 3 Table 7 7 explains how to troubleshoot Position Proportional Output failure symptoms 1
177. low supply system conductor Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements UDC3200 Universal Digital Controller Product Manual 1 1 1 1 2 1 3 1 4 2 1 22 2 3 2 4 2 5 2 6 2 7 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 Contents INTRODUCTION suicida 1 OVETVIC Wiis eeced sto A cake te as ined decal behead date AA eda hd eee tend eae de chk 1 Operator Interact ached il Weseven te a teat ates eas Weare a a adele ieee intee aeRO 5 1 2 Function of Displays and Ki did 6 Process Instrument Explorer Software ccccccccssccesesssceesceeeeeeseeesceeseecsaecsaeceaeceseceaeeneeeeeeeneeeeneeesees 7 CE Conformity Europe Jenessa A Sine 8 INSTALLATION siii as 11 DI o a o da Y 11 Condensed Specifications ccccccccesccesscessceseceeeeeeseeeeeceseeeseeeaeecsaecsaecsaeceseceseesseeseeseeeeeee
178. lowing topics are covered in this section YA WARNING SHOCK HAZARD OUTPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION 4 08 UDC3200 Universal Digital Controller Product Manual 143 6 2 Current Output Calibration Introduction Calibrate the controller so that the output provides the proper amount of current over the desired range The controller can provide an output current range of from 0 to 21 milliamperes and is usually calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 0 mA and 21 mA It is not necessary to re calibrate the controller in order to change from 4 to 20 mA operation over to 0 to 20 mA operation a simple configuration change is all that is required See the CO RANGE configuration in Sub section 3 8 for details Equipment Needed You will need a standard shop type milliammeter with whatever accuracy is required capable of measuring 0 to 20 milliamps Calibrator Connections Refer to Figure 6 1 and wire the controller according to the procedure given in Table 6 1 Table 6 1 Set Up Wiring Procedure for Current Output 1 Apply power and allow the controller to warm up 30 minutes before you calibrate 2 Set LOCK in the Tuning Set Up group to NONE 3 Tag and disconnect the field wiring at the rear of the controller fro
179. lts and signal source Radiamatic e Two insulated copper leads for connecting the calibrator to the controller e Place current source at zero before switching ON e Do not switch current sources OFF ON while connected to the UDC3200 input 4 08 UDC3200 Universal Digital Controller Product Manual 135 Input Calibration 5 4 Input 1 or 2 Set Up Wiring 5 4 1 Thermocouple Inputs Using an Ice Bath Refer to Figure 5 2 and wire the controller according to the procedure given in Table 5 3 Table 5 3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath 1 Connect the copper leads to the calibrator 2 Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points into the ice bath 3 Connect the thermocouple extension wires to the terminals for Input 1 See Figure 5 2 q bd 22 23 Input 2 24 25 26 Input 1 27 le SN NZ AIN a Y e E R 2 Millivolt Source le A Ice Bath Copper Leads D wes COLL A 57 ANS E Thermocouple Extension Wire Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath 136 UDC3200 Universal Digital Controller Product Manual 4 08 Input Calibration 5 4 2 Thermocouple Inputs Using a Thermocouple Source Refer to Figure 5 3 and wire the controller according to the procedure given in Table 5 4 Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs using
180. lts or Thermocouple Differential Imputs oooonnnnnnnnnncnn o 138 4 08 UDC3200 Universal Digital Controller Product Manual vi e A AS A RR 139 II E Sini enina tees iv cetcaes aa Sale an Cares nA aa Cheat E hiones 139 5 5 Input 1 or 2 Calibration Procedure ecccecccecscesseeesseeeeescecscecscecaeceaeceseceseceeeseeeeeneeeseseeeeeeeaaes 140 5 6 Restore Input Factory Calibrati0M ooooonccnoconocnnonnconnnonnnonnonnncon ccoo nono nono noc nn cnn rnnn rra nan rrrnn ranas 141 6 OUTPUT CALIBRATION coiciiiiniiiniii inanakan aiani n inanan 143 OI e OVETVI EW A AS a Gee ag A R E E a due chien dea Sates ve 143 6 2 Current Output Calibration can oil AGEN 144 6 3 Auxiliary Output Calibration 0 0 cc ceccccccesecessceesceeeeeeseesseeeseecseecseecsaecaecseceseeeeeseeeseeeeeeeeeeeesees 146 6 4 Position Proportional and Three Position Step Output Calibration ooononionnononionnncnnonncnnnonnnoos 148 6 5 Restore Output Factory Calibration ccccccsccesccssscsesceeseeeseeeseeeseeesecsseceseeseeseeeseaeeeseeeeeeseeaaes 151 7 TROUBLESHOOTING SERVIGCE 3 siissccccstssscrsitzaiswcdtcoatnsieepasyadtvantcedisoacusiivaerecsed 153 PU LOC WD oe U Meanie E Td cen sat eet 153 T Troubleshootiie Ads ads 154 Ta Power p Tdi A ai 156 TA Status TES A AA ee eee 156 T S Backoround Teta iia 157 7 6 Controller Failure Symptoms s rescrierea e ie e a a E e i a E 158 7 7 Troubleshooting Procedures ccccesccssscessceseceesceeecee
181. m terminals 21 2 and 19 See Figure 6 1 4 Connect a milliammeter across these terminals Milliammeter E wy NS e gt 9 Figure 6 1 Wiring Connections for Calibrating Current Proportional Output 144 UDC3200 Universal Digital Controller Product Manual 4 08 Output Calibration Procedure The procedure for calibrating the Current Output is listed in Table 6 2 Make sure LOCK in the Tuning Set Up group is set to NONE See Subsection 3 4 Tuning Set Up Group Table 6 2 Current Output Calibration Procedure Estes operation Pess ea 1 Enter Calibration a Upper Display CALIB Mode NE Lower Display CURRENT until you see 2 Calibrate 0 Function You will see Upper Display A Value Lower Display ZERO VAL A ory Until the desired 0 output is read on the milliammeter use the values shown below depending on the action of your controller Normally this will be the setting that produces 4 mA 3 Calibrate 100 Function This stores the 0 value and NE you will see Upper Display A Value Lower Display SPAN VAL A ory Until the desired 100 output is read on the milliammeter use the values shown below depending on the action of your controller Normally this will be the setting that produces 20 mA 4 Exit the Calibration Mode The controller stores the span value To exit the calibration mode 4 08 UDC3200 Universal Digital Controller Product Manual 145 Ou
182. made to allow write access to override information The registers which are designated as Override values are listed below These registers do not have restrictions on the number of writes ID Tag Register Number UDC Usage 125 7Dh Computer Setpoint Restrictions on Parameter Numbers in One Message The maximum number of writeable parameters per write request is 1 4 08 UDC3200 Universal Digital Controller Product Manual 183 Modbus RTU Function Codes 9 4 1 Write Configuration Examples Example 1 The following is an example of a request to write the Gain 1 value using Function code 21 15 Hex Request Message Write Gain 1 1 5 ID Tag 1 02 15 0B 06 00 03 00 01 00 02 3F CO 00 00 CRC16 Where 02 Address 15 Function Code 21 15 Hex 0B Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 01 Register Address Standard Access Gain 1 ID Tag 1 00 02 Register Count Floating Point Data 3FC00000 1 50 CRC16 This is the response to the above request Response Message The response is an echo of the request 02 15 0B 06 00 01 00 02 00 02 3F CO 00 00 CRC16 184 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 Modbus Read Write and Override Parameters plus Exception Codes 10 1 Overview Introduction This section contains information concerning Reading Writing and Overriding para
183. ments TIME TIME in hours minutes EU MIN RATE in Enineering units per minute EU HR RATE in Enineering units per hour RECYCLES 0 to 99 recycles Number of Program Recycles SOAK DEV 0 to 99 Guaranteed Soak Deviation Value The number selected will be the PV value in engineering units above or below the setpoint outside of which the timer halts PROG END LASTSP Hold at last Program Termination State setpoint in the program F SAFE Manual mode Failsafe output STATE DISABLE Program State at Program End HOLD KEYRESET DISABLE Reset Rerun SP Program ToBEGIN RERUN HOTSTART DISABLE Hot Start ENABLE SEG1RAMP or 0 99 hours 0 59 minutes Segment 1 Ramp Time or SEG1RATE Engineering units minute Segment 1 Ramp Rate or Engineering units hour Select TIME EU MIN or EU HR at prompt RAMPUNIT All ramps will use the same selection 46 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition SEG2 SP Within the Setpoint limits Segment 2 Soak Setpoint Value SEG2TIME 0 99 hours 0 59 minutes Segment 2 Soak Duration SEG3RAMP or SEG3RATE SEG4 SP SEG4TIME SEG5RAMP or SEG5RATE SEG6 SP SEG6TIME SEG7RAMP or SEG7RATE SEG8 SP SEG8TIME SEG9RAMP or SEG9RATE SG10 SP SG10TIME SG11RAMP or SG11RATE SG12 SP SG12TIME Selections are same as above
184. meters in the UDC3200 Process Controller There are two types of parameters e Data Transfer These parameters include reading control data option status and reading or changing setpoints e Configuration Data All the configuration data is listed in the order in which it appears in the controller Each type of parameter has the identifying codes listed with it What s in this section The following topics are covered in this section 10 1 Overview 185 10 2 Reading Control Data 186 10 3 Read Options Status 187 10 4 Miscellaneous Read Onlys 188 10 5 Setpoints 189 10 6 Using a Computer Setpoint Overriding Controller Setpoint 190 10 7 Configuration Parameters 191 10 8 Modbus RTU Exception Codes 219 General Information Non volatile Memory Retention e This controller uses non volatile memory to store configuration data These memories are guaranteed to retain data for a minimum of ten years as long as the data is not written and erased more than 10 000 times In order not to exceed this number it is strongly recommended that configurations which change rapidly such as Computer Setpoint use the Override feature which does not affect non volatile memory 4 08 UDC3200 Universal Digital Controller Product Manual 185 Modbus Read Write and Override Parameters plus Exception Codes Analog Parameters e Whenever analog register addresses 0001 through 0074 those that can be changed via communications are changed a Write cyc
185. ming Introduction The term programming is used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required setpoint versus time profile also called a program A segment is a ramp or soak function which together make up a setpoint program Setpoint Ramp Soak Programming lets you configure six ramp and six soak segments to be stored for use as one program or several small programs You designate the beginning and end segments to determine where the program is to start and stop Review program data and configuration While the procedure for programming is straightforward and aided by prompts we suggest you read Program Contents Table 4 24 lists the program contents and an explanation of each to aid you in configuration Then refer to Subsection 3 5 Configuration to do the setpoint program Make sure SPRAMP is disabled Fill out the worksheet Refer to the example in Figure 4 3 and draw a Ramp Soak Profile on the worksheet provided Figure 4 4 and fill in the information for each segment This will give you a record of how the program was developed Operation Refer to Table 4 25 Run Monitor the program Program Contents Table 4 24 lists all the program contents and a description of each 4 08 UDC3200 Universal Digital Controller Product Manual 125 Monitoring and Operating the Controller STRT SEG END SEG RECYCLES STATE PROG END
186. mocouple High W TC L W5W26 Thermocouple Low 100 PT 100 Ohm RTD High 100 LO 100 Ohm RTD Low 200 PT 200 Ohm RTD 500 PT 500 Ohm RTD RAD RH Radiamatic RH RAD Rl Radiamatic RI 0 20mA 0 to 20 Milliamperes 4 20mA 4 to 20 Milliamperes 0 10mV to 10 Millivolts 0 50mV to 50 Millivolts 0 100mV 0 to 100 Millivolts 0 5 V 0 to 5 Volts 1 5 V 1 to 5 Volts 0 10 V 0 to 10 Volts TC DIFF Thermocouple Differential Carbon Carbon Probe Input Oxygen Oxygen Probe Input 64 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display XMITTER B TC S TC TRANSMITTER CHARACTERIZATION This ETCH TTCH selection lets you instruct the controller to ETCL TTCL characterize a linear input to represent a non linear J TC H WTCH sone If characterization is performed by the J TCM WTCL transmitter itself then select LINEAR JTCL 100 PT KTCH 100 LO ATTENTION Prompt only appears when a linear K TC M 200 PT actuation is selected at prompt IN1 TYPE KTCL 500 PT NNM H RADRH FOR EXAMPLE NNM L RAD RI If input 1 is a 4 to 20 mA signal but the signal NIC H LINEAR represents a type K H thermocouple then configure K TC H and the controller will characterize the 4 to NIC L SQROOT suk RTC 20 mA signal so that it is treated as a type K thermocouple input high ra
187. n 3 8 Three Position Step Control Models using slidewire feedback This model must have its output calibrated per the entire procedure to ensure the displayed output slidewire position agrees with the final control element position Equipment needed None Connections Apply power and leave all field wiring connected to the rear terminals Procedure The procedure for calibrating the Three Position Step control output is listed in Table 6 5 For Three Position Step Control 3Pstep these prompts only appear when SLIDEW is selected in the INPUT 2 Setup group For Position Proportional Control the Output algorithm must also be configured for POSITON Make sure LOCKOUT in Tuning Set Up group is set to NONE See Subsection 3 4 For Three Position Step Control 3Pstep these prompts only appear when SLIDEW is selected in the INPUT 2 Setup group For Position Proportional Control the Output algorithm must also be configured for POSITON The Motor Time must be entered in the Output Algorithm Group for both Position Proportional or for 3Pstep control See Subsection 3 8 for details Table 6 5 Position Proportional and Three Position Step Output Calibration Procedure Step Description Press Action 1 Enter Calibration Mode Csetup until you see A Upper Display CALIB Lower Display POS PROP continued 148 UDC3200 Universal Digital Controller Product Manual 4 08 Output Calibration
188. n in engineering units SET POINT LOW LIMIT This selection prevents the local and remote setpoints from going below the value selected here The setting must be equal or greater than the lower range of the PV ACTION DIRECT REVERSE CONTROL OUTPUT DIRECTION Select direct or reverse output action DIRECT ACTING CONTROL The controller s output increases as the process variable increases REVERSE ACTING CONTROL The controller s output decreases as the process variable increases OUT RATE ENABLE DISABLE OUTPUT CHANGE RATE Enables or disables the Output Change Rate The maximum rate is set at prompt PCT M UP or PCT M DN Only available for PID A PID B PD MR control algorithms ENABLE Allows output rate DISABLE Disables output rate 74 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display PCT M UP 0 to 9999 per minute OUTPUT RATE UP VALUE This selection limits the rate at which the output can change upward Enter a value in percent per minute Appears only if OUT RATE is enabled 0 means no output rate applied PCT M DN 0 to 9999 per minute OUTPUT RATE DOWN VALUE This selection limits the rate at which the output can change downward Enter a value in percent per minute Appears only if OUT RATE is enabled 0
189. nccconnncnoncnanccnonnnnnons 101 Removing The Chassis ooooncnioninnioninioniononos 175 Operator Interface cece eeeeteetees 5 58 97 Rerun Current Segment oooocccoconocccnconononncnnoss 126 Option AAA 187 O eatin te o 41 Output Algorithm ooccocinininnononrnnnrnoonoornnnnos 60 Reset a das 41 Output Calibrati0M oonciicnnininnnnnnnnnononncnnnnoso 143 Reset Program To Beginning ee 126 Output Change Rate oococcnocnonnncconconccononncnnnnnos 74 Reset Units acc kta need cei 77 Output Rate Down Value oooooonoccnoconocccononnnonns 75 Restore Factory Calibration 141 151 Output Rate Up Value eee eerie 75 Restoring Factory Configuration 0 170 Output TYPES n ro 3 Reverse Acting Control sssesseeeessesersreseeee 74 Overriding Controller Setpoint 190 RSS ta aa a 7 OXY Pla rifa 55 RS422 485 Modbus Rtu Communications P Q Interface mne ne aaa np 14 PA O 174 II A aenea a 137 a tae dae 173 Rui Fold aa A PD With Manual Reset 5 Run Hold A ae Bee te ott aac 123 Permissible Wiring Bundling cscssssssssesese 21 Rue Monitor The RTOs at ias 130 Physical Considerations ooooconncnononononccnconinnnnnos 18 PIDA olor 51 PID Bis idas 51 4 08 UDC3200 Universal Digital Controller Product Manual 225 Index S ECU dd doo RES 4 o serr ne seousencuds Hesoeius 42 Security Codere eek ee 97 Segment Time Remaining In Hours 188 Set Point Select Function Key
190. nd Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Controller Status 00B4 180 INT R W 0 Last Setpoint and Mode at Program End 1 Manual Failsafe Output Reset SP Program 00B3 179 INT R W 0 Disable ToBEGIN 1 Via Keypad PV Hotstart 00E2 226 INT RW 0 Disabled 1 Enabled Segment 1 Ramp 0039 057 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 2 Soak 003A 058 FP R W Within Setpoint Limits Setpoint Value Segment 2 Soak 003B 059 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 3 Ramp 003C 060 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 4 Soak 003D 061 FP R W Within Setpoint Limits Setpoint Value Segment 4 Soak 003E 062 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 5 Ramp 003F 063 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 6 Soak 0040 064 FP R W Within Setpoint Limits Setpoint Value Segment 6 Soak 0041 065 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 7 Ramp 0042 066 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 8 Soak 0043 067 FP R W Within Setpoint Limits Setpoint Value 4 08 UDC3200 Universal Digital Controller Product Manual 195 Modbus Read Write and Override Parame
191. nd or break the tab If you break or bend the tab and can t reattach the front snugly you ll need to reattach the front using the 4 NEMA4 screws provided See Section 2 5 Mounting UDC3200 Universal Digital Controller Product Manual 175 Modbus RTU Function Codes 9 Modbus RTU Function Codes 9 1 Overview This section describes the function codes needed to upload and download the configuration from a host computer into the instrument What s in this section The following topics are covered in this section 9 1 Overview 176 9 2 General Information 176 9 3 Function Code 20 178 9 4 Function Code 21 182 9 2 General Information This instrument uses a subset of the standard Modbus RTU function codes to provide access to process related information Several MODICON function codes are implemented It is appropriate to define instrument specific user defined function codes Where differences occur between the two protocols it will be noted Several standard Modbus RTU function codes are supported Configuration ID Tags Function codes 20 and 21 use the RS422 485 tag IDs for accessing configuration and process related data These tags are fully explained in Section 10 The tag IDs represent the register addresses used in the Request Message 176 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus RTU Function Codes Register Address Structure Table 9 1 Integer Parameter Type Register Numbers Dec
192. net Input not configured correctly for 3 eck for gross over ranging with a multimeter the sensor being used 4 Restore factory calibration Input source is grossly out of See Subsection 5 6 range INP2 RNG Input 2 out of range The remote input is Same as INP1RNG above outside the range limits INP2FAIL Two consecutive failures of input 2 Same as INP1FAIL above integration i e cannot make analog to digital conversion 4 08 UDC3200 Universal Digital Controller Product Manual 157 Troubleshooting Service Lower Reason for Failure How to Correct the Problem Display CONF ERR e PV low limit is gt PV high limit 1 Check the configuration for each item and e SP low limit is gt SP high limit reconfigure if necessary e Output low limit gt Output high limit PV LIMIT PV out of range 1 Make sure the input signal is correct PV INP1 x RATIO1 INP1 BIAS 2 Make sure the Ratio and Bias settings are correct 3 Recheck the calibration Use Bias of 0 0 RV LIMIT The result of the formula shown below is 1 Make sure the input signal is correct beyond the range of the remote variable f 2 Make sure the Ratio2 and Bias2 settings are RV INP2 X RATIO BIAS correct 3 Recheck the calibration Use a Ratio2 of 1 0 and a Bias2 of 0 0 SEGERR Setpoint Program start segment number is Check SP Program configuration subsection 3 5 Set less than ending segment number up Group SPPR
193. nge Parameter definitions are the same as in IN1 TYPE IN1 HIGH 999 To 9999 Floating INPUT 1 HIGH RANGE VALUE in engineering units in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization Scale the 1 input signal to the display value you want for 100 EXAMPLE Process Variable Flow Range of Flow 0 to 250 Liters Minute Actuation Input 1 4 to 20 mA Characterization XMITTER LINEAR Set IN1 HI display value to 250 Set IN1 LO display value to O Then 20 mA 250 Liters Minute and 4 mA 0 Liters Minute ATTENTION The control setpoint will be limited by the range of units selected here IN1 LOW 999 To 9999 Floating INPUT 1 LOW RANGE VALUE in engineering units in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization Scale the 1 input signal to the display value you want for 0 See example above ATTENTION The control setpoint will be limited by the range of units selected here RATIO 1 20 00 to 20 00 RATIO ON INPUT 1 Select the Ratio value you Floats to 3 decimal places want on Input 1 BIAS IN1 999 to 9999 BIAS ON INPUT 1 Bias is used to compensate in engineering units the input for drift of an input value due to deterioration of a sensor or some other cause Select the bias value you want on Input 1 4 08 UDC3200 Universal Digit
194. nostic message will be shown on the lower display In the case of more than one simultaneous malfunction only the highest priority diagnostic message will be displayed Table 4 4 shows the error messages in order by priority If any of these diagnostic messages appear on the lower display refer to Section 7 Troubleshooting for information on how to correct the problem Table 4 4 Diagnostic Messages Prom een EE FAIL FAILSAFE INP1FAIL INP2FAIL SW FAIL CONF ERR SOOTING IN1 RNG IN2 RNG PV LIMIT FAILSAFE RV LIMIT SEG ERR CAL MTR SW FAIL TC1 WARN TC2 WARN TC1 FAIL Unable to write to nonvolatile memory A subsequent successful write to nonvolatile memory removes this message This error message appears whenever the controller goes into a failsafe mode of operation Failsafe operation occurs when an analog input fails or when configuration is corrupted Two consecutive failures of input 1 integration or input value is outside of Out of Range limits Two consecutive failures of input 2 integration or input value is outside of Out of Range limits Slidewire input failure Position Proportional Control automatically switched to Three Position Step Control Configuration Errors Low limit greater than high limit for PV SP Reset or Output Carbon Potential Problem Percent Carbon outside of sooting boundary Input 1 Out of Range lInput is outside of the High or Low Limits Out of range c
195. o minimize electrical noise and transients that may adversely affect the system supplementary bonding of the controller enclosure to local ground using a No 12 4 mm copper conductor is recommended Before powering the controller see Prelimnary Checks in this section of the Product Manual Ot is the user s responsibility to provide a switch and non time delay North America quick acting high breaking capacity Type F Europe 1 2A 250V fuse s or circuit breaker for 90 264 Vac applications or 1 A 125 V fuse or circuit breaker for 24 Vac dc applications as part of the installation 3 CAUTION Applying 90 264 Vac to an instrument rated for 24 Vac dc will severely damage the instrument and is a fire and smoke hazard Figure 2 5 Mains Power Supply 4 08 UDC3200 Universal Digital Controller Product Manual 25 Installation 26 Thermocouple RTD Input 1 Millivolt or Volts except 0 10 Volts Use Thermocouple extension wire only Use Thermocouple extension wire only Supply O The 250 ohm resistor for milliamp inputs or the voltage divider for 0 10 Volt inputs are supplied with the controller when those inputs are specified These items must be installed prior to start up when the controller is wired For 0 20 mA applications the resistor should be located at the transmitter terminals if Burnout detection is desired Splice and tape this junction between the two thermocouples This junction may be lo
196. o the size of the error and the time the error has existed The amount of corrective action depends on the value of proportional Gain Derivative Rate Regulates the controller s output in proportion to the rate of change of the error The amount of corrective action depends on the value of proportional Gain PID B Unlike the PID A equation the controller gives only an integral response to a setpoint change with no effect on the output due to the gain or rate action and it gives full response to PV changes Otherwise controller action is as described for the PID A equation See note on PID A PD WITH MANUAL RESET is used whenever integral action is not wanted for automatic control The equation is computed with no integral contribution The MANUAL RESET which is operator adjustable is then added to the present output to form the controller output Switching between manual and automatic mode will be bumpless If you select PD with Manual Reset you can also configure the following variations PD Two Mode control e P Single Mode control Set Rate D to 0 ATTENTION Other prompts affected MAN RSET in the Tuning Set Up group 4 08 UDC3200 Universal Digital Controller Product Manual 51 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition CONT ALG continued 3PSTEP THREE POSITION STEP The Three Positi
197. on 0 eee 15 Program Termmanon ae papane ee Moisture Protection sccesesesecneeeeeeeneeerenes 4 Proportional Banid sosssccssesessrseseevnnsseerinnseseven D Motor Position Display ccoo 120 Proportional Band 2 OE 41 Motor Li iia adios 148 Proportional Band Units ssssssssssenssseen is O coe 62 Pruna rico 82 A iinn 18 O E Mounting Method cccccccssssesesesessesescscscssseees 19 R Mounting Procedure ooooooccoocnocnnoncnoncconcnnnonnninnos 19 Ramp Time Or Rate Segments c00000 127 Multiplier A EEE S E RE er saehe seen 54 Ramp Soak Profile Example CEE E SNE SO 128 Multiplier Divide oococonicncnnnionocnncnncnnncnnanen neones 54 A EN 40 Multiplier Divider With Square RO0t 54 A terete eect nee oh 41 Multiplier With Square RO0t oooococoninoononoor o 54 Rate Down Value c ooccocnininononononononononononanocnnso 45 N Rate Up Valle 45 Noise Immumiity cocinas 4 RAO en a e e ens e a 65 69 Non Daichino es an AE ea EEN N 122 Read Onlys A is Rata 188 Reading Control Data oonoooncnnnnonnnocnnoncnononnss 186 O Recycle Number c ceecceeceeseeeteeeteeneeenes 126 On Off Algorithm ee eee cence teeneesees 50 Register Address Structure cece 177 Open Collector Output eseceeeesecenteeeneees 30 Register ONIN as hares Oe Rate Seen rah aca eat 177 Open Collector Outputs eee eee eens 13 Remote Setpoint Source coocccconinonoocnncnnannnnonoso 73 Operating Parameters ooonc
198. on Step Control algorithm allows the control of a valve or other actuator with an electric motor driven by two controller relay outputs one to move the motor upscale the other downscale without a feedback slidewire linked to the motor shaft The deadband is adjustable in the same manner as the duplex output algorithm The Three Position Step Control algorithm provides an output display OUT which is an estimated motor position since the motor is not using any slidewire feedback Although this output indication is only an approximation it is corrected each time the controller drives the motor to one of its stops 0 or 100 It avoids all the control problems associated with the feedback slidewire wear dirt noise When operating in this algorithm the estimated OUT display is shown to the nearest percent i e no decimal This selection forces the Output Algorithm selection to POSITON See Subsection 3 8 Refer to the Operation section for motor position displays As acustomer configurable option when a second input board is installed the motor slidewire can be connected to the controller The actual slidewire position is then shown on the lower display as POS This value is used for display only It is NOT used in the Three Position Step algorithm To configure this option set Input 2 actuation to SLIDEW and then calibrate Input 2 per Subsection 6 4 ATTENTION Other prompts affected DEADBAND
199. one the prompt CAL MTR will appear to suggest that the controller be calibrated Refer to Subsection 6 4 Three Position Step Output Calibration 7 4 Status Tests Introduction When required the results of these tests can be checked to determine the reason the controller has gone to Failsafe How to check the status tests The procedure in Table 7 2 tells you how to display the results of the status tests Table 7 2 Procedure for Displaying the Status Test Results A Select oF Upper Display READ STATUS NA Lower Display STATUS Set Up Group 2 Read the test Function You will see results a Upper Display NO or YES YES indicates a failure Lower Display FAILSAFE Function Upper Display PASS or FAIL NA Lower Display TEST 156 UDC3200 Universal Digital Controller Product Manual 4 08 7 5 Background Tests Introduction Troubleshooting Service The UDC3200 performs ongoing background tests to verify data and memory integrity If there is a malfunction a diagnostic message will be displayed blinking in the lower display In the case of simultaneous malfunctions the messages will appear in sequence in the lower display Table 7 3 lists these background tests the reason for their failure and how to correct the problem Diagnostic messages may be suppressed stop the blinking by pressing the RUN HOLD key The messages will still be available for viewing by pressing the LOWER DISPLAY key
200. ons None Auxiliary Output Digital Inputs 1 Aux and 1 DI or 2 Dl RS 485 Modbus Plus Auxiliary Output Digital Inputs 10 Base T Ethernet Modbus RTU Plus Auxiliary Output Digital Inputs Standard Functions Includes Accutune Math Option Set Point Programming 1 Program 12 Segments Set Point Programming Plus Math Infrared interface Infrared Interface Included Can be used with a Pocket PC Communications Software Selections TABLE Ill Input 1 can be changed in the field using external resistors TC RTD mV 0 5V 1 5V TC RTD mV 0 5V 1 5V 0 20mA 4 20mA TC RTD mV 0 5V 1 5V 0 20mA 4 20mA 0 10V Carbon Oxygen or Dewpoint Requires Input 2 None TC RTD mV 0 5V 1 5V 0 20mA 4 20mA TC RTD mV 0 5V 1 5V 0 20mA 4 20mA 0 10V Slidewire Input Requires two Relay Outputs 4 08 UDC3200 Universal Digital Controller Product Manual 15 Installation TABLE IV Options Approvals CE Standard Pp CE UL and CSA None Tags Linen Customer ID Tag 3 lines w 22 characters line Stainless Steel Customer ID Tag 3 lines w 22 characters line Future Options TABLE V Product Manuals Product Information on CD All Languages 0 English Manual E French Manual E G S Manuals German Manual Italian Manual Spanish Manual m None Genificate Certificate of Conformance F3391 TABLE VI Lo ele Figure 2 1 Model Number Interpretation 16 UDC3200 Universal Digital Controller Product Manual 4 0
201. or W to switch between sets Configure the values for Gain Rate Reset Cycle Time Gain 2 Rate 2 Reset 2 Cycle 2 Time 4 08 UDC3200 Universal Digital Controller Product Manual 71 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition PID SETS continued SW VALUE 2PV SW 2SP SW Value in engineering units within PV or SP range limits TWO SETS PV AUTOMATIC SWITCHOVER When the process variable is GREATER than the value set at prompt SW VALUE Switchover Value the controller will use Gain Rate Reset and Cycle Time The active PID SET can be read in the lower display When the process variable is LESS than the value set at prompt SW VALUE the controller will use Gain 2 Rate 2 Reset 2 and Cycle 2 Time The active PID SET can be read in the lower display ATTENTION Other prompts affected SW VALUE TWO SETS SP AUTOMATIC SWITCHOVER When the setpoint is GREATER than the value set at prompt SW VALUE Switchover Value the controller will use Gain Rate Reset and Cycle When the setpoint is LESS than the value set at prompt SW VALUE the controller will use Gain 2 Rate 2 Reset 2 and Cycle 2 ATTENTION Other prompts affected SW VALUE AUTOMATIC SWITCHOVER VALUE This is the value of Process Variable or Setpoint at which the controller will switch from Tuning Constant Set 2 to Set 1
202. or one of the following reasons e Parameter not available or locked out e Not in setup mode press SET UP key first e Individual key locked out 4 08 UDC3200 Universal Digital Controller Product Manual 99 Monitoring and Operating the Controller 4 5 Monitoring Your Controller 4 5 1 Annunciators The following annunciator functions have been provided to help monitor the controller Table 4 2 Annunciators ALM 1 2 A visual indication of each alarm Blinking 1 indicates an alarm latched condition The blinking will continue even after the alarm condition ends until it is acknowledged by pressing the RUN HOLD key OUT 1 2 A visual indication of the control relays DI12 A visual indication of each Digital Input A or MAN A visual indication of the mode of the controller A Automatic Mode MAN Manual Mode None F or C A visual indication of the temperature units None No temperature unit annunciator F Degrees Fahrenheit C Degrees Celsius n A visual Lamp to indicate when the lower display is showing the Active Setpoint Local 1 Local 2 Local 3 Remote Setpoint or Computer Setpoint The upper left digit of the display is used to show other annunciator functions T Accutuning in process C Computer overide active O Output override active 100 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 5 2 Viewing the operating parameters Press the LOWER DISPLAY ke
203. os 66 69 C Calibration Mode oocococcnnnonccinonanccinananono 142 151 Calibration Steps oooooocnincnnoninonionncononononnnnnnonos 133 Carbon Potential 0 0 0 ce eeeseseeeetecreeeeeneeeees 57 Carbon Potential Selecti0MS ooooooonccnnn 55 CE Conformity Europe oooooconoccnoninoninnninnnonnnnos 8 CEM 4 Changing Control Modes ooooooiccccociocncononnnno 106 Changing The Local Setpoints eee 107 Communications ak eni RAS ae 3 Communications Failure oooooonnonnnninnincnnn 167 Communications Group ccooocoonconnnoncconcnnninnninnn 84 Communications Selection ccceceseeeeres 84 Index 13 Index Composite Wiring Diagram 24 Computer Setpoint ccccceccsseesseeteeeeeeeeees 190 Contigurationvc o3cnrcsaiarn seen 36 Configuration Data ccccesesseesseeseeeseeereees 185 Configuration Parameters eseeeeeneees 192 Configuration Procedure ccesseseeeeeees 39 Configuration Prompt Hierarchy 37 Configuration Record Sheet secseeceeee 94 Control Algorithm cceeceeseeteeeteeseeneeeees 50 Control And Alarm Relay Contact Information E OE 17 Control Mode Definiti0NS oooococincnmmmom 105 Control Modes cooooccoccconocconccononcnnncnncnncnncononos 105 Control Rel tion 17 Control Set Up GrOUP cooonoccoccnocononcconccononnnonnos 71 Control Alarm Circuit Wiring 0 0 0 0 20 Controller Dropoff Value ooooono
204. oubleshooting Service Table 7 11 explains how to troubleshoot a RS 485 Communications failure 1 Table 7 12 Troubleshooting a RS 485 Communications Failure Step What to do How to do it Check the Address Number ComState and Baud Rate settings Check the field wiring and termination resistor Make sure the Communications Printed Wiring Board is installed properly in the controller Determine if the Communications board is faulty by running a LOCAL LOOPBACK TEST If the test fails replace the board If the test passes the problem is most likely elsewhere in the communications network See Section 3 13 Using an ohm meter check the resistance across the communications rear terminals See Section 2 7 for wiring diagrams Withdraw the chassis from the case and inspect the board See the exploded view Figure 8 1 for location of the board Return the chassis to the case Disconnect the communications cable from the rear terminals Run the Local Loopback Test Press SET UP until you see Upper Display SET UP Lower Display COM Press FUNCTION until you see Upper Display DISABLE Lower Display LOOPBACK Press or W you will see Upper Display ENABLE Oo z o S U n O w lt LOOPBACK The test will run until the operator disables it here UDC3200 Universal Digital Controller Product Manual 167 Troubleshooting Service Procedure 9 Table 7 13 explains how to troubles
205. ould be located at the transmitter terminals if Burnout detection is desired Splice and tape this junction between the two thermocouples This junction may be located anywhere between the thermocouples and the instrument terminals it does not need to be close to the other thermocouple junctions Both thermocouples must be of the same type For best accuracy the two thermocouples should be matched or preferably made from the same batch of wire This controller does not produce a steady current for burnout detection For that reason when a thermocouple is used in parallel with another instrument it may be desirable to configure the burnout selection for this controller to NOFS and use the burnout current from theother instrument to also drive this controller Input 2 is used to measure the Slidewire Input for Position Proportional Control Figure 2 7 Input 2 Connections UDC3200 Universal Digital Controller Product Manual 27 Installation Time Simplex N C Lt Relay jane ISH Mice ASNO Supply To terminal o p o Power 19 or 21 QO Load o Supply Power o To terminal 4or6 Load o Supply Power o To terminal 7or9 Relay Load Alarm N o Relay 1 26 Relay Load Load Relay Load O O Supply To terminal C Power 19 or 21 R 19 R _ ES Output ae SET L1 Relay 1 i NO 1 21 82 Load o O Relay Load Load Supply 4 Power ES
206. ound Tests 7 6 Controller Failure Symptoms 7 7 Troubleshooting Procedures 160 e Power Failure e Current Proportional Output Failure e Time Proportional Output Failure e Time Current Current Time Proportional Output Failure e Alarm Relay Output Failure e Keyboard Failure 7 8 Restore Factory Configuration 7 9 Software Upgrades 4 08 UDC3200 Universal Digital Controller Product Manual 153 Troubleshooting Service Installation related problems Read the Installation section in this manual to make sure the UDC3200 has been properly installed The installation section provides information on protection against electrical noise connecting external equipment to the controller and shielding and routing external wiring ATTENTION System noise induced into the controller will result in diagnostic error messages recurring If the diagnostic error messages can be cleared it indicates a soft failure and is probably noise related If system noise is suspected completely isolate the controller from all field wiring Use calibration sources to simulate PV and check all controller functions i e Gain Rate Reset Output Alarms etc Application related problems Review the application of the controller then if necessary direct your questions to the local sales office Hardware and software related problems Use the troubleshooting error message prompts and controller failure symptoms to identify typical failures
207. our process control needs 4 08 UDC3200 Universal Digital Controller Product Manual 1 Introduction Analog Inputs The UDC3200 has two analog inputs with a typical accuracy of 0 20 of full scale input and a typical resolution of 16 bits Both analog inputs are sampled six times per second every 166 ms The first or Process Variable input can be one of the various thermocouple RTD Radiamatic or linear actuations Linear actuations have thermocouple RTD and Radiamatic transmitter characterization capability as a standard feature Linear actuations also have square root capability The optional second input is isolated and accepts the same actuations as input one or it provides the Slidewire input for Position Proportional control All actuations and characterizations are keyboard configurable Cold junction compensation is provided for thermocouple type inputs Upscale downscale or failsafe sensor break protection is keyboard configurable A configurable digital filter of 0 to 120 seconds provides input signal damping Thermocouple Health In addition to the standard configurable upscale downscale or failsafe output burnout selections the condition of the thermocouple can be monitored to determine if it is good failing or in danger of imminent failure Math Functions Algorithm A pre configured algorithm is available for easy implementation This includes the capability of using a Ratio and Bias with any input You can
208. ow Tune Fast Tune will tune the process in such a way that the temp is reached faster a slight overshoot will be allowed 4 UDC3200 Universal Digital Controller Product Manual 4 08 Introduction Slowtune will minimize overshoot but it will take more time for the process temperature to reach the target setpoint Heat Cool Duplex Tune will automatically tune both the heating and cooling sides of the process Fuzzy Logic This standard feature uses fuzzy logic to suppress process variable overshoot due to SP changes or externally induced process disturbances It operates independently from Accutune III tuning It does not change the PID constants but temporarily modifies the internal controller response to suppress overshoot This allows more aggressive tuning to co exist with smooth PV response It can be enabled or disabled depending on the application or the control criteria 1 2 Operator Interface 4 08 Figure 1 1 UDC3200 Operator Interface UDC3200 Universal Digital Controller Product Manual 5 Introduction 1 2 1 Function of Displays and Keys Table 1 1 Function of Displays and Keys Display Indicators Upper display with 4 larger digits shows Process Variable value normal operation and special annunciator features During Configuration the upper display provides guidance for the operator through prompts 7 characters During normal operation the lower display shows key selected operating par
209. parameters There are two alarm output selections High and Low You can configure each setpoint to alarm either High or Low These are called single alarms You can also configure the two setpoints to alarm on the same event and to alarm both high and low A single adjustable Hysteresis of 0 to 100 is configurable for the alarm setpoint See Table 2 3 in the Installation section for Alarm relay contact information The prompts for the Alarm Outputs appear whether or not the alarm relays are physically present This allows the Alarm status to be shown on the display and or sent via communications to a host computer Function Prompts Table 3 14 ALARMS Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display A1S1 VAL Value in engineering units ALARM 1 SETPOINT 1 VALUE T his is the value at which you want the alarm type chosen in prompt A1S1TYPE to actuate The value depends on what the setpoint has been configured to represent No setpoint is required for alarms configured for Communications SHED For SP Programming the value is the segment number for which the event applies This prompt does not appear for Alarm on Manual type alarm For example A1S1TYPE MANUAL A1S2 VAL Value in engineering units ALARM 1 SETPOINT 2 VALUE This is the value at which you want the alarm type chosen in prompt A1S2TYPE to actuate The details are the same
210. play shows the target or final setpoint value XXRAHR MN RAMP SEGMENT NUMBER AND TIME REMAINING Set Point Programming display XX is the current segment number and HR MN is the time remaining for this segment in Hours Minutes XXSKHR MN SOAK SEGMENT NUMBER AND TIME REMAINING Set Point Programming display XX is the current segment number and HR MN is the time remaining for this segment in Hours Minutes RECYC XX NUMBER OF SP PROGRAM RECYCLES REMAINING To BEGIN RESET SP PROGRAM TO START OF FIRST SEGMENT RERUN RESET SP PROGRAM TO START OF CURRENT SEGMENT AUX XXXX AUXILIARY OUTPUT Displayed only when output algorithm is not Current Duplex BIA XXXX BIAS Displays the manual reset value for algorithm PD MR TUNE OFF LIMIT CYCLE TUNING NOT RUNNING Appears when Accutune is enabled but not operating DO FAST Limit Cycle Tuning with the objective of producing quarter damped tuning parameters This tuning may result in PV overshoot of the SP setting DO SLOW Limit Cycle Tuning with the objective of producing damped or Dahlin tuning parameters depending upon the detected process deadtime The tuning parameters calculated by this selection are aimed at reducing PV overshoot of the SP setting UDC3200 Universal Digital Controller Product Manual 101 Monitoring and Operating the Controller 4 5 3 Diagnostic Messages 102 The UDC3200 performs background tests to verify data and memory integrity If there is a malfunction a diag
211. plays and indicators are reacting Symptoms Compare your symptoms with those shown in Table 7 4 158 UDC3200 Universal Digital Controller Product Manual 4 08 Troubleshooting Service Table 7 4 Controller Failure Symptoms Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Blank Blank Off None Power Failure 1 OK OK Current 2 Proportional Output OK Displayed OK Controller Position 3 Output Output Proportional or disagrees disagrees TPSC Output with Controller with Displayed OK Output OK Output Time Proportional 4 Output OK OK Current Time 5 Proportional Output OK OK OK External Alarm Malfunction in 6 function does alarm output not operate properly Display does not change when a key is pressed Keyboard 7 Malfunction Controller fails to go into Slave operation during communications Communications 8 Failure OK Displayed OK Controller Auxiliary Output 9 Output Auxiliary Output disagrees with disagrees Auxiliary Output with Displayed Auxiliary Output 4 08 UDC3200 Universal Digital Controller Product Manual 159 Troubleshooting Service Other symptoms If a set of symptoms or prompts other than the one you started with appears while troubleshooting re evaluate the symptoms This may lead
212. put value using the increment and decrement keys to the limits allowed by the output type 0 to 100 for a time proportioning output or 5 to 105 for a current output 4 08 UDC3200 Universal Digital Controller Product Manual 105 Monitoring and Operating the Controller 4 7 2 What happens when you change modes Table 4 7 Changing Control Modes Manual to The Local Setpoint is usually the value previously stored as the Local Setpoint Automatic Local Setpoint PV tracking is a configurable feature which modifies this For this configuration when the controller is in manual mode the local setpoint value tracks the process variable value continuously Manual or Auto The Remote Setpoint uses the stored ratio and bias to calculate the control Local to Automatic setpoint Remote SP Auto bias is a configurable feature which modifies this When it is selected the transfer from automatic local to automatic remote or from manual remote to automatic remote adjusts the bias based on the local setpoint such that Bias LSP RSP Input x R Automatic Remote If configured for local setpoint tracking RSP when the controller transfers out of Setpoint to Manual remote setpoint the last value of the remote setpoint is inserted into the local or Auto Local setpoint Setpoint If LSP tracking is not configured the local setpoint will not be altered when the transfer is made 4 8 Setpoints Introduction You can configure the follow
213. r OUTPUT and 3 Scale the Auxiliary Output as necessary for the desired output algorithm type For these 4 08 UDC3200 Universal Digital Controller Product Manual 23 Installation selections the Output 1 HEAT and Output 2 COOL signals will be present both on the Auxiliary Output and on the two relays normally used for Time Duplex Wiring the Controller Using the information contained in the model number select the appropriate wiring diagrams from the composite wiring diagram below Refer to the individual diagrams listed to wire the controller according to your requirements See table for callout details Figure 2 4 Composite Wiring Diagram Callout Details AC DC Line Voltage Terminals See Figure 2 5 Output 3 Terminals See Figure 2 8 through Figure 2 14 Output 4 Terminals See Figure 2 8 through Figure 2 14 Outputs 1 and 2 Terminals See Figure 2 8 through Figure 2 14 Input 2 Terminals See Figure 2 7 Input 1 Terminals See Figure 2 6 Aux Output and Digital Inputs Terminals See Figure 2 17 MINI OD aA A JN Communications Terminals See Figure 2 15 and Figure 2 16 24 UDC3200 Universal Digital Controller Product Manual 4 08 Installation Earth Ground Voltage PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National and local electrical codes T
214. r Restart After a Power Loss Introduction If the power to the controller fails and power is reapplied the controller goes through the power up tests then goes to a user configured FAILSAFE OUTPUT VALUE Set a Failsafe Value Table 4 21 Procedure for Setting a Failsafe Value ee ommen e OO e Select Control setup Until you see Set up Group NA Upper Display SET Lower Display CONTROL 2 Select Failsafe Function You will see Function Prompt Naa Upper Display range within the range of the Output 0 to 100 for all output types except Three Position Step Three Position Step 0 motor goes to closed position 100 motor goes to open position Lower Display F SAFE 3 Select a value To select a failsafe output value in the upper display 4 Return to Normal At power up the output will go to the value set Display 4 08 UDC3200 Universal Digital Controller Product Manual 121 Monitoring and Operating the Controller 4 16 Setting Failsafe Mode Introduction You can set the Failsafe Mode to be Latching or Non Latching Set Failsafe Mode Table 4 22 Procedure for Setting a Failsafe Mode CO E Select Control setup X Until you see Set up Group NA Upper Display SET Lower Display CONTROL 2 Select Failsafe Function You will see Function Prompt NA Upper Display LATCH Controller goes to manual and output goes to failsafe value NoLATCH Controller mode does not change and output goes to failsafe valu
215. r of Input A x Ratio A Bias A or Input B x Ratio B Bias B LO SEL INPUT LOW SELECT WITH RATIO AND BIAS See Note 2 This selection specifies the PV or SP as the lower of Input 1 or Input 2 The following formula applies Alg1 lower of Input A x Ratio A Bias A or Input B x Ratio B Bias B VMuDIV MULTIPLIER DIVIDER WITH SQUARE ROOT See Note 1 The following formula applies Alg1 K Sq Rt Input A x Ratio A Bias A x Input C x Ratio C Bias C Input B Ratio B Bias B x Calc Hi Calc Lo Alg1Bias See Figure 3 1 at the end of this section for an example of Mass Flow Compensation using the Multiplier Divider Algorithm VMULT See Note 1 MULTIPLIER WITH SQUARE ROOT The following formula applies Alg1 K x Sq Rt Input A x Ratio A Bias A x Input B x Ratio B Bias B x Input C x Ratio C Bias C x Calc Hi Calc Lo Alg1Bias MuDIV See Note 1 MULTIPLIER DIVIDER The following formula applies 54 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display Alg1 K x Input A x Ratio A Bias A x Input C x Ratio C Bias C Input B x Ratio B Bias B x Calc Hi Calc Lo Alg1Bias MULT MULTIPLIER The following formula applies See Note 1 Alg1 K x Input A x Ratio A Bias A x Input C
216. range Input 1 signal developed by the Burnout circuitry NO FAILSAFE This selection does not provide input failure detection and should only be used when a thermocouple input is connected to another instrument which supplies the Burnout current For this selection no burnout signal is sent to the sensor ATTENTION For Burnout to function properly on a 0 20 mA input type or a 0 5V type that uses a dropping resistor the dropping resistor must be remotely located across the transmitter terminals Otherwise the input at the instrument terminals will always be 0 mA i e within the normal operating range when the 0 20 mA line is opened 66 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display EMISSIV1 0 01 to 1 00 EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator Available only for Radiamatic inputs 4 08 UDC3200 Universal Digital Controller Product Manual 67 Configuration 3 10 Input 2 Set Up Group Introduction This data deals with various parameters required to configure Input 2 Function Prompts Table 3 10 INPUT 2 Group Function Prompts Function Prompt Lower Display Selections or Range of Se
217. relay output types can only be scaled 0 to 100 HIGH VAL High Scale Value within AUXILIARY OUTPUT HIGH SCALING FACTOR the range of the selected This is a value in engineering units used to variable to represent the represent all AUX OUT parameters except Output maximum output 20 mA q For Output this is a value in percent and can be any value between 5 and 105 However keep in mind that relay output types can only be scaled 0 to 100 DIG INP1 DIGITAL INPUT 1 SELECTIONS All selections are available for Input 1 The controller returns to its original state when contact opens except when overruled by the keyboard NO DIGITAL INPUT SELECTIONS TO MANUAL Contact closure puts the affected loop into manual mode Contact open returns controller to former mode TO LOCAL SETPOINT When a remote setpoint is configured contact closure puts the controller into local setpoint 1 When contact opens the controller returns to former operation local or remote setpoint unless SP Select key is pressed while digital input is active If this happens the controller will stay in the local setpoint mode when contact opens TO LOCAL SETPOINT TWO Contact closure puts the controller into local setpoint 2 TO LOCAL SETPOINT THREE Contact closure puts the controller into local setpoint 3 TO DIRECT ACTION Contact closure selects direct controller action 4 08 Configuration Function Prompt Lower Displ
218. rent setpoint can be viewed as SPn in the lower display Entering a 0 will imply an immediate step change in Setpoint i e no rate applies EU HR DN 4 08 0 to 9999 in engineering units per hour RATE DOWN Rate down value When making a setpoint change this is the rate at which the controller will change from the original setpoint down to the new one The ramping current setpoint can be viewed as SPn in the lower display Entering a 0 will imply an immediate step change in Setpoint i e no rate applies UDC3200 Universal Digital Controller Product Manual 45 Configuration appear If SP Rate is enabled it does not operate while an SP Program is running Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display SP PROG SETPOINT RAMP SOAK PROGRAM Available optional feature only with controllers that contain this option SP Ramp must be SP RAMP must be disabled disabled for SP Program prompts to DISABLE DISABLE Disables setpoint programming ENABLE ENABLE Enables setpoint programming ATTENTION Detailed information for the prompts for SP Programming may be found Section 4 17 The listing below is only for reference purposes STRT SEG 1to11 Start Segment Number END SEG 2 to 12 even numbers End Segment Number Always end in a soak segment 2 4 12 RAMPUNIT RAMPUNIT Engineering Units for Ramp Seg
219. resistance and the current position of the slidewire This voltage should vary smoothly as the motor moves and the wiper travels across the slidewire If the voltage jumps at a particular position while the motor is moving this could indicate a deadspot and mean that the slidewire may be worn out and need replacing Refer to the motor manufacturer s instructions UDC3200 Universal Digital Controller Product Manual 4 08 7 Make sure the output relays are actuating properly Recalibrate the controller Change the two Output Relays or the Dual Relay Board depending upon unit Troubleshooting Service Put the controller into Manual mode Vary the output above and below the present value Observe OUT indicators and the output value OUT on the lower display When the OUT 1 indicator is on the output value should be increasing When the OUT 2 indicator is on the output value should be decreasing If these are not working properly check the field wiring then go to Step 5 If they are go to Step 8 Refer to Section 6 Output Calibration Installation instructions supplied with the new relays or board Procedure 4 Table 7 8 explains how to troubleshoot Time Proportional Output failure Table 7 8 Troubleshooting Time Proportional Output Failure Step What to do How to do it 1 Make sure the controller is configured Make Output Algorithm Set Up group function for Time
220. riteria Linear range 10 Characterized range 1 Input 2 Out of Range Same criteria as Input 1 PV beyond limits PV outside of PV Hi Low Limits PV PV source x PV source ratio PV source bias Failsafe Check inputs or configuration Remote Variable beyond limits RSP outside of SP Hi Low Limits RV RV source x RV source ratio RV source bias Segment Error SP Program starting segment number is less than ending segment number Slidewire not calibrated Perform Slidewire calibration Position Proportional slidewire input failure The Thermocouple on Input 1 is starting to burnout The Thermocouple on Input 2 is starting to burnout Thermocouple on Input 1 is in imminent danger of burning out UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Promt ee TC2 FAIL Thermocouple on Input 2 is in imminent danger of burning out OUT1FAIL Current Output is less than 3 5 mA OUT2FAIL Current Output 2 is less than 3 5 mA Ratio Ratio To RSP e e 1 y e 2 IN2 In Alg1 To RSP PV Source e Input 1 INPUT e Input 2 ALGORITHM 1 INPUT A e Output 1 FEEDFORWARD INPUT A ONLY e Input 1 INPUT B e Input 2 e Output 1 Remote SP CONTROL ALGORITHM Local SP e Input 1 INPUT C e Input 2 e Output 1 o o FEEDFO RWARD LSP1 0 LSP3 SUMMER OR LSP2 MULTIPLIER Manual Mode gt 0 o4 Output To Final OUTPUT Con
221. roller stores the calibration constants and exits the Calibration Mode N 4 calibration mode 5 6 Restore Input Factory Calibration Introduction The factory calibration constants for all the input actuation types that can be used with the controller are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for a given input actuation type by simply changing the actuation type to another type and then changing it back to the original type Refer to Table 5 10 Restore Factory Calibration for procedure 4 08 UDC3200 Universal Digital Controller Product Manual 141 Input Calibration ATTENTION A restored factory calibration overwrites any previous field calibration done for the input and may change the High and Low Range Limits Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See Section 3 Configuration for specific instructions to set the lockout Table 5 10 Restore Factory Calibration ET Rew 1 Set LOCKOUT to a until you see NONE NA Upper Display SET UP Lower Display TUNING VE N Until you see G Upper Display one of the following NONE all parameters are read write CALIB all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted VIEW Tuning and Setpoint Ramp parameters are read write No other parameters can be viewed AL
222. rompts Table 4 1 Procedure to Enter a Security Code Table 4 2 Annunciators Table 4 3 Lower Display Key Parameter Prompts Table 4 4 Diagnostic Messages Table 4 5 Procedure for Starting Up the Controller Table 4 6 Control Mode Definitions Table 4 7 Changing Control Modes Table 4 8 Procedure for Changing the Local Setpoints Table 4 9 Procedure for Switching Between Setpoints Table 4 10 Procedure for Starting TUNE Table 4 11 Procedure for Using AUTOMATIC TUNE at Start up for Duplex Control Table 4 12 Procedure for Using BLENDED TUNE at Start up for Duplex Control Table 4 13 Procedure for Using MANUAL TUNE for Heat side of Duplex Control Table 4 14 Procedure for Using MANUAL TUNE for Cool side of Duplex Control Table 4 15 Procedure for Accessing Accutune Error Codes Table 4 16 Accutune Error Codes Table 4 17 Set Up Procedure Table 4 18 Procedure for Switching PID SETS from the Keyboard Table 4 19 Procedure for Displaying Alarm Setpoints Table 4 20 Procedure for Displaying 3Pstep Motor Position Table 4 21 Procedure for Setting a Failsafe Value Table 4 22 Procedure for Setting a Failsafe Mode Table 4 23 Running A Setpoint Ramp Table 4 24 Program Contents Table 4 25 Run Monitor Functions ix UDC3200 Universal Digital Controller Product Manual 107 110 112 113 113 114 115 115 117 118 119 120 121 122 124 126 130
223. roubleshooting Service ccccceceeseeeee 153 O A 110 Tune For Duplex Heat Cool 111 A ohehtvtes E A 40 Tuning Constants iniinis 4 Tuning Indicators oooonccincnnoninoncncnnnnnnnnonononos 109 Tuning Parameter SetS oooooncnnncincnnnncnonocnnonnos 71 Tuning Set Up Group ccooccocccocononononcnononnnonnnonnss 40 Two Sets Of Tuning Constants 116 TED ti aia 85 U Universal Output Functionality And Restrictions O A A A 22 23 Universal Switching Power oooooonocnoniocncononnnonos 4 Vv Voltage And Resistance Equivalents For 0 And 100 Range Values ceeeeee 133 W X Y Z Nc nenni 14 Weighted Average Ratio oooooocionnncicnnioncocnconoo 56 A SO 20 Wiring Bundling oocooiocnnncnncnnocnoonnncnconncanononno 21 Wiring Connections For Calibrating Auxiliary QUO wads and E R wenn 146 Wiring Connections For Calibrating Current Proportional Output ecceceeeesseereeeeees 144 Wiring Connections For Radiamatic Milliampere Millivolts Or Volts Except 0 To 10 Volts 138 139 Wiring Connections For Rtd Resistance Thermometer Device cccssecseeseeeees 137 Wiring Diagrams oooooonnoniocnnonononcoonconnconccnnocnnoos 22 Wiring The Controller oooononnnonncnnncnoncocomo 24 Works Esti 125 WS Elodtincucniitia cet it 85 226 UDC3200 Universal Digital Controller Product Manual Sales and Service Sales and Service 14 Sales and Service For applicat
224. roups Read Write e CALIB Calibration prompts are deleted from the Setup List e CONFIG Timer Tuning SP Ramp and Accutune are Read Write All other Setup are Read only Calibration Group is not available e VIEW Timer Tuning and SP Ramp are Read Write No other parameters are available e ALL Timer Tuning and SP Ramp are Read only No other parameters are viewable See Subsection 3 4 Tuning Parameters Set Up Group prompts to select one of the above Security Code see Subsection 4 3 98 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Individual key lockout There are three keys that can be disabled to prevent unauthorized changes to the parameters associated with these keys First set the Lock prompt to NONE These keys are TD Key you can disable the Run Hold key for Set Point Programming at configuration Set Up group prompt Tuning function prompt RN HLD Pian N 2 Key you can disable the Auto Manual key at configuration Set Up group prompt Tuning function prompt AUTOMA aane Na El HA Key you can disable the Set Point Select function key at configuration Set Up group prompt Tuning function prompt SP SEL See Subsection 3 4 Tuning Parameters Set Up Group prompts to enable or disable these keys Key error When a key is pressed and the prompt Key Error appears in the lower display it will be f
225. s can be configured For more information on Set Point Rate Ramp and Programming see Sections 4 17 through 4 20 Y ou can start and stop the ramp program using the RUN HOLD key PV Hot Start is a configurable feature and means that at initialization the setpoint is set to the current PV value and the Ramp or Rate or Program then starts from this value Function Prompts Table 3 5 SPRAMP Group Function Prompts Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display SP RAMP SINGLE SETPOINT RAMP Make a selection to enable or disable the setpoint ramp function Make SP Program must be sure you configure a ramp time and a final setpoint disabled for SP Ramp value prompts to appear SP Programming must be disabled DISABLE DISABLE SETPOINT RAMP Disables the setpoint ramp option ENABLE ENABLE SETPOINT RAMP Allows the single setpoint ramp prompts to be shown TIME MIN 0 to 255 minutes SETPOINT RAMP TIME Enter the number of minutes desired to reach the final setpoint A ramp time of 0 implies an immediate change of setpoint 44 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition FINAL SP Within setpoint limits SETPOINT RAMP FINAL SETPOINT Enter the value desired for the final setpoint The controller will
226. seeeceeeseeeseeesaecseecsaecaeceseceseeseeeseeeeeeeseneeesees 160 7 8 Restoring Factory Configuration ooocococonnnonnnoonnnononononon nono nonnncon ccoo nono nono nn no nar n rra r rra rana n nn rrn rin 170 HO Software Ups iii a a liada a a ees 171 8 PARTS LIS sicario ii TET 173 8 1 Exploded Vis Wisin Ada a adas daa se 173 8 2 Removing this chassis it Ti ve a a a tes aandale 175 9 MODBUS RTU FUNCTION CODES onncccccccccnnncccnnnnncnononononananananonononnnonananananennns 176 RN 176 92 General Information iba iia ida 176 9 3 Function Code 20 14h Read Configuration Reference Data ooonnoccnnccnnnnocnnocnnoonononnnanccnnccnnnos 178 9 3 1 Read Configuration Examples c cccccccscessseesseessecssecseecssecesecnseesseeseeeseeeeeneeeseeeseeeeeeaaes 180 9 4 Function Code 21 15h Write Configuration Reference Data cccceeccesceesesteeeteeeteeenseeates 182 9 4 1 Write Configuration Examples 0 cccccccccccsseesseesceesseessecssecesecesecnseeseeeseeeseeeeeseeeseeeeeesaes 184 10 MODBUS READ WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION CODES A boned E E OERE 185 VOM ZQVETVIC Wii E OOO 185 10 2 Reading Control Data ccccccccccesscetscessceesceeeeeeeesececeseeeseecseecsaecsaecsaeceaecnsecseeeeeeseeeseneeneeeesees 186 10 3 Read Software Options Status cccccecccescsssceseceesceeeeeeceeeeeeeseecseecseecsaecaeceaecnseeeseeseeeseeeseseeenes 187 vii UDC3200 Universal Digital Controller Product Manual 4 08 10 4
227. select from the following menu Feedforward Summer Uses either input followed by a Ratio Bias calculation summed directly with the computed PID output value to provide a resultant output to the final control element standard feature Weighted Average Computes the weighted average of a PV or SP for the control algorithm from two inputs standard feature Feedforward Multiplier Uses any input multiplied by the calculated PID output to provide a resultant output which is sent to the final control element standard feature Summer Subtractor Will add or subtract inputs with the result used as the derived PV Multiplier Divider Uses the analog inputs to calculate a derived PV Available with or without Square Root Input High Low Select Specifies the PV input as the higher or lower of the two inputs Digital Inputs Two isolated digital inputs are provided for remote dry contact closure to select one of 25 actions Also the digital inputs can allow one of six selections to be combined with one of the above selections 2 UDC3200 Universal Digital Controller Product Manual 4 08 Introduction Outputs Output Types The UDC3200 may have up to five of the following outputs e Current Outputs 4 20 or 0 20 ma e Electromechanical Relays 5 amps e Solid State Relays 1 amp e Dual Electromechanical Relays 2 amps e Open Collector Outputs Alarms One or two electromechanical alarm relays are available to activat
228. seneenneeesees 12 Model Number Interpretation cccccccccssccseessecseceeceeeceeeeeeeeeeseeeseeeseecsaecsaecteceseseeeseeeseseseneeaes 15 Control and Alarm Relay Contact Information cccccceccsecseesseesceeseceseceseeseeeseeeeenecsseeeeeeeeeaaes 17 MOI A A a ia hued do ds 18 Mee o AN eae ates 20 2 6 1 Electrical Considerations 00d anios 20 Wiring Diagrams iseia a ana a a a a a a a a a an aain 22 CONFIGURATION a E A A 36 OVAS A AA AA E E v sede 36 Configuration Prompt Hierarchy asen rosa ataca dais 37 Configuration Procedure iii di lidia 39 Tuning Set Up ro ai IiS 40 SP Ramp Set Up Group eint aan d 44 Accutune Set Up Group ccccccssscssssecssscecessssssecssnsecseccesnscssnsecsencesescessntecsenseseecesseuessentesseneeseneees 48 Algorithm Set Up Group cccccccsccsssssssesssceeseesseeeseeeeecsaecsaecsseceseeeseseeeseeeseseeeseeeseeessecseeeaeceseeeaeees 50 Output Set UP TOUR AA A dada eke 60 Input t Set Up TU ii 64 Input 2 Set Up COUPE AA da A aba tds 68 Control Set Up TOUS AT eie Bets 71 Options Groups ro ornan e rie E Ta RE behets sand E Aaron rial 78 Communications Group ccccccsccesscsseceteceseceeeceeeeseeeeeseeeaeeesaecaeecsaecsaecaecseceseesseeseeeseeeeeeeeeneeesees 84 Alarms Set Up OOPS E A a a aaa a aR 87 Display Set Up GTOUP ii aa 92 Configuration Record estic as ai 94 UDC3200 Universal Digital Controller Product Manual 4 08 4 MONITORING AND OPERATING THE CONTROLLER cc
229. sired direction in the time allowed For the Degrees C configuration the PV must move by 2 in the desired direction in the time allowed For the NONE selection the PV must move 1 of the PV range in the time allowed Loop Break alarms do not have a HIGH LOW State configuration they are always assumed to be a HIGH state alarm NOTE 5 Thermocouple Warning means that the instrument has detected that the Thermocouple Input is starting to fail Not valid for other input types NOTE 6 Thermocouple Failing means that the instrument has detected that the Thermocouple Input is in imminent danger of failing Not valid for other input types NOTE 7 For the Digital Input selections DIG INP1 can be either enabled or disabled in the Options Group See Sub Section 3 12 but DIG INP2 must be enabled in the Options Group for the alarm to function properly A1S1 HL A1S1 EV HIGH LOW BEGIN END If Setpoint Programming is disabled or if the Alarm Type is not configured for Event On Off ALARM 1 SETPOINT 1 STATE Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm High or Low HIGH ALARM LOW ALARM If Setpoint Programming is enabled and if the Alarm Type is configured for Event On Off ALARM 1 SEGMENT EVENT 1 Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm the beginning or end of a segment in setpoint Ramp Soak programming BEGINNING OF SEGMENT END OF S
230. slave condition that caused the exception 4 08 UDC3200 Universal Digital Controller Product Manual 219 Modbus Read Write and Override Parameters plus Exception Codes Query Example Internal slave error reading 2 registers starting at address 1820h from slave at slave address 02 02 03 18 20 00 02 CRC CRC Response Example Return MSB in Function Code byte set with Slave Device Failure 04 in the data field 02 83 04 CRC CRC Table 10 21 Modbus RTU Data Layer Status Exception Codes Exception Definition Description Code Illegal Function The message received is not an allowable action for the addressed device Illegal Data Address The address referenced in the function dependent data section of the message is not valid in the addressed device Illegal Data Value The value referenced at the addressed device location is no within range Slave Device Failure The addressed device has not been able to process a valid message due to a bad device state Slave Device Busy The addressed device has ejected a message due to a busy state Retry later 07 NAK The addressed device cannot process the current Negative Acknowledge message Issue a PROGRAM POLL to obtain device dependent error data Buffer Overflow The data to be returned for the requested number of registers is greater than the available buffer space Function Code 20 only 220 UDC3200 Universal Digital Controller Product Manual 4 08 Ethernet TCP IP 1
231. splay shows the CSP value as CSP XXXX Table 10 7 1 Shed Timer Reset Parameter Register Data Range or Description Address Enumerated Selection Shed Timer Exit Slave Mode Reset dl IR Only Associated Parameters Refer to Table 10 8 for the codes to display or change any of the parameters associated with the computer setpoint Table 10 8 Computer Setpoint Associated Parameters Parameter Register Address 0007 0008 007 008 Local Setpoint 1 0027 Local Setpoint 2 0035 Computer Setpoint Ratio 005A 4 08 UDC3200 Universal Digital Controller Product Manual 191 Modbus Read Write and Override Parameters plus Exception Codes 10 7 Configuration Parameters Overview Listed on the next pages are the identifying codes for the parameters in the various Set up Groups in the UDC3200 Process Controller Most of the parameters are configurable through the hosts Some are Read Only and are indicated as such and cannot be changed Reading or Writing Do a Read or Write depending on your requirements using the identifying code and format code listed in the tables The range or selection available for each range is listed in the tables 10 7 1 Tuning Table 10 9 lists all the register addresses and ranges or selections for the function parameters in the Set up Group Tuning Table 10 9 Set up Group Tuning Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex
232. t 0007 High Limit Access Data Range or Enumerated Selection Control Setpoint 0008 Low Limit Control Output 0087 Direction Output Rate 009C Enable Output Rate Up 006E Output Rate 006F Down High Output 000E Limit Low Output 000F Limit High Integral 0010 Limit Low Integral 0011 Limit Output Deadband 004C for Time Duplex Output Deadband 0014 for TPSC Output Drop Off 0014 Limit Output 0013 Hysteresis Failsafe Mode 00D5 Failsafe Output 0028 Level TPSC Power 00B7 Output 007 FP R W 0 to 100 of PV engineering units 008 FP R W 0 to 100 of PV engineering units 135 INT R W 0 Direct 1 Reverse 156 INT R W 0 Disable 1 Enable 110 FP R W 0 00 to 9999 per minute 111 FP R W 0 00 to 9999 per minute 014 FP R W 5 to 105 of output 015 FP R W 5 to 105 of output 016 FP R W 5 to 105 017 FP R W 5 to 105 018 FP R W 5 to 25 0 020 FP R W 0 5 to 5 0 020 FP R W 5 to 105 019 FP R W 0 0 to 100 0 of PV 213 INT R W 0 Latching 1 Non latching 040 FP R W 0 to 100 183 INT R W 0 Last 1 Failsafe 210 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal TPSC Failsaf
233. t provides up to 30 volts de to power a 2 wire transmitter it requires the use of alarm 2 open collector output selection or the second current output UDC3200 Universal Digital Controller Product Manual 3 Introduction Three Local and one Remote Setpoints Can be configured to provide three Local and one Remote Setpoints which are selectable either via the keyboard or by Digital Input Universal Switching Power Operates on any line voltage from 90 to 264 Vac 50 60 Hz without jumpers 24 Vac dc instrument power is available as an option Timer This standard feature provides a configurable time period of 0 to 99 hours 59 minutes or units of minutes and seconds It can be started via the keyboard alarm 2 or by a digital input The timer output is Alarm 1 which energizes at the end of the Timer Period Alarm 1 can be automatically reset The Timer Period can be changed between each batch Status is shown on the lower display Moisture Protection The NEMA4X and IP66 rated front face permits use in applications where 1t may be subjected to moisture dust or hose down conditions Setpoint Ramp Soak Programming Optional Enables you to program and store six Ramp and six Soak segments for setpoint programming Run or Hold of program is keyboard or remote digital switch selectable Setpoint Rate Lets you define a ramp rate to be applied to any local setpoint change A separate upscale or downscale rate is configurable A single se
234. tandard Access Gain 1 Tag ID 1 0002 Register Count Floating Point Data CRC16 This is the response to the above request Response Message 02 14 06 05 06 3F CO 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex 06 Byte Count 05 Sub Message Length 06 Reference Type IEEE Floating Point 3F C0 0000 1 50 Value of Proportional Band CRC16 180 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus RTU Function Codes Example 2 4 08 The following is another example of a request and response message using Function code 20 Request Message Read LSP 1 ID Tag 39 and LSP 2 ID Tag 53 02 14 OE 06 00 03 00 27 00 02 06 00 03 00 35 00 02 CRC16 Where 02 Address 14 Function Code 20 14 Hex OE Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 27 Register Address Standard Access LSP 1 ID Tag 39 00 02 Register Count to read Floating Point Data 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 35 Register Address Standard Access LSP 2 ID Tag 53 00 02 Register Count to read Floating Point Data CRC16 This is the response to the above request Response Message 02 14 0C 05 06 43 C8 00 00 05 06 44 60 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex 0C Byte Count 05 Data Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 43 C8 0000
235. ter Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Burnout Open 00A4 164 INT R W 0 None and Failsafe Circuit 1 Upscale Detection 2 Downscale 3 No Failsafe Emissivity 0017 023 FP R W 0 01 to 1 00 4 08 UDC3200 Universal Digital Controller Product Manual 205 Modbus Read Write and Override Parameters plus Exception Codes 10 7 7 Input 2 Table 10 15 lists all the register addresses and ranges or selections for the function parameters in Set up Group Input 2 Table 10 15 Set up Group Input 2 Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 2 Type OOAA 170 INT R W 0 Disable 1 BTC 2 ETCH 3 ETCL 4 JTCH 5 JTCM 6 JTCL 7 KTCH 8 K TC M 9 KTCL 10 NNMH 11 NNML 12 Nicrosil H TC 13 Nicrosil L TC 14 RTC 15 STC 16 TTCH 17 TTCL 18 WTCH 19 WTCL 20 100 PT RTD 21 100 PT LO RTD 22 200 PT RTD 23 500 PT RTD 24 Radiamatic RH 25 Radiamatic RI 26 0 20 mA 27 4 20 mA 28 0 10 mV 29 0 50 mV 30 0 100 mV 31 0 5 Vdc 32 1 5 Vdc 33 0 10 Vdc 34 Slidewire 35 Unused 36 Unused 37 Thermocouple Differential ATTENTION Changing the Input Type will result in the loss of Field Calibration values and will restore the Factory Calibration values 206 UDC3200 Universal Digital Controller Product Manu
236. tering 0 implies an immediate step change in setpoint to the next soak SEGx SP Soak segments A soak segment is a combination of soak setpoint value and SEGxTIME a soak duration time e Soaks are even number segments 2 4 12 e Segment 2 will be the initial soak value and soak time The soak setpoint range value must be within the setpoint high and low range limits in engineering units Soak time is the duration of the soak and is determined in TIME Hours Minutes Range 0 99 hr 59 min SOAK DEV Guaranteed soak All soak segments can have a deviation value of from 0 to 99 specified by SOK DEV which guarantees the deviation value for that segment Guaranteed soak deviation values greater than zero guarantee that the soak segment s process variable is within the deviation value for the configured soak time Whenever the deviation value is exceeded the soak timer stops until the process variable gets within the deviation value There are no guaranteed soaks whenever the deviation value is configured to 0 that is soak segments start timing soak duration as soon as the soak setpoint is first reached regardless of where the process variable remains relative to the soak segment The soak deviation value is the number in engineering units above or below the setpoint outside of which the timer halts The range is 0 to 99 XX The decimal location here corresponds decimal configuration chos
237. ters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Segment 8 Soak 0044 068 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 9 Ramp 0045 069 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 10 0046 070 FP R W Within Setpoint Limits Soak Setpoint Value Segment 10 0047 071 FP R W 99 59 0 99 Hrs 0 59 Min Soak Time Segment 11 0048 072 FP R W 99 59 0 99 Hrs 0 59 Min Ramp Time or 0 to 999 Degrees Minute Segment 12 0049 073 FP R W Within Setpoint Limits Soak Setpoint Value Segment 12 004A 074 FP R W 99 59 0 99 Hrs 0 59 Min Soak Time 196 UDC3200 Universal Digital Controller Product Manual 4 08 Modbus Read Write and Override Parameters plus Exception Codes 10 7 3 Accutune Table 10 11 lists all the register addresses and ranges or selections for the function parameters in Set up Group Adaptive Tune Table 10 11 Set up Group Adaptive Tune Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Fuzzy Overshoot 00C1 193 INT R W 0 Disabled Suppression 1 Enabled Accutune Enable 0098 152 INT R W 0 Accutune Disabled 1 Tune Accutune Duplex OOEI 225 INT R W 0 Manual selection 1 Auto 2 Disable blend Accutune Error 0097 151 INT R W 0
238. th protective earthing grounding EN61010 1 8 UDC3200 Universal Digital Controller Product Manual 4 08 Introduction Enclosure Rating This controller must be panel mounted with the rear terminals enclosed within the panel The front panel of the controller is rated at NEMA4X and IP66 when properly installed Installation Category Overvoltage Category Category II EN61010 1 Pollution Degree Pollution Degree 2 Normally non conductive pollution with occasional conductivity caused by condensation Ref IEC 664 1 EMC Classification Group 1 Class A ISM Equipment EN61326 emissions Industrial Equipment EN61326 immunity Method of EMC Assessment Technical File TF Declaration of Conformity 51453663 Deviation from the installation conditions specified in this manual and the special conditions for CE conformity in Subsection 2 1 may invalidate this product s conformity with the Low Voltage and EMC Directives ATTENTION The emission limits of EN61326 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment Operation of this equipment in a residential area may cause harmful interference This equipment generates uses and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 meters 98 feet to the antenna e In special cases when highly susceptible appar
239. the procedure in this section 104 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller 4 7 Control Modes ATTENTION After changing a Local Setpoint value if no other key is pressed it then takes a minimum of thirty 30 seconds elapsed time before the new value is stored in non volatile memory If controller power is removed before this time the new setpoint value is lost and the previous setpoint value is used at power up If after changing the LSP value another key is pressed then the value is stored immediately 4 7 1 Mode Definitions Table 4 6 Control Mode Definitions AUTOMATIC with In automatic local mode the controller operates from the local setpoints and LOCAL automatically adjusts the output to maintain the PV at the desired value SETPOINT In this mode you can adjust the setpoint See Subsection 4 8 Setpoints AUTOMATIC with In automatic remote mode the controller operates from the setpoint measured at the REMOTE remote setpoint input Adjustments are available to ratio this input and add a SETPOINT constant bias before it is applied to the control equation optional See Subsection 3 9 Input 1 or 3 10 Input 2 MANUAL In the manual mode the operator directly controls the controller output level The optional process variable and the percent output are displayed The configured High and Low Output Limits are disregarded and the operator can change the out
240. the lower display PROPBD2 or GAIN 2 0 1 to 9999 or 0 001 to 1000 PROPORTIONAL BAND 2 or GAIN 2 RATE 2 and RESET 2 parameters are the same as previously described for Heat except that they refer to the cool zone tuning constants on duplex models or the second set of PID constants whichever is pertinent RATE2MIN 0 00 to 10 00 minutes This is the same as above except that it applies to Duplex models for the COOL zone of Heat Cool applications or for the second set of PID constants RSET2MIN RSET2RPM 0 02 to 50 00 These are the same as above except that they apply to Duplex models for the COOL zone of Heat Cool applications or for the second set of PID constants 4 08 UDC3200 Universal Digital Controller Product Manual 41 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition CYC SEC or CYC SX3 1 to 120 CYCLE TIME HEAT determines the length of one time proportional output relay cycle Defined as HEAT cycle time for Heat Cool applications CYC SEC Electromechanical relays CYC SX3 Solid state relays ATTENTION Cycle times are in either second or 1 3 second increments depending upon the configuration of RLY TYPE in the Output Algorithm Set Up group CYC2 SEC or CYC2 SX3 1 to 120 CYCLE TIME 2 COOL is the same as above except it applies to Duplex models as t
241. the setpoint with the setpoint select function key disabled e appears to the left of the active setpoint 4 08 UDC3200 Universal Digital Controller Product Manual 107 Monitoring and Operating the Controller 4 9 Timer Introduction The Timer provides a configurable Time out period of from 0 to 99 hours 59 minutes or 0 to 99 minutes 99 seconds Timer Start is selectable as either the RUN HOLD key or Alarm 2 The Timer display can be either Time Remaining or Elapsed Time Configuration check Make sure TIMER is enabled A TIMEOUT period has been selected in hours and minutes or minutes and seconds A TIMER FUNCTION START has been selected KEY or AL2 A TIMER display has been selected Time remaining or Elapsed time A timer increment selected Timer reset selected Refer to Subsection 3 7 Algorithm Set Up Group for details Viewing Times The times are viewed on the lower display as follows TIME REMAINING will show as a decreasing Hrs Min value HH MM or Min Sec value MM SS plus a counterclockwise rotating clock face ELAPSED TIME will show as an increasing Hrs Min value HH MM or Min Sec 108 value MM SS plus a clockwise rotating clock face UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Operation When the Timer is enabled RUN HOLD key or ALARM 2 it has exclusive control of Alarm 1 relay At TIME OUT e Alarm is act
242. the value set here NOTE 1 AUTO OUT 0 to 100 POWER UP PRESET AUTOMATIC OUTPUT At power up the controller will begin its automatic control at the output value set here NOTE 1 PBorGAIN 76 PB PCT PROPORTIONAL BAND UNITS Select one of the following for the Proportional P term of the PID algorithm PROPORTIONAL BAND selects units of percent proportional band for the P term of the PID algorithm Where PB 100 FS GAIN UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition GAIN GAIN selects the unitless term of gain for the P term of the PID algorithm Where GAIN 100 FS PB MINUTESorRPM RPM MINUTES RESET UNITS Selects units of minutes per repeat or repeats per minute for the I term of the PID algorithm 20 Repeats per Minute 0 05 Minutes per Repeat REPEATS PER MINUTE The number of times per minute that the proportional action is repeated by reset MINUTES PER REPEAT The time between each repeat of the proportional action by reset NOTE 3 These selections appear when A Control Algorithm is selected for 3PSTEP B Control Algorithm is selected for PD MR and Output Algorithm is selected for Position Proportional NOTE 4 The local setpoint will automatically adjust itself to be within the setpoint limit rang
243. tio and Bias calculation as a value summed directly with the PID computed output value and sent as an output value to the final control element This algorithm will only function in automatic mode and is not used for Three Position Step Control applications The following formula applies UDC3200 Universal Digital Controller Product Manual 53 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display Controller Output PID Output Input A x Ratio A Bias A x 100 Input A Range FFWDMu FEEDFORWARD MULTIPLIER Feedforward uses Input A following a Ratio and Bias calculation as a value multiplied directly with the PID computed output value and sent as an output value to the final control element Standard feature on controllers with two analog inputs This algorithm will only function in automatic mode and cannot be used for Three Position Step Control applications The following formula applies Controller Output PID Output x Input A x Ratio A Bias A Input A Range SUMMER SUMMER WITH RATIO AND BIAS The following See Note 2 formula applies Alg1 Input A x Ratio A Bias A Input B x Ratio B Bias B Input C x Ratio C Bias C Alg1Bias HI SEL INPUT HIGH SELECT WITH RATIO AND BIAS See Note 2 This selection specifies the PV or SP as the higher of Input 1 or Input 2 The following formula applies Alg1 highe
244. tpoint ramp is also available as an alternative CE Mark Conformity with 73 23 EEC Low Voltage Directive and 89 336 EEC the EMC Directive as a standard feature Approval Body Options CSA certification is available as an option UL listing is standard Two Sets of Tuning Constants Two sets of PID parameters can be configured for each loop and automatically or keyboard selected Data Security Five levels of keyboard security protect tuning configuration and calibration data accessed by a configurable 4 digit code Nonvolatile EEPROM memory assures data integrity during loss of power Diagnostic Failsafe Outputs Continuous diagnostic routines detect failure modes trigger a failsafe output value and identify the failure to minimize troubleshooting time High Noise Immunity The controller is designed to provide reliable error free performance in industrial environments that often affect highly noise sensitive digital equipment Accutune III This standard feature provides a truly plug and play tuning algorithm which will at the touch of a button or through a digital input accurately identify and tune any process including those with deadtime and integrating processes This speeds up and simplifies start up plus allows retuning at any setpoint The algorithm used is an improved version of the Accutune II algorithm found on earlier controllers Two possibilities are now offered when tuning your process Fast Tune and Sl
245. tput Calibration 6 3 Auxiliary Output Calibration Introduction Calibrate the controller so that the auxiliary output provides the proper amount of current over the desired range The controller can provide an auxiliary current output range of from 0 mA to 21 mA and and is usually calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 0 mA and 21 mA It is not necessary to re calibrate the controller in order to change from 4 to 20 mA operation over to 0 to 20 mA operation a simple configuration change is all that is required See the CO RANGE configuration in Sub section 3 12 for details Equipment Needed You will need a calibrating device with whatever accuracy is required capable of measuring 0 to 20 mA Calibrator Connections Refer to Figure 6 2 and wire the controller according to the procedure given in Table 6 3 Table 6 3 Set Up Wiring Procedure for Auxiliary Output 1 Apply power and allow the controller to warm up 30 minutes before you calibrate 2 Set LOCK in the Tuning Set Up group to NONE 3 Tag and disconnect the field wiring at the rear of the controller from terminals 12 and 13 See Figure 6 2 4 Connect a milliammeter across these terminals Milliammeter Figure 6 2 Wiring Connections for Calibrating Auxiliary Output 146 UDC3200 Universal Digital Controller Product Manual 4 08 Output Calibration Procedure The procedure for calibrating the auxiliary ou
246. tput is listed in Table 6 4 Make sure LOCK in the Tuning Set Up group is set to NONE see Subsection 3 4 Table 6 4 Auxiliary Output Calibration Procedure Cse operon mes A OO 1 Enter Calibration C setup Upper Display CALIB Mode NA Lower Display AUX OUT until you see 2 Calibrate 0 Function You will see bd Upper Display A Value Lower Display ZERO VAL A ory until the desired 0 output is read on the milliammeter Normally this will be the setting that produces 4 mA 3 Calibrate 100 Function To store the 0 value you will see m Upper Display A Value Lower Display SPAN VAL MAorw until the desired 100 output is read on the milliammeter Normally this will be the setting that produces 20 mA 4 Exit the Function The controller stores the span value Calibration Mode Na To exit the calibration mode 4 08 UDC3200 Universal Digital Controller Product Manual 147 Output Calibration 6 4 Position Proportional and Three Position Step Output Calibration Position Proportional control Position Proportional Control Output Models This model must have its output calibrated per the entire procedure to ensure the displayed output slidewire position agrees with the final control element position Three position step control Three Position Step Control Output Models not using slidewire feedback This model only requires that the Motor Time be entered as shown in Subsectio
247. trol Element Figure 4 2 Functional Overview Block Diagram of the UDC3200 Controller 4 08 UDC3200 Universal Digital Controller Product Manual 103 Monitoring and Operating the Controller 4 6 Start Up Procedure for Operation Table 4 5 Procedure for Starting Up the Controller Step Operation Press Result Select Manual Mode P man Y Until M indicator is ON The controller is in manual mode Adjust the Output AOIw To adjust the output value and ensure that the final control element is functioning correctly Upper Display PV Value Lower Display OUT and the output value in Enter the Local Setpoint Upper Display PV Value Lower Display SP and the Local Setpoint Value To adjust the local setpoint to the value at which you want the process variable maintained The local setpoint cannot be changed if the Setpoint Ramp function is running Select Automatic Mode Until A indicator is ON The controller is in Automatic mode The controller will automatically adjust the output to maintain the process variable at setpoint Tune the Controller Make sure the controller has been configured properly and all the values and selections have been recorded on the Configuration Record Sheet Refer to Tuning Set Up group to ensure that the selections for PBor GAIN RATE T and MIN or RPM have been entered Use Accutune to tune the controller see
248. ts two for each alarm The type and state High or Low is selected during configuration See Subsection 3 13 Configuration for details 118 UDC3200 Universal Digital Controller Product Manual 4 08 Monitoring and Operating the Controller Alarm Setpoints Display Table 4 19 Procedure for Displaying Alarm Setpoints step operation press mesa 1 Select Alarm a Until you see Set up Group NA Upper Display SET Lower Display ALARMS 2 Access the Alarm Function To successively display the alarm setpoints and their values Setpoint Values NA Their order of appearance is shown below Upper Display the alarm setpoint value Range values are within the range of the selected parameters except DEVIATION DEV value PV Span EVENTS EV ON EV OFF value Event Segment Number PV RATE OF CHANGE PVRATE The amount of PV change in one minute in engineering units LOOP BREAK ALARMS BREAK The timer value may be changed only for controllers configured for ON OFF control Lower Display A1S1 VAL Alarm 1 Setpoint 1 Value A1S2 VAL Alarm 1 Setpoint 2 Value A2S1 VAL Alarm 2 Setpoint 1 Value A2S2 VAL Alarm 2 Setpoint 2 Value NOTES With Three position step control alarms set for output will not function MANUAL RSP and F SAFE selections do not have setpoint values 3 Change a value A or To change any alarm setpoint value in the upper display 4 Return to Normal Display 4 08 UDC3
249. tting Upper Display Parameter Definition IN2 TYPE ATTENTION Changing the input INPUT 2 ACTUATION TYPE This selection determines what actuation you are going to use for Input 2 type will result in the DISABLE DISABLE Disables Input loss of Field BTC B TC B Thermocouple Calibration values and E TC H E TC H E Thermocouple High will restore Factory ETCL E TC L E Thermocouple Low Calibration values JTG H J TC H J Thermocouple High JTCM J TC M J Thermocouple Med Selecting Position JTCL J TC L J Thermocouple Low Proportional Control in K TC H K TC H K Thermocouple High the Output Setup KTCM K TC M K Thermocouple Med Group forces Input 2 KTCL K TC L K Thermocouple Low to the Slidewire NNM H NNM H Ni Ni Moly Thermocouple High Selection NNM L NNM L Ni Ni Moly Thermocouple Low NIC H NIC H Nicrosil Nisil Thermocouple High NIC L NIC L Nicrosil Nisil Thermocouple Low RTC R TC R Thermocouple STC S TC S Thermocouple TTCH T TC H T Thermocouple High TTCL T TC L T Thermocouple Low W TC H W TC H W5W26 Thermocouple High WTCL W TC L W5W26 Thermocouple Low 100 PT 100 PT 100 Ohm RTD High 100LO 100 LO 100 Ohm RTD Low 200 PT 200 PT 200 Ohm RTD 500 PT 500 PT 500 Ohm RTD RAD RH RAD RH Radiamatic RH RAD RI RAD Rl Radiamatic RI 0 20mA 0 20mA 0 to 20 Milliamperes 4 20mA 4 20mA 4 to 20 Milliamperes 0 10mV 0 10mV to 10 Millivolts 0 50mV 0 50mV to 50 Millivolts
250. uction 1 3 Process Instrument Explorer Software Overview Process Instrument Explorer lets you configure your instrument on a desktop laptop or Pocket PC For details see Process Instrument Explorer manual 51 52 25 131 Features 4 08 Create configurations with intuitive software program running on a Pocket PC a Desktop or a laptop computer Create edit configurations live just connect software to the controller via a communications port Create edit configurations offline and download to controller later via a communications port Communication types available on every UDC3200 o Infrared standard o RS 485 optional o Ethernet optional Same port types on UDC2500 and UDC3500 allow interconnectivity This software is available in English Spanish Italian German and French E 112 ok Communication Upload Setup as ca m Offline Download Configuration Te a Online Maintenance Configuration Data xe Menu Ej Figure 1 2 Screen capture of Process Instrument Explorer running on a Pocket PC UDC3200 Universal Digital Controller Product Manual 7 Introduction Infrared communications The infrared connection provides a non intrusive wireless connection with the instrument and maintains NEMA4X AND IP66 integrity No need to get access to the back of the controller to communicate with the instrument no need to take your screw driver to wire the communication cable no wiring mistake possi
251. uning Constants Introduction You can use two sets of tuning constants for single output types and choose the way they are to be switched this does not apply for Duplex control which always uses two PID sets The sets can be e keyboard selected e automatically switched when a predetermined process variable value is reached e automatically switched when a predetermined setpoint value is reached 116 UDC3200 Universal Digital Controller Product Manual 4 08 Set up Procedure Monitoring and Operating the Controller The following procedure Table 4 17 to e select two sets e set the switch over value e set tuning constant value for each set Table 4 17 Set Up Procedure sep operation mes Jm 1 Select Control Set up Group 2 Select PID SETS 3 Select PID SETS Function 4 Set Tuning Values for Each Set 5 Set Switchover Value for 2 PVSW or 2 SPSW Selection y E gt AXorw iP coms Y Until you see Upper Display SET Lower Display CONTRL Until you see Upper Display available selections Lower Display PID SETS To select the type of function Available selections are 1 ONLY 1 set of constants 2KEYBD 2 sets keyboard selectable 2PV SW 2 sets auto switch at PV value 2SP SW 2 sets auto switch at SP value Refer to TUNING Set up group subsection 3 4 and set the following tuning parameters PB or GAIN RATE MIN RSET MIN or RSET RPM CYC SE
252. up in SPP SEG1RAMP Ramp Time 1 1 hr SG10 TIME Soak Time 10 0 hr 30 min SEG2SP _ Soak SP 2 300 SG11RAMP Ramp Time 11 3 hr 30 min SEG2TIME Soak Time 2 1 hr 30 min SG12SP Soak SP 12 200 SEG3RAMP Ramp Time 3 1 hr SG12TIME Soak Time 12 0 hr 30 min SEG4SP Soak SP 4 400 128 UDC3200 Universal Digital Controller Product Manual 4 08 Program record sheet Monitoring and Operating the Controller Draw your ramp soak profile on the record sheet shown in Figure 4 4 and fill in the associated information in the blocks provided This will give you a permanent record of your program and will assist you when entering the Setpoint data Figure 4 4 Program Record Sheet STRT SEG Start Seg SEG4TIME Soak Time 4 END SEG End Seg SEG5RAMP Ramp Time 5 RAMPUNIT Engr Unit for SEG6 SP Soak SP 6 Ramp RECYCLES Number of SEG6TIME Soak Time 6 Recycles SOAK DEV Deviation SEG7RAMP Ramp Time 7 Value PROG END Controller SEG8 SP Soak SP 8 Status STATE Controller SEG8TIME Soak Time 8 State at end KEYRESET Reset SP SEG9RAMP Ramp Time 9 Program HOT PV Hot Start SG10SP Soak SP 10 START Program Initialization or power up in SPP SEG1RAMP Ramp Time 1 SG10 TIME Soak Time 10 SEG2SP Soak SP 2 SG11RAMP Ramp Time 11 SEG2TIME Soak Time 2 SG12SP Soak SP 12 SEG3RAMP Ramp Time 3 SG12TIME Soak Time 12 SEG4 SP Soak SP 4 4 08 UDC3200 Univ
253. uplex when an Auxiliary Output board is present This enables the normal control current output to provide heat control and the auxiliary current output to provide cool control To enable this e AUX OUT in the Options Set Up group must be selected for Output e The Auxiliary Current Output is scaled as desired for 0 50 controller output e Deadband for this configuration only applies to the Current Output The Auxiliary Output must have the Deadband scaled in FOR EXAMPLE UDC3200 Universal Digital Controller Product Manual 61 Configuration Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition 100PCT If a 2 Deadband is desired then enter 2 0 for the Deadband selection in the Control Algorithm group This will apply Deadband to the Current Output In the Options group set the Auxiliary Output LOW VAL selection to 49 0 and the HIGH VAL selection to 0 0 CURRENT DUPLEX RANGE FULL enables the Current Output to provide both heat and cool functions for control over 0 100 of the controller output The PID heat parameters apply when the output is greater than 50 and the PID cool parameters apply when the output is less than 50 The second current output is not required for this type of duplex operation RLYSTATE 10F 20F 10N 20F 10F 20N 10N 20N DIGITAL OUTPUT STATUS AT 0 OUTPUT allows the following selections 10F 20F Output 1 de energi
254. utput Transmitter Power using Auxiliary Output UDC3200 Universal Digital Controller Product Manual 11 Installation Pre installation Information If the controller has not been removed from its shipping carton inspect the carton for damage then remove the controller e Inspect the unit for any obvious shipping damage and report any damage due to transit to the carrier e Make sure a bag containing mounting hardware is included in the carton with the controller e Check that the model number shown on the inside of the case agrees with what you have ordered 2 2 Condensed Specifications Honeywell recommends that you review and adhere to the operating limits listed in Table 2 1 when you install your controller Table 2 1 Condensed Specifications Specifications Analog Inputs Accuracy 0 20 of full scale typical 1 digit for display Can be field calibrated to 0 05 of full scale typical 16 bit resolution typical Sampling Rate Both inputs are sampled six times per second Temperature Stability 0 01 of Full Scale span C change typical Input Impedance 4 20 Milliampere Input 250 ohms 0 10 Volt Input 200K ohms All Others 10 megohms Maximum Lead Wire Resistance Thermocouples 50 ohms leg 100 ohm 200 ohm and 500 ohm RTD 100 ohms leg 100 ohm Low RTD 10 ohms leg Slidewire Inputs for Position Proportional Control 100 ohm minimum to 1000 ohms maximum Analog Input Signal Failure
255. utput and Digital Input 2 are mutually exclusive Figure 2 17 Auxiliary Output and Digital Inputs Option Connections 34 UDC3200 Universal Digital Controller Product Manual 4 08 Installation 2 Wire Transmitter Configure A2S1TY NONE A2S2TY NONE OUTPUT 3 INPUT 1 If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc Figure 2 18 Transmitter Power for 4 20 mA 2 wire Transmitter Using Open Collector Alarm 2 Output 2 Wire Transmitter Configure AUXOUT OUT Auxiliary Output Calibration ZEROVAL 16383 SPANVAL 16383 AUXILIARY OUTPUT INPUT 1 If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc Figure 2 19 Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output 4 08 UDC3200 Universal Digital Controller Product Manual 35 Configuration 3 Configuration 3 1 Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish configure pertinent control data best suited for your application To assist you in the configuration process there are prompts that appear in the upper and lower displays These prompts let you know what group of configuration data Set Up prompts you are working with
256. w display DISABLE Upper RESTORE Lower 5 Press the A key The instrument will now display CONFIG Upper RESTORE Lower 6 Press the 4 Key The instrument will now display OPTIONS Upper RESTORE Lower 7 Press the FUNCTION Key The instrument will now display XXXX Upper ENTER Lower where XXXX is a unique code number for this particular instrument Write this number down 8 Press the FUNCTION Key The instrument will now display XXXX ENTER2 Write this number down 9 Press the FUNCTION Key The instrument will now display XXXX ENTER3 Write this number down 10 Write down the Model and Serial Numbers of your instrument 4 08 UDC3200 Universal Digital Controller Product Manual 171 Troubleshooting Service 172 11 12 13 14 15 16 17 Contact your Honeywell Representative to place an order Please have a company purchase order number available before you call The order entry person will ask for the following information 1 Software Upgrade Part Number you require Math Software Upgrade 50004635 501 or Set Point Programming Software Upgrade 50004635 502 Model Number of your instrument s Serial Number of your instrument s Code Numbers 1 2 and 3 from your instrument s Purchase order number apron With this information a new code number set will be generated for your instrument When you have the new code number set
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258. x Ratio C Bias C x Input B x Ratio B Bias B x Calc Hi Calc Lo Alg1Bias CARB A CARBON POTENTIAL A Make this selection if you have a Cambridge or Marathon monitor type Zirconium Oxide sensor See Note 3 CARB B CARBON POTENTIAL B Make this selection if you have a Corning type Zirconium Oxide sensor This algorithm requires a temperature range within the region of 1380 to 2000 F See Note 3 CARB C CARBON POTENTIAL C Make this selection if you have an A A C C type Zirconium Oxide sensor This algorithm requires a temperature range within the region of 1380 F to 2000 F See Note 3 CARB D CARBON POTENTIAL D Make this selection if you have a Barber Coleman MacDhui or Bricesco type Zirconium Oxide sensor This algorithm requires a temperature range within the region of 1380 to 2000 F See Note 3 FCC CARBON POTENTIAL FCC Make this selection if you have a Furnace Controls Corp Accucarb type Zirconium Oxide sensor This algorithm requires a temperature range within the region of 1380 F to 2000 F See Note 3 DEW PT DEWPOINT OF CARBONIZING ATMOSPHERE Use this selection if you are using any Zirconium Oxide Carbon Probe and you want to measure the atmosphere in terms of Dewpoint The range is 50 F to 100 F or 48 C to 38 C This algorithm requires a temperature range within the region of 1000 F to 2200 F and a minimum carbon probe value of 800 millivolts OXYGEN PERCE
259. y them The Accutune feature automatically selects Gain Rate and Reset on demand ATTENTION Because this group contains functions that have to do with security and lockout we recommend that you configure this group last after all other configuration data has been loaded Function Prompts Table 3 4 TUNING Group Function Prompts Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition PROP BD or GAIN 0 1 to 9999 or 0 001 to 1000 PROPORTIONAL BAND simplex is the percent of the range of the measured variable for which a proportional controller will produce a 100 change in its output GAIN is the ratio of output change over the measured variable change that caused it 100 PB where PB is the proportional band in If the PB is 20 then the Gain is 5 And at those settings a 3 change in the error signal SP PV will result in a 15 change in the controller s output due to proportional action If the Gain is 2 then the PB is 50 Also defined as HEAT Gain on Duplex models for variations of Heat Cool applications The selection of Proportional Band or Gain is made in the CONTROL parameter group under prompt PBorGAIN RATE MIN 0 00 to 10 00 minutes RATE action in minutes affects the controller s output whenever the deviation is changing and affects it more when the deviation is changing faster Also defined
260. y to scroll through the operating parameters listed in Table 4 3 The lower display will show only those parameters and their values that apply to your specific model Table 4 3 Lower Display Key Parameter Prompts OUT XX X OUTPUT Output value is shown in percent with one decimal point for all output types except Three Position Step Control TPSC For TPSC when no slidewire is connected this display is an estimated motor position and is shown with no decimal point For Position Proportional Control if the slidewire fails then the instrument automatically switches over to TPSC and the OUT display changes with it SP XXXX LOCAL SETPOINT 1 Also current setpoint when using SP Ramp 2SP XXXX LOCAL SETPOINT 2 3SP XXXX LOCAL SETPOINT 3 RSP XXXX REMOTE SETPOINT 1IN XXXX INPUT 1 Used only with combinational input algorithms 2IN XXXX INPUT 2 POS XX SLIDEWIRE POSITION Used only with TPSC applications that use a slidewire input CSP XXXX COMPUTER SETPOINT When SP is in override DEV XXXX DEVIATION Maximum negative display is 999 9 PIDSET X TUNING PARAMETER where X is either 1 or 2 ET HR MN ELAPSED TIME Time that has elapsed on the Timer in Hours Minutes OTR HR MN TIME REMAINING Time remaining on the Timer in Hours Minutes The O is a rotating clock face RAMPXXXM SETPOINT RAMP TIME Time remaining in the Setpoint Ramp in minutes SPN XXXX SETPOINT NOW Current Setpoint when SP Rate is enabled The SP XXXX dis
261. zed Output 2 de energized 10N 20F Output 1 energized Output 2 de energized 10F 20N Output 1 de energized Output 2 energized 10N 20N Output 1 energized Output 2 energized RLY TYPE MECHAN SOL ST RELAY CYCLE TIME INCREMENT selection is used only for Time Simplex and Duplex output configurations This configuration sets the increment size of the relay cycle times in the Tuning and Tuning 2 Set Up groups ELECTROMECHANICAL RELAY Cycle time in one second increments SOLID STATE RELAY Cycle time in 1 3 second increments This is useful for solid state relay applications that require shorter cycle times DO NOT use this setting unless cycle times of less than 1 second are required ATTENTION The Lockout selection must be set to NONE in order to view this selection MOTOR TI 5 to 1800 seconds MOTOR TIME Appears only when POSITON is selected as the Output algorithm This is the time it takes the motor to travel from 0 to 100 fully closed to fully open This time can usually be found on the nameplate of the motor 62 UDC3200 Universal Digital Controller Product Manual 4 08 Configuration Function Prompt Selections or Parameter Lower Display Range of Setting Definition Upper Display CUR OUT CURRENT OUTPUT If Current Output 1 is not used to perform one of the above output algorithms it may be used to perform an Auxiliary Output function D

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