Honeywell UDC3500 User manual

Industrial Measurement and Control
UDC3500
Universal Digital Controller
Product Manual
51-52-25-120
October 2005

10/05 UDC3500 Universal Digital Controller Product Manual ii
Notices and Trademarks
Copyright 2005 by Honeywell
Revision 0
October 2005
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.
Industrial Measurement and Control
Honeywell
1100 Virginia Drive
Fort Washington, PA 19034
UDC3500 is a U.S. registered trademark of Honeywell
Other brand or product names are trademarks of their respective owners.

10/05 UDC3500 Universal Digital Controller Product Manual iii
About This Document
Abstract
This document provides descriptions and procedures for the Installation, Configuration, Operation, and Troubleshooting of
your UDC3500 Controller.
Contacts
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
Industrial Measurement and Control http://www.honeywell.com/imc
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
Web
http://content.honeywell.com/ipc/faq/

10/05 UDC3500 Universal Digital Controller Product Manual iv
Symbol Definitions
The following table lists those symbols used in this document to denote certain conditions.
Symbol Definition
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/yellow) 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.

v UDC3500 Universal Digital Controller Product Manual 10/05
Contents
1INTRODUCTION ...................................................................................................1
1.1 Overview.........................................................................................................................................1
1.2 Operator Interface ...........................................................................................................................6
1.2.1 Function of Displays and Keys ............................................................................................7
1.3 Process Instrument Explorer Software............................................................................................8
1.4 CE Conformity (Europe)...............................................................................................................10
2INSTALLATION...................................................................................................11
2.1 Overview.......................................................................................................................................11
2.2 Condensed Specifications .............................................................................................................13
2.3 Model Number Interpretation .......................................................................................................17
2.4 Control and Alarm Relay Contact Information.............................................................................19
2.5 Mounting.......................................................................................................................................20
2.6 Wiring ...........................................................................................................................................22
2.6.1 Electrical Considerations ...................................................................................................22
2.7 Wiring Diagrams...........................................................................................................................24
3CONFIGURATION............................................................................................... 43
3.1 Overview.......................................................................................................................................43
3.2 Configuration Prompt Hierarchy ..................................................................................................45
3.3 Configuration Procedure...............................................................................................................48
3.4 Loop 1 Tuning Set Up Group .......................................................................................................49
3.5 Loop 2 Tuning Set Up Group .......................................................................................................53
3.6 SP Ramp Set Up Group ................................................................................................................56
3.7 Accutune Set Up Group ................................................................................................................62
3.8 Algorithm Set Up Group...............................................................................................................67
3.9 Math Set Up Group.......................................................................................................................82
3.10 Logic Gates Set Up Group ........................................................................................................89
3.11 Output Set Up Group.................................................................................................................96
3.12 Input 1 Set Up Group ..............................................................................................................106
3.13 Input 2 Set Up Group ..............................................................................................................110
3.14 Input 3 Set Up Group ..............................................................................................................113
3.15 Input 4 Set Up Group ..............................................................................................................117
3.16 Input 5 Set Up Group ..............................................................................................................120
3.17 Control Set Up Group .............................................................................................................123
3.18 Control 2 Set Up Group ..........................................................................................................132

10/05 UDC3500 Universal Digital Controller Product Manual vi
3.19 Options Set Up Group .............................................................................................................140
3.20 Communications Set Up Group...............................................................................................150
3.21 Alarms Set Up Group ..............................................................................................................154
3.22 Real Time Clock Set Up Group...............................................................................................162
3.23 Maintenance Set Up Group .....................................................................................................163
3.24 Display Set Up Group .............................................................................................................166
3.25 Read Maintenance Set Up Group............................................................................................168
3.26 Time Events Set Up Group .....................................................................................................169
3.27 P.I.E. Tool Ethernet and Email Configuration Screens...........................................................171
3.28 Configuration Record Sheet ....................................................................................................174
4MONITORING AND OPERATING THE CONTROLLER................................... 181
4.1 Overview.....................................................................................................................................181
4.2 Operator Interface .......................................................................................................................182
4.3 Entering a Security Code ............................................................................................................182
4.4 Lockout Feature ..........................................................................................................................183
4.5 Monitoring Your Controller........................................................................................................185
4.5.1 Annunciators ....................................................................................................................185
4.5.2 Viewing the operating parameters....................................................................................186
4.5.3 Diagnostic Messages........................................................................................................187
4.6 Start Up Procedure for Operation ...............................................................................................188
4.7 Control Modes ............................................................................................................................189
4.7.1 Mode Definitions .............................................................................................................189
4.7.2 What happens when you change modes...........................................................................190
4.8 Setpoints......................................................................................................................................190
4.9 Timer...........................................................................................................................................192
4.10 Accutune III.............................................................................................................................193
4.10.1 Tune for Simplex Outputs ............................................................................................195
4.10.2 Tune for Duplex (Heat/Cool) .......................................................................................196
4.10.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool).................................197
4.10.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool)......................................198
4.10.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool).......................................199
4.10.6 ACCUTUNE Error Codes............................................................................................200
4.11 Fuzzy Overshoot Suppression .................................................................................................201
4.12 Using Two Sets of Tuning Constants......................................................................................202
4.13 Input Math Algorithms............................................................................................................204
4.14 Logic Gate Operation ..............................................................................................................206
4.15 Digital Input Option (Remote Switching) ...............................................................................208
4.16 Auto/Manual Station ...............................................................................................................213
4.17 Two Loops of Control .............................................................................................................217
4.18 Configuring Two Loops of Control.........................................................................................220

vii UDC3500 Universal Digital Controller Product Manual 10/05
4.19 Monitoring Two Loops of Control..........................................................................................221
4.20 Operating Two Loops of Control ............................................................................................222
4.21 Alarm Setpoints.......................................................................................................................222
4.22 Three Position Step Control Algorithm...................................................................................225
4.23 Setting a Failsafe Output Value for Restart After a Power Loss.............................................226
4.24 Setting Failsafe Mode..............................................................................................................227
4.25 Carbon Potential, Oxygen and Dewpoint Algorithms.............................................................227
4.26 Healthwatch.............................................................................................................................230
4.27 Setpoint Rate/Ramp/Program Overview .................................................................................230
4.28 Setpoint Rate ...........................................................................................................................231
4.29 Setpoint Ramp .........................................................................................................................231
4.30 Setpoint Ramp/Soak Programming .........................................................................................233
4.31 P.I.E. Tool Maintenance Screens ............................................................................................242
4.32 Configuring your Ethernet Connection ...................................................................................252
5INPUT CALIBRATION.......................................................................................257
5.1 Overview.....................................................................................................................................257
5.2 Minimum and Maximum Range Values .....................................................................................258
5.3 Preliminary Information..............................................................................................................260
5.4 Input Set Up Wiring....................................................................................................................262
5.4.1 Thermocouple Inputs Using an Ice Bath..........................................................................262
5.4.2 Thermocouple Inputs Using a Thermocouple Source......................................................263
5.4.3 RTD Inputs.......................................................................................................................264
5.4.4 Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential Inputs....265
5.4.5 0 to 10 Volts or –1 to 1 Volts...........................................................................................267
5.4.6 Milliamperes ....................................................................................................................268
5.4.7 Dual High Level Voltage Inputs ......................................................................................269
5.4.8 Dual High Level Milliamperes Inputs..............................................................................270
5.5 Input Calibration Procedure........................................................................................................271
5.6 Restore Input Factory Calibration...............................................................................................273
6OUTPUT CALIBRATION................................................................................... 275
6.1 Overview.....................................................................................................................................275
6.2 First Current Output Calibration.................................................................................................276
6.3 Second Current Output Calibration.............................................................................................278
6.4 Third Current Output Calibration ...............................................................................................280
6.5 Position Proportional and Three Position Step Output Calibration ............................................282
6.6 Restore Factory Output Calibration ............................................................................................285
7TROUBLESHOOTING/SERVICE......................................................................287
7.1 Overview.....................................................................................................................................287

10/05 UDC3500 Universal Digital Controller Product Manual viii
7.2 Troubleshooting Aids..................................................................................................................288
7.3 Power-up Tests............................................................................................................................290
7.4 Status Tests .................................................................................................................................290
7.5 Background Tests and Diagnostic Messages ..............................................................................291
Controller Failure Symptoms ...............................................................................................................295
7.6 Troubleshooting Procedures .......................................................................................................296
7.6.1 Procedure #1 – Power ......................................................................................................297
7.6.2 Procedure #2 – Current Outputs.......................................................................................297
7.6.3 Procedure #3 – Position Proportional ..............................................................................299
7.6.4 Procedure #4 – Time Proportional ...................................................................................302
7.6.5 Procedure #5 – Current/Time or Time Current/Proportional...........................................303
7.6.6 Procedure #6 – Alarm Relays ..........................................................................................304
7.6.7 Procedure #7 – Keyboard.................................................................................................306
7.6.8 Procedure #8 – Analog Input ...........................................................................................307
7.6.9 Procedure #9 – RS-485 ....................................................................................................308
7.6.10 Procedure #10 – Ethernet .............................................................................................311
7.6.11 Procedure #11 – Email .................................................................................................312
7.7 Restoring Factory Configuration ................................................................................................313
7.8 Software Upgrades......................................................................................................................314
8PARTS LIST ...................................................................................................... 316
8.1 Exploded View............................................................................................................................316
8.2 Removing the chassis..................................................................................................................318
9MODBUS RTU FUNCTION CODES..................................................................319
9.1 Overview.....................................................................................................................................319
9.2 General Information....................................................................................................................319
9.3 Function Code 20 (14h) - Read Configuration Reference Data..................................................321
9.3.1 Read Configuration Examples .........................................................................................323
9.4 Function Code 21 (15h) - Write Configuration Reference Data.................................................325
9.4.1 Write Configuration Examples ........................................................................................327
10 MODBUS READ, WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION
CODES........................................................................................................................ 328
10.1 Overview .................................................................................................................................328
10.2 Reading Control Data..............................................................................................................329
10.3 Read Software Options Status.................................................................................................331
10.4 Miscellaneous Read Onlys ......................................................................................................332
10.4.1 Register Addresses for Read Onlys ..............................................................................332
10.4.2 SetPoint Program Read Only Information....................................................................332
10.5 Setpoints ..................................................................................................................................333
10.6 Using a Computer Setpoint (Overriding Controller Setpoint) ................................................335

ix UDC3500 Universal Digital Controller Product Manual 10/05
10.7 Configuration Parameters........................................................................................................338
10.7.1 Tuning Loop 1 ..............................................................................................................338
10.7.2 Tuning Loop2 ...............................................................................................................340
10.7.3 SP Ramp/Rate/Program................................................................................................341
10.7.4 Accutune.......................................................................................................................348
10.7.5 Algorithm .....................................................................................................................350
10.7.6 Math..............................................................................................................................355
10.7.7 Logic.............................................................................................................................358
10.7.8 Output Algorithms........................................................................................................362
10.7.9 Input 1...........................................................................................................................364
10.7.10 Input 2...........................................................................................................................366
10.7.11 Input 3...........................................................................................................................368
10.7.12 Input 4...........................................................................................................................370
10.7.13 Input 5...........................................................................................................................372
10.7.14 Control..........................................................................................................................374
10.7.15 Control Loop 2 .............................................................................................................377
10.7.16 Options .........................................................................................................................380
10.7.17 Communications...........................................................................................................384
10.7.18 Alarms ..........................................................................................................................386
10.7.19 Maintenance .................................................................................................................391
10.7.20 Time Event ...................................................................................................................394
10.7.21 Display..........................................................................................................................396
10.7.22 Clock ............................................................................................................................397
10.8 Modbus RTU Exception Codes...............................................................................................398
11 FURTHER INFORMATION................................................................................ 400
11.1 Modbus RTU Serial Communications ....................................................................................400
11.2 Modbus Messaging on Ethernet TCP/IP .................................................................................400
11.3 How to Apply Digital Instrumentation in Severe Electrical Noise Environments..................400
12 INDEX................................................................................................................401
13 SALES AND SERVICE...................................................................................... 406

10/05 UDC3500 Universal Digital Controller Product Manual x
Tables
Table 2-1 Condensed Specifications ____________________________________________________ 13
Table 2-2 Control Relay Contact Information _____________________________________________ 19
Table 2-3 Alarm Relay Contact Information ______________________________________________ 19
Table 2-4 Mounting Procedure _________________________________________________________ 21
Table 2-5 Permissible Wiring Bundling__________________________________________________ 23
Table 2-6 Single or Cascade Loop Controller – Loop 1 Output Functionality and Restrictions _______ 25
Table 2-7 Dual Loop Controller – Loop 2 Output Functionality and Restrictions __________________ 26
Table 2-8 Terminals for connecting a UDC to a MDI Compliant Hub or Switch utilizing a cross-over cable
______________________________________________________________________________ 39
Table 2-9 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable ________ 40
Table 3-1 Configuration Topics ________________________________________________________ 43
Table 3-2 Configuration Prompt Hierarchy _______________________________________________ 45
Table 3-3 Configuration Procedure _____________________________________________________ 48
Table 3-4 TUNING Group Function Prompts _____________________________________________ 49
Table 3-5 TUNING 2 Group Function Prompts____________________________________________ 53
Table 3-6 SPRAMP Group Function Prompts _____________________________________________ 56
Table 3-7 ACCUTUNE Group Function Prompts __________________________________________ 63
Table 3-8 ALGORTHM Group Function Prompts _________________________________________ 67
Table 3-9 MATH Group Function Prompts _______________________________________________ 82
Table 3-10 LOGIC Group Function Prompts ______________________________________________ 89
Table 3-11 OUTPUT Group Function Prompts ____________________________________________ 96
Table 3-12 INPUT 1 Group Function Prompts ___________________________________________ 106
Table 3-13 INPUT 2 Group Function Prompts ___________________________________________ 110
Table 3-14 INPUT 3 Group Function Prompts ___________________________________________ 113
Table 3-15 INPUT 4 Group Function Prompts ___________________________________________ 117
Table 3-16 INPUT 5 Group Function Prompts ___________________________________________ 120
Table 3-17 CONTROL Group Function Prompts __________________________________________ 123
Table 3-18 CONTROL2 Group Function Prompts _________________________________________ 132
Table 3-19 OPTION Group Function Prompts ___________________________________________ 140
Table 3-20 Communications Group Function Prompts _____________________________________ 150
Table 3-21 ALARMS Group Function Prompts __________________________________________ 155
Table 3-22 CLOCK Group Function Prompts ____________________________________________ 162
Table 3-23 MAINTENANCE Group Function Prompts ____________________________________ 163
Table 3-24 DISPLAY Group Function Prompts __________________________________________ 166
Table 3-25 READ MAINTENANCE Group Function Prompts ______________________________ 168
Table 3-26 TIME EVT Group Function Prompts _________________________________________ 169
Table 3-27 Configuration Record Sheet _________________________________________________ 174
Table 4-1 Procedure to Enter a Security Code ____________________________________________ 183
Table 4-2 Annunciators _____________________________________________________________ 185
Table 4-3 Lower Display Key Parameter Prompts_________________________________________ 186
Table 4-4 Procedure for Starting Up the Controller ________________________________________ 188
Table 4-5 Control Mode Definitions ___________________________________________________ 189
Table 4-6 Changing Control Modes ____________________________________________________ 190
Table 4-7 Procedure for Changing the Local Setpoints _____________________________________ 191
Table 4-8 Procedure for Switching Between Setpoints _____________________________________ 191
Table 4-9 Procedure for Starting “TUNE” _______________________________________________ 195
Table 4-10 Procedure for Using AUTOMATIC TUNE at Start-up for Duplex Control ____________ 197
Table 4-11 Procedure for Using BLENDED TUNE at Start-up for Duplex Control_______________ 198

xi UDC3500 Universal Digital Controller Product Manual 10/05
Table 4-12 Procedure for Using MANUAL TUNE for Heat side of Duplex Control ______________ 199
Table 4-13 Procedure for Using MANUAL TUNE for Cool side of Duplex Control ______________ 199
Table 4-14 Procedure for Accessing Accutune Error Codes _________________________________ 200
Table 4-15 Accutune Error Codes _____________________________________________________ 200
Table 4-16 Set Up Procedure _________________________________________________________ 202
Table 4-17 Procedure for Switching PID SETS from the Keyboard ___________________________ 203
Table 4-18 Logic Gates Constraints and Dynamic Operation Status ___________________________ 206
Table 4-19 Digital Input Option Action on Contact Closure _________________________________ 208
Table 4-20 Digital Input Combinations “DIG IN1” or “DIG IN2” ____________________________ 211
Table 4-21 Digital Inputs 1 and 2 Combination___________________________________________ 212
Table 4-22 Auto/Manual Station Mode Configuration Procedure _____________________________ 214
Table 4-23 Procedure for selecting Two Loop Algorithm ___________________________________ 220
Table 4-24 Digital Display Indication—Two Loops _______________________________________ 221
Table 4-25 Procedure for Displaying Alarm Setpoints _____________________________________ 223
Table 4-26 Procedure for Displaying TPSC Motor Position _________________________________ 225
Table 4-27 Procedure for Setting a Failsafe Value_________________________________________ 226
Table 4-28 Procedure for Setting a Failsafe Mode_________________________________________ 227
Table 4-29 Running A Setpoint Ramp __________________________________________________ 232
Table 4-30 Program Contents_________________________________________________________ 234
Table 4-31 Run/Monitor Functions ____________________________________________________ 240
Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input Range Values _______________ 258
Table 5-2 Equipment Needed_________________________________________________________ 260
Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath ________________ 262
Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using a Thermocouple Source _______ 263
Table 5-5 Set Up Wiring Procedure for RTD Inputs _______________________________________ 264
Table 5-6 Set Up Wiring Procedure for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple
Differential Inputs (Except 0-10 Volts and –1 to 1 Volts) ________________________________ 265
Table 5-7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the
Factory Setting _________________________________________________________________ 266
Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts or –1 to 1 Volts _________________________ 267
Table 5-9 Set Up Wiring Procedure for Milliampere Inputs _________________________________ 268
Table 5-10 Set Up Wiring Procedure for Dual High Level Voltage Inputs ______________________ 269
Table 5-11 Set Up Wiring Procedure for Dual High Level Milliampere Inputs __________________ 270
Table 5-12 Input Calibration Procedure _________________________________________________ 271
Table 5-13 Restore Factory Calibration _________________________________________________ 273
Table 6-1 Set Up Wiring Procedure for the First Current Output _____________________________ 276
Table 6-2 First Current Output Calibration Procedure______________________________________ 277
Table 6-3 Set Up Wiring Procedure for the Second Current Output ___________________________ 278
Table 6-4 Second Current Output Calibration Procedure ___________________________________ 279
Table 6-5 Set Up Wiring Procedure for the Third Current Output ____________________________ 280
Table 6-6 Third Current Output Calibration Procedure _____________________________________ 281
Table 6-7 Position Proportional and Three Position Step Output Calibration Procedure ___________ 283
Table 6-8 Restore Factory Calibration __________________________________________________ 285
Table 7-1 Procedure for Identifying the Software Version __________________________________ 289
Table 7-2 Procedure for Displaying the Status Test Results _________________________________ 290
Table 7-3 Background Tests__________________________________________________________ 291
Table 7-4 Controller Failure Symptoms_________________________________________________ 295
Table 7-5 Troubleshooting Power Failure Symptoms ______________________________________ 297
Table 7-6 Troubleshooting Current Output Failure ________________________________________ 297
Table 7-7 Troubleshooting Position Proportional Output Failure _____________________________ 299

10/05 UDC3500 Universal Digital Controller Product Manual xii
Table 7-8 Troubleshooting Time Proportional Output Failure _______________________________ 302
Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure ___________ 303
Table 7-10 Troubleshooting Alarm Relay Output Failure ___________________________________ 305
Table 7-11 Troubleshooting a Keyboard Failure __________________________________________ 306
Table 7-12 Troubleshooting an Analog Input Failure ______________________________________ 307
Table 7-13 Troubleshooting a RS-485 Communications Failure______________________________ 308
Table 7-14 Troubleshooting an Ethernet Communications Failure ____________________________ 311
Table 7-15 Troubleshooting an Email Failure ____________________________________________ 312
Table 7-16 Restoring Factory Configuration _____________________________________________ 313
Table 7-17 Software Upgrades________________________________________________________ 314
Table 8-1 Parts Identification _________________________________________________________ 317
Table 8-2 Parts Not Shown___________________________________________________________ 317
Table 8-3 Software Upgrades (see Section 7.8) ___________________________________________ 318
Table 9-1 Integer Parameter Type _____________________________________________________ 320
Table 9-2 Floating Point Parameter Type________________________________________________ 320
Table 9-3 Register Parameter ID Address Format for Function Code 20 _______________________ 322
Table 9-4 Register Parameter ID Address Format for Function Code 21 _______________________ 326
Table 10-1 Control Data Parameters ___________________________________________________ 330
Table 10-2 Option Status ____________________________________________________________ 331
Table 10-3 Miscellaneous Read Onlys__________________________________________________ 332
Table 10-4 SetPoint Program Read Only Information ______________________________________ 332
Table 10-5 Setpoint Code Selections ___________________________________________________ 333
Table 10-6 Setpoint Associated Parameters ______________________________________________ 334
Table 10-7 Computer Setpoint Selection ________________________________________________ 335
Table 10-8 Computer Setpoint Associated Parameters for Loop 1 ____________________________ 336
Table 10-9 Computer Setpoint Associated Parameters for Loop2 _____________________________ 337
Table 10-10 Set-up Group – Tuning Loop 1 _____________________________________________ 338
Table 10-11 Set-up Group – Tuning Loop 2 ______________________________________________ 340
Table 10-12 Set-up Group – Setpoint Ramp/Rate _________________________________________ 341
Table 10-13 Set-up Group – Adaptive Tune _____________________________________________ 348
Table 10-14 Set-up Group – Algorithm _________________________________________________ 350
Table 10-15 Set-up Group – Math _____________________________________________________ 355
Table 10-16 Set-up Group – Logic_____________________________________________________ 358
Table 10-17 Set-up Group – Output Algorithms __________________________________________ 362
Table 10-18 Set-up Group – Input 1____________________________________________________ 364
Table 10-19 Set-up Group – Input 2____________________________________________________ 366
Table 10-20 Set-up Group – Input 3____________________________________________________ 368
Table 10-21 Set-up Group – Input 4____________________________________________________ 370
Table 10-22 Set-up Group – Input 5____________________________________________________ 372
Table 10-23 Set-up Group – Control ___________________________________________________ 374
Table 10-24 Set-up Group – Control2 __________________________________________________ 377
Table 10-25 Set-up Group – Options ___________________________________________________ 380
Table 10-26 Set-up Group – Communications____________________________________________ 384
Table 10-27 Set-up Group – Alarms ___________________________________________________ 386
Table 10-28 Set-up Group – Maintenance _______________________________________________ 391
Table 10-29 Set-up Group – Time Event ________________________________________________ 394
Table 10-30 Set-up Group – Display ___________________________________________________ 396
Table 10-31 Set-up Group – Clock ____________________________________________________ 397
Table 10-32 Modbus RTU Data Layer Status Exception Codes ______________________________ 399

xiii UDC3500 Universal Digital Controller Product Manual 10/05
Figures
Figure 1-1 UDC3500 Operator Interface __________________________________________________ 6
Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket PC _________________ 8
Figure 1-3 Depiction of infrared communications ___________________________________________ 9
Figure 2-1 Model Number Interpretation _________________________________________________ 18
Figure 2-2 Mounting Dimensions (not to scale)____________________________________________ 20
Figure 2-3 Mounting Methods _________________________________________________________ 21
Figure 2-4 Composite Wiring Diagram___________________________________________________ 27
Figure 2-5 Mains Power Supply ________________________________________________________ 28
Figure 2-6 Input 1 Connections_________________________________________________________ 29
Figure 2-7 Input 2 Connections_________________________________________________________ 30
Figure 2-8 Input 3 Connections_________________________________________________________ 31
Figure 2-9 HLAI Inputs 2 and 4 Connections ______________________________________________ 32
Figure 2-10 HLAI Inputs 3 and 5 Connections _____________________________________________ 33
Figure 2-11 Optional Analog Input Jumper Positions________________________________________ 33
Figure 2-12 First Current Output________________________________________________________ 34
Figure 2-13 Second Current Output _____________________________________________________ 34
Figure 2-14 Output #2 – Electromechanical Relay Output ____________________________________ 35
Figure 2-15 Output #2 – Solid State Relay Output __________________________________________ 35
Figure 2-16 Output #2 – Open Collector Output- Third ______________________________________ 36
Figure 2-17 Output #2 – Third Current Output _____________________________________________ 36
Figure 2-18 Output #2 – Dual Relay Output for Time Duplex _________________________________ 37
Figure 2-19 Output #2 – Dual Relay Output for Position Proportional or Three Position Step Control _ 37
Figure 2-20 RS-422/485 Communications Option Connections________________________________ 38
Figure 2-21 Ethernet Communications Option with Adaptor Board_____________________________ 38
Figure 2-22 Ethernet Communications Option without Adaptor Board __________________________ 39
Figure 2-23 Digital Inputs _____________________________________________________________ 40
Figure 2-24 Optional Electromechanical Relay Outputs______________________________________ 41
Figure 2-25 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open Collector Output_____ 41
Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Second Current Output ____ 42
Figure 3-1 Mass Flow Example ________________________________________________________ 80
Figure 3-2 Example of Eight Segment Characterizer________________________________________ 88
Figure 3-3 Ethernet Configuration Screen _______________________________________________ 171
Figure 3-4 Email Configuration Screen _________________________________________________ 172
Figure 4-1 Operator Interface_________________________________________________________ 182
Figure 4-2 Auto/Manual Station_______________________________________________________ 213
Figure 4-3 Functional Overview Block Diagram of a Single Loop (Loop #1) or Dual Loop Controller (Loop #1
and Loop #2) __________________________________________________________________ 218
Figure 4-4 Functional Overview Block Diagram of Internal Cascade Controller _________________ 219
Figure 4-5 Hi/Lo Override Selector ____________________________________________________ 220
Figure 4-6 Carbon Potential Control ___________________________________________________ 229
Figure 4-7 Ramp/Soak Profile Example_________________________________________________ 237
Figure 4-8 Program Record Sheet _____________________________________________________ 238
Figure 4-9 Loop Data Maintenance Screen ______________________________________________ 242
Figure 4-10 Alarm Details Maintenance Screen __________________________________________ 243
Figure 4-11 Status Data Maintenance Screen_____________________________________________ 245
Figure 4-12 Diagnostic History Maintenance Screen_______________________________________ 246
Figure 4-13 Ethernet Status Maintenance Screen__________________________________________ 247
Figure 4-14 Healthwatch Data Maintenance Screen _______________________________________ 248

10/05 UDC3500 Universal Digital Controller Product Manual xiv
Figure 4-15 Healthwatch Data Reset Screen _____________________________________________ 249
Figure 4-16 Totalizer Maintenance Screen ______________________________________________ 250
Figure 4-17 Real Time Clock Maintenance Screen ________________________________________ 251
Figure 4-18 IR Communications Address _______________________________________________ 252
Figure 4-19 Configuration Upload in Progress ___________________________________________ 253
Figure 4-20 Ethernet Communications Address __________________________________________ 255
Figure 4-21 Configuration Upload in Progress ___________________________________________ 256
Figure 5-1 Input Wiring Terminals ____________________________________________________ 260
Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath ____________________ 262
Figure 5-3 Wiring Connections for Thermocouple Inputs Using a Thermocouple Source __________ 263
Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device) ____________________ 264
Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential
Inputs (Except 0-10 Volts and –1 to 1 Volts)__________________________________________ 265
Figure 5-6 Wiring Connections for 0 to 10 Volts or –1 to 1 Volts_____________________________ 267
Figure 5-7 Wiring Connections for Milliampere Inputs_____________________________________ 268
Figure 5-8 Wiring Connections for Dual High Level Voltage Inputs __________________________ 269
Figure 5-9 Wiring Connections for Dual High Level Milliampere Inputs_______________________ 270
Figure 6-1 Wiring Connections for Calibrating the First Current Output _______________________ 276
Figure 6-2 Wiring Connections for Calibrating the Second Current Output _____________________ 278
Figure 6-3 Wiring Connections for Calibrating Third Current Output _________________________ 280
Figure 8-1 UDC3500 Exploded View __________________________________________________ 316
Figure 10-1 Software Option Status Information __________________________________________ 331

Introduction
10/05 UDC3500 Universal Digital Controller Product Manual 1
1 Introduction
1.1 Overview
Function
The UDC3500 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 UDC3500 monitors and controls temperatures and other variables in applications
such as environmental chambers, plastic processing machines, furnaces and ovens, and
packaging machinery.
Features
• 3 Universal Analog Inputs (can be configured to act as one Universal and four High
Level)
• ± 0.10% Analog Input Accuracy (can be Field Calibrated to ± 0.05%)
• 16-bit Analog Input resolution typical
• Fast scanning rate (166ms)
• Up to 7 Analog and Digital Outputs
• 4 Digital Inputs
• Two Math Functions, two Characterizers, one Polynomial equation and one
Totalizer available
• Two Independent Loops or Cascade Loop
• Ethernet TCP/IP with Email or RS-485 Modbus communication
• Infrared PC & Pocket PC configuration
• NEMA4X and IP66 front face protection
• Multilanguage prompts
• ¼ DIN Size
• Easily Field Upgradeable
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 your process control needs.

Introduction
2 UDC3500 Universal Digital Controller Product Manual 10/05
Analog Inputs
The UDC3500 has three universal analog inputs with a typical accuracy of ±0.10% of
full-scale input and a typical resolution of 16 bits. These can be configured to act as one
Universal and four High Level Inputs for a total of five analog inputs. All analog inputs
are sampled six times per second (every 166 ms).
The 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 and third inputs are isolated from each other and all other inputs and
outputs and accept the same actuations as input one. Input 3 provides the Slidewire input
for Position Proportional control. These optional inputs can each be split into two high
level inputs. The fourth input is enabled by first configuring Input 2 as a 20 mA or 5 Vdc
type (high level) input and moving a jumper on the Second Optional Input Board. Input 4
will then be available as a high level input. The fifth input is enabled by first configuring
Input 3 as a 20 mA or 5 Vdc type (high level) and moving a jumper on the Third Optional
Input Board. Input 5 will then be available as a high level input.
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—Two pre-configured algorithms are available for easy implementation. This
includes the capability of using a Ratio and Bias with any input. You can select from the
following menu:
Feedforward Summer—Uses any 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. It is available
with or without Square Root.
Input High/Low Select—Specifies the PV input as the higher or lower of two inputs.

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10/05 UDC3500 Universal Digital Controller Product Manual 3
8 Segment Characterizers—Two characterizers are available that can be applied to any
Analog Input, to Loop 1 Output or to Loop 2 Output. The Characterizers can be
combined to produce a single 16-segment characterizer.
Totalizer—Calculates and displays the total flow volume as measured by any of the
analog inputs or as derived by either Math algorithm. Displayed value is eight digits with
a configurable scaling factor. The totalizer value may be reset.
Combinational Inputs—Inputs can be combined for use with Relative Humidity, %
Oxygen, Carbon Potential, Dewpoint or Math Algorithms. This controller can accept
carbon probes from Cambridge, Marathon Monitors, Corning, A.A.A.C, Barber
Coleman, MacDhui, Bricesco or Furnace Controls.
Polynomial Curve Characterizer—A fifth order polynomial equation can be used on
any one of the analog inputs.
Logic Gates—Five Logic Gates configurable as OR, NOR, AND, NAND, XOR, XNOR,
or COMPARATOR. Each Gate has two inputs and one output. The Gates may be linked
together to perform more complex functions.
Digital Inputs
Four isolated digital inputs are provided for remote dry contact closure to select one of 25
actions. Also, two of these digital inputs can allow one of six additional selections to be
combined with one of the above selections.
Outputs
Output Types - The UDC3500 may have up to seven of the following outputs:
• Current Outputs (4-20 or 0-20 mA)
• Electromechanical Relays (5 amps)
• Solid State Relay (1 amp)
• Dual Electromechanical Relays (2 amps)
• Open Collector Output (+30 VDC @ 20 mA)
Alarms
Up to four electromechanical alarm relays are available to activate external equipment
when preset alarm setpoints are reached. Each of the four 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. An individual alarm hysteresis setting is
provided for each relay and these are configurable from 0 to 100% of range.
• Alarms can be configured as latching or non-latching.

Introduction
4 UDC3500 Universal Digital Controller Product Manual 10/05
• Alarm blocking is also available which allows start-up without alarm energized
until after it first reaches the operating region.
• PV rate of change alarm.
• Loop break alarm.
• Timer output reset.
• Diagnostic Alarm
Communications
A communications link is provided between the UDC3500 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
Auxiliary Output * (optional)—All of the three current outputs can function as Auxiliary
Outputs which can be scaled from 4-20 ma for 0 to 100% for any range. These can be
configured to represent any analog input, PV, active Setpoint, Local SP1, Deviation, or
the Control Output for either control loop.
Transmitter Power—This feature provides up to 30 volts dc to power a 2-wire transmit-
ter (requires the use of open collector output selection or one of the current outputs).
Four Local and one Remote Setpoints—Can be configured to provide four 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.
Healthwatch—Consists of three timers and three counters, which can each be assigned to
track UDC3500 controller functions. Selected Maintenance & Diagnostic data can be
accessed from the front panel or via communications. Alarms can be configured to
activate when a desired threshold is reached. A security code is required to perform
resetting of any of the above listed counter or timer functions.
Real Time Clock—An optional battery-backed clock feature that allows the user to
perform such things as starting an SP Program on a specific date and time.
Auto/Manual Station Plus Back-up Control—A UDC3500 can act as both an
Auto/Manual Station PLUS as a back-up PID Controller, should the primary loop
controller fail. Since the PID control is sometimes implemented via a PLC, this feature
provides a very cost-effective way to insure the process does not have to shutdown or

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10/05 UDC3500 Universal Digital Controller Product Manual 5
remain in manual mode if the PLC should fail. Switching from the Auto/Manual Station
to the back-up control mode is accomplished using the Digital Input option.
Moisture Protection—The NEMA4X and IP66 rated front face permits use in
applications where it may be subjected to moisture, dust, or hose-down conditions. UL
and CSA approved as Type 4 protection.
Setpoint Ramp/Soak Programming (Optional)—Enables you to program and store ten
Ramp and ten Soak segments (total of twenty 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 setpoint ramp is also
available as an alternative.
Output Rate Limiter—A maximum output rate may be configured for both the upscale
and the downscale output directions.
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 and UL listing are available as an option.
Four Sets of Tuning Constants—Four 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 IITM algorithm found on earlier controllers. Two
possibilities are now offered when tuning your process: Fast Tune and Slow Tune.
Fast Tune will tune the process in such a way that the temp is reached faster, a
slight overshoot will be allowed.
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.

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6 UDC3500 Universal Digital Controller Product Manual 10/05
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.
* The Second Current Output option is mutually exclusive with the Ethernet
Communications option.
1.2 Operator Interface
Figure 1-1 UDC3500 Operator Interface