Honeywell UDC3500 Installation and operating instructions

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Controller Failure Symptoms
Introduction
In addition to the error message prompts, there are failure symptoms that can be
identified by noting how the controller displays and indicators are reacting.
Symptoms
Compare your symptoms with those shown in Table-1.
Table-1 Controller Failure Symptoms
Upper
Display Lower Display Indicators Controller Output Probable Cause Trouble- shooting
Procedure
Blank Blank Off None Power Failure 0
OK OK
Current
Proportional
Output
0
OK OK
Position
Proportional or
TPSC Output
0
OK OK
Time Proportional
Output 0
OK
Displayed
Output
disagrees
with Controller
Output
OK
Controller
Output
disagrees
with Displayed
Output
Current/Time
Proportional
Output
0
OK OK OK
External Alarm
function does
not operate
properly
Malfunction in
alarm output 0
OK Displayed
Output
disagrees with
First Current
Output
OK Controller
Current Output
#1 disagrees
with Displayed
First Current
Output
First Current
Output 0
OK Displayed
Output
disagrees with
Second Current
Output
OK Controller
Current Output
#2 disagrees
with Displayed
Second Current
Output
Second Current
Output 0
OK Displayed
Output
disagrees with
Third Current
Output
OK Controller
Output
disagrees with
Displayed Third
Current Output
Third Current
Output 0
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Upper
Display Lower Display Indicators Controller Output Probable Cause Trouble- shooting
Procedure
Display does not change when a key is pressed Keyboard
Malfunction 0
Controller fails to go into “Slave” operation during communications Communications
Failure RS-485: 0
Ethernet: 0
Bad PV Reading Bad InX
Reading OK OK
Analog Input
Failure 0
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 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.
Troubleshooting Procedures
Introduction
The troubleshooting procedures are listed as they appear in Table-1. Each procedure
describes 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.
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:
• Multimeter – Capable of measuring millivolts, volts, milliamps and resistance.
• Calibration sources – T/C, mV, Volt, etc.
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Procedure #1 – Power
Table 2 explains how to troubleshoot power failure symptoms.
Table 2 Troubleshooting Power Failure Symptoms
Step What to do How to do it
1 Check the AC or DC line
voltage. Use a voltmeter to measure the AC or DC 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
into the rear of the case
properly.
Withdraw the chassis and visually inspect the
controller board and the inside of the case.
Reseat the boards into the Chassis if
necessary.
3 Check the system for Brown-
outs, heavy load switching, etc.,
and conformance to installation
instructions.
Refer to Installation Section.
4 Change Power board. Installation instructions supplied with new
board.
Procedure #2 – Current Outputs
Table 3 explains how to troubleshoot Current Output failure symptoms.
Table 3 Troubleshooting Current Output Failure
Step What to do How to do it
1 Make sure that the controller is
configured correctly and that the
proper range (4 to 20 or 0 to 20)
is configured.
Refer to Configuration Section.
Configuration incorrect: Fix configuration
Configuration correct: Go to Step 2.
2 Check the field wiring. Output impedance must be less than or equal
to 1000 ohms.
3a First Current Output: Test for
operation. Change Output Set Up group function prompt OUT ALG = CUR.
Make the Output Set up group function prompt
CO RANGE = 4–20
Go to Step 4
3b Second Current Output: Test for
operation. Change Options Set Up group function prompt CUR2 OUT = OUTPUT
Make the Current #2 Options Set up group
function prompt CO RANGE = 4–20
Go to Step 4
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Step What to do How to do it
3c Third Current Output: Test for
operation. Change Options Set Up group function prompt CUR3 OUT = OUTPUT
Make the Current #3 Options Set up group
function prompt CO RANGE = 4–20
Go to Step 4
4 Check the output. Put the controller into Manual mode and
change the output via the front keyboard from
0 % to 100 %. Use a DC milliammeter at the
rear terminals for the output being diagnosed
to verify the output.
Output works correctly: Return the controller
to its original configuration and check output
again.
Output does not work correctly: Go to Step 5.
5 Restore Factory Calibration For the output being diagnosed, change the
CO RANGE prompt from its present setting to
its other setting. Exit the setup group and then
return and change CO RANGE back to its
previous setting.
Output works correctly: Finished
Output does not work correctly: Go to Step 6.
6 Field Calibrate the output. Refer to Output Calibration Section for details.
Output works correctly: Finished
Output does not work correctly: Go to Step 7.
7 Change Current Output board. Installation instructions provided with new
board.
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Procedure #3 – Position Proportional
Table 4explains how to troubleshoot Position Proportional Output failure symptoms.
Table 4 Troubleshooting Position Proportional Output Failure
Step What to do How to do it
1 Make certain that the controller
is configured properly for
Position Proportional output.
Make Output Algorithm Set Up group function
prompt OUT ALG = POSPROP.
Make Input 3 Set Up group function prompt
IN3 TYPE = SLIDEW
Refer to Configuration Section.
If the “CAL MTR” diagnostic prompt is flashing
on the lower display, then this means that the
instrument was never calibrated for your
application. See the Position Proportional field
calibration procedure in Output Calibration
Section for motor slidewire calibration
procedure.
2 Check the field wiring. Refer to Installation Section for details.
3 Check whether the motor
drives in both directions. 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 and the “OUT 2” indicator is
off, then the motor should be opening and the
output value shown on the lower display
should be increasing. When the “OUT 1”
indicator is off and the “OUT 2” indicator is on,
then the motor should be closing and the
output value on the lower display should be
decreasing. Listen for a click from a relay
when the OUT1 and OUT 2 indicators change
state.
a) Motor moves in both directions but the
displayed Output value does not change or
does not have a decimal point – Go to Step 4
b) Motor does not move in one or both
directions – Go to Step 5
c) Motor moves in both directions but the
displayed Output value moves in the wrong
direction: This means that the motor or the
slidewire or both are incorrectly wired. Check
the motor manufacturer’s wiring diagram and
then refer to Installation Section to rewire the
controller.
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Step What to do How to do it
4 Motor moves in both directions
but the displayed Output value
does not change or does not
have a decimal point
Slidewire input is malfunctioning. See the
Position Proportional field calibration
procedure in Output Calibration Section for
motor slidewire calibration procedure. Follow
that procedure to Field Calibrate the
instrument. If after a Field Calibration the
problem is still not fixed, then go to Step 6.
5 Motor does not move in one or
both directions Wiring Problem. Check the motor manufacturer’s wiring diagram and then refer
to Installation Section –to rewire the controller.
If wiring is correct, then go to Step 7.
6 Determine if Motor Slidewire or
Input 3 is at fault. Disconnect and tag the field wiring for the slidewire. Refer to Installation Section .
Measure the voltage between the R (28) and
the – (30) terminals.
Voltage is +1.2Vdc ±0.2Vdc: Bad motor
slidewire. Refer to the motor manufacturer’s
instructions.
Voltage not +1.2Vdc ±0.2Vdc: Check the
Jumper on the Input 3 Board . Jumper should
be in W1 position. If not, then move it to W1
position and recalibrate the instrument per
Output Calibration Section. If the Jumper is in
the W1 position, then replace the Input 3
board. Installation instructions supplied with
the new board.
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Step What to do How to do it
7 Check the Relays. Turn off power to the motor and to the
instrument. Disconnect and tag the field wiring
to the relays. Relay 1 (MOTOR – OPEN) is on
terminals 8 and 9. Relay 2 (MOTOR – CLOSE)
is on terminals 7 and 8.
Turn on power to the instrument. Put the
controller into Manual mode. Connect your
multimeter to terminals 8 and 9 and set the
multimeter to measure resistance. Now, vary
the output above and below the present value
and observe the “OUT” indicators and your
multimeter. When the “OUT 1” indicator is on,
then Relay 1 should be closed and there
should be only a few ohms between terminals
8 and 9. When the “OUT 1” indicator is off,
then Relay 1 should be open and there should
be infinite resistance between terminals 8 and
9. Listen for a click from the relay when the
OUT1 indicator changes state.
Repeat this test for Relay 2 by connecting your
multimeter to terminals 7 and 8. When the
“OUT 2” indicator is on, the relay should be
closed and there should be only a few ohms
between terminals 7 and 8. When the “OUT 2”
indicator is off, the relay should be open and
there should be infinite resistance between
terminals 7 and 8. Listen for a click from the
relay when the “OUT 2” indicator changes
state.
Relays measure correctly: Check motor. Refer
to manufacturer’s instructions.
Relays do not measure correctly: Go to Step 8.
8 Replace the Dual Relay Board. Installation instructions supplied with the new
board.
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Procedure #4 – Time Proportional
Table -5 explains how to troubleshoot Time Proportional Output failure.
Table -5 Troubleshooting Time Proportional Output Failure
Step What to do How to do it
1 Make sure the controller is configured
for Time Proportional output. Make Output Algorithm Set Up group function prompt OUT ALG (Loop 1) or OUT2 ALG (Loop 2)
= RLY or RLYD.
Refer to Configuration Section.
2 Check the field wiring. Make sure the NO or NC contact wiring is correct.
Refer to Installation Section - for details.
3 Check the output. Put the controller into Manual mode. Vary the
output above and below the present value.
Observe OUT1 indicator (Loop 1) or OUT3
indicator (Loop 2) on the operator interface.
Contact should change state. 0 % open, 100 %
closed. Listen for a click from the relay when the
OUT1 or OUT3 indicator changes state.
4 Check relay. Change relay.
5 Change relay board. Installation instructions supplied with the new
board.
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Procedure #5 – Current/Time or Time Current/Proportional
Table -6 explains how to troubleshoot Current/Time or Time/Current Proportional Output
failure.
Table -6 Troubleshooting Current/Time or Time/Current Proportional
Output Failure
Step What to do How to do it
1 Make sure the controller is configured
for Time/Current or Current/Time
Proportional output.
Make Output Algorithm Set Up group function
prompt OUT ALG = TCUR or CURT.
Refer to Configuration Section
2 Check the field wiring. Make sure the NO or NC contact wiring selection
is correct.
Refer to Installation Section 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 (Loop 1) or OUT3
indicator (Loop 2) on the operator interface.
Contact should change state. 0 % open, 100 %
closed. Listen for a click from the relay when the
OUT1 or OUT3 indicator changes state.
4 Check the Current Proportional
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.
5 Recalibrate the controller. Refer to Output Calibration Section for details.
6 Change Current Output or Relay
board. Installation instructions supplied with new board.
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Procedure #6 – Alarm Relays
ATTENTION
Control Outputs take precedence over Alarms which in turn take precedence over Logic
Gate Outputs. For example, if you select the Loop 2 Output Algorithm as Time
Simplex, then the instrument will use Relay #3 to perform the Time Simplex output.
Therefore, Relay #3 would not be available for Alarm 3 or Logic Gate functions.
The prompts for the Alarm Outputs appear whether or not the alarm relays are
physically present or used for some other function. This allows the Alarm status to be
shown on the display and/or sent via communications to a host computer.
Table 7 explains how to troubleshoot Alarm Relay Output failure.
Table 7 Troubleshooting Alarm Relay Output Failure
Step What to do How to do it
1 Check the alarm configuration
data. If it is correct, check the
field wiring.
Reconfigure if necessary.
Refer to Configuration Section for details.
2 Check that the applicable alarm
relay actuates properly
depending on what you have set
at prompt AxSxTYPE.
If it does, check the field wiring.
If the alarm type is set for PV, place the
controller in manual mode. Vary the input
to raise and lower the PV around the
setpoint. Listen for a click from the relay
as the PV moves in either direction and
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 sure the NO or NC contact wiring is
correct.
Refer to Installation Section for relay
contact information.
4 Change the relay and/or the
relay output board. Installation instructions supplied with the new relay or board.
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Procedure #7 – Keyboard
Table -8 explains how to troubleshoot a Keyboard failure.
Table -8 Troubleshooting a Keyboard Failure
Step What to do How to do it
1 Make sure the keyboard is
connected properly to the
MCU/output and power/input
boards.
Withdraw the chassis from the
case and visually inspect the
connection.
2 Controller Keyboard or specific
keys may be LOCKED OUT via
the security code.
Use your four-digit security code
number to change the lockout
level. Refer to Section 3 –
Configuration.
3 Run the keyboard test. Simultaneously press both the
Func
Loo
p
1/2 key and the
SetupSetup key.
The controller will now run a
display test which lights every
element in the display. Following
that test, you will then see:
TRY ALL
Lower Display
KEYS
Upper Display
Press each key. If instrument
reads the key, then the key’s
name will appear in the lower
display. After fifteen seconds, the
unit returns to normal operation.
4 Replace the Display/Keyboard
Assembly if any keys do not
function.
Refer to “Parts Replacement
Procedures” in this section.
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Procedure #8 – RS-485
Table -8 explains how to troubleshoot a RS 485 Communications failure.
Table 9 Troubleshooting a RS-485 Communications Failure
Step What to do How to do it
1 Check the Address Number,
ComState and Baud Rate
settings.
See Configuration Section.
2 Check if the controller is wired
correctly to the Network. See Section Installation for wiring diagrams.
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Step What to do How to do it
3 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.
Disconnect the communications cable from the
rear terminals. Run the Local Loopback Test.
Press SetupSetup key until you see:
COM
Lower Display
SET UP
Upper Display
Press
Func
Loo
p
1/2 key until you see:
LOOPBACK
Lower Display
DISABLE
Upper Display
Press or and you will see:
LOOPBACK
Lower Display
ENABLE
Upper Display
Press
Lower
Display
Lower
Display
Lower
Display key and you will see:
LOOPBACK
Lower Display
START
Upper Display
Then you will see either PASS or FAIL in the
Upper Display. The test will run until the
operator disables it or until the unit is power-
cycled.
If you see FAIL, go to Step 4. If you see PASS,
then the problem is most likely not in the
instrument, but somewhere else in the
network. Go to Step 7.
4 Make sure that the
Communications Printed Wiring
Board is installed properly in
the controller.
Withdraw the chassis from the case and
inspect the board. See the exploded view for
location of the board. Return the chassis to the
case and go back to Step 3.
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Step What to do How to do it
5 Change RS-485
Communications board. Installation instructions provided with new board.
6 Change Controller
7 Follow these next two steps if
you saw PASS in Step 3.
Check the field wiring and
termination resistor.
Turn off the power to all instruments on the
Network. Using an ohm meter, check the
resistance across the communications rear
terminals. See Installation Section for wiring
diagrams. There should be a reading
equivalent to the value of the termination
resistor.
8 Check the rest of the Network.
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Procedure #9 – Ethernet
Table 10 explains how to troubleshoot an Ethernet Communications failure.
Table 10 Troubleshooting an Ethernet Communications Failure
Step What to do How to do it
1 Check the IP address, Subnet
Mask address and Gateway
address settings.
See the PIE Tool Manual. As shipped from the
factory, all units are configured for an IP
address of 10.0.0.2. The MAC address is
printed on the product label located on the
instrument’s case.
2 Check if the Ethernet
Connection is active. If the lower display is showing the diagnostic message “EUNPLGED” (Ethernet Unplugged),
then this means that either the Ethernet link
itself is bad or that the unit is improperly
connected to the Ethernet. See Section
Installation for wiring diagrams.
3 Change Ethernet
Communications board. Installation instructions provided with new board.
ATTENTION The replacement Ethernet
Communications board will have a label
showing its MAC address. To avoid confusion,
it is strongly recommended that you change
the MAC address shown on the label on your
instrument’s case to be the same as the MAC
address shown on your new board.
4 Change Controller
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Procedure #10 – Analog Input
Table 11 explains how to troubleshoot an Analog Input failure.
Table 11 Troubleshooting an Analog Input Failure
Step What to do How to do it
1 Check Input Configuration. Check if the input configurations are correctly
set for the kind of sensor attached to the input
terminals. See Section (Input 1) through
Section (Input 5).
2 Check input wiring and external
resistor assemblies. See the Input Wiring Diagrams and confirm that the instrument is properly connected to
the sensor.
Thermocouple, Milliamp, 0 to 10 Volt and –1 to
1 Volt input types all require that external
resistor assemblies be connected to the input
terminals. These are provided with your
instrument based upon the Model Number
ordered. See the Input Wiring Diagrams for
installation information.
3 Check interconnection wiring If the actual sensor does not come directly to
the UDC but is instead connected via one or
more intermediate junction panels which in
turn are connected to the UDC, then check the
continuity of the sensor to the UDC. Check the
tightness of the screws or connectors at the
junction panels.
4 Check Input Signals. Using a multimeter, measure the actual signal
present at the terminals to ensure that it is
within the allowed input range as shown in
Installation Section.
5 Change the Input Type in order
to restore Factory Calibration. See Configuration Section
6 Replace Input Board. Installation instructions provided with new
board.
7 Replace Controller.
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