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

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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