Grieve Corporation UDC3500 Installation Manual
UDC3500
Universal Digital Controller
Product Manual
51-52-25-120
October 2005
Industrial Measurement and Control
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.
Notices and Trademarks
Copyright 2005 by Honeywell
Revision 0
October 2005
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 ii
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.
United States and Canada Honeywell 1-800-423-9883 Tech. Support
Organization Phone Number
1-800-525-7439 Service
Web
http://content.honeywell.com/ipc/faq/
10/05 UDC3500 Universal Digital Controller Product Manual iii
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.
10/05 UDC3500 Universal Digital Controller Product Manual iv
Contents
1 INTRODUCTION ...................................................................................................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
2 INSTALLATION................................................................................................... 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
3 CONFIGURATION............................................................................................... 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
v UDC3500 Universal Digital Controller Product Manual 10/05
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
4 MONITORING 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
10/05 UDC3500 Universal Digital Controller Product Manual vi
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
5 INPUT 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
6 OUTPUT 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
7 TROUBLESHOOTING/SERVICE...................................................................... 287
7.1 Overview.....................................................................................................................................287
vii UDC3500 Universal Digital Controller Product Manual 10/05
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
8 PARTS LIST ......................................................................................................316
8.1 Exploded View............................................................................................................................316
8.2 Removing the chassis..................................................................................................................318
9 MODBUS 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
10/05 UDC3500 Universal Digital Controller Product Manual viii
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
ix UDC3500 Universal Digital Controller Product Manual 10/05
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
10/05 UDC3500 Universal Digital Controller Product Manual x
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
xi UDC3500 Universal Digital Controller Product Manual 10/05
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
10/05 UDC3500 Universal Digital Controller Product Manual xii
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
xiii UDC3500 Universal Digital Controller Product Manual 10/05
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
10/05 UDC3500 Universal Digital Controller Product Manual xiv
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
Introduction
1 Introduction
• 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.
10/05 UDC3500 Universal Digital Controller Product Manual 1
Introduction
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.
2 UDC3500 Universal Digital Controller Product Manual 10/05
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
Introduction
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:
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.
• 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 can be configured as latching or non-latching.
10/05 UDC3500 Universal Digital Controller Product Manual 3
Introduction
• 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 transmitter (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
4 UDC3500 Universal Digital Controller Product Manual 10/05
Introduction
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
TM
improved version of the Accutune II
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.
10/05 UDC3500 Universal Digital Controller Product Manual 5
Introduction
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
6 UDC3500 Universal Digital Controller Product Manual 10/05
1.2.1 Function of Displays and Keys
Table 1-1 Function of Displays and Keys
Display Indicators
Introduction
3200
3500
SP 3500
SP
ALMALM
3200
DIDI
Upper display with 4 larger digits shows
Process Variable value (normal operation)
and special annunciator features. During
Configuration, the upper display provides
guidance for the operator through prompts (7
– characters)
During normal operation, the lower display
shows key-selected operating parameters
such as Output, Setpoints, Inputs, Deviation,
active Tuning Parameter Set, Timer Status, or
minutes remaining in a setpoint ramp (4
digits). During configuration, the lower display
provides guidance for the operator through
prompts (8-characters).
Indicates Alarm 1 and/or Alarm 2 conditions
exist.
Indicates Digital Input 1 and/or 2 on.
Keys and Functions
Indicates Control Relay 1 and/or 2 on.
OUT
FF
Or
Indicates either degrees Fahrenheit or
Centigrade.
CC
MAN
Or
Indicates either Manual or Auto mode.
AA
Indicates Local Setpoint #1. Also, a bar is
SPSP
lighted when the setpoint being used is shown
on the lower display.
Func
Loop 1/2
Selects functions within each
configuration group. Switches between
Loop Displays for Two Loop and
Man
Man
Man
Auto
Auto
Auto
Selects Manual or Auto mode.
Cascade units.
SetupSetup
Lower
Lower
Lower
Display
Display
Display
Scrolls through the configuration
groups.
Returns Controller to normal display
from Set Up mode. Toggles various
operating parameters for display.
Increases setpoint or output value.
Increases the configuration values or
changes functions in Configuration
mode groups.
Infrared transceiver
SP
SP
SP
Select
Select
Select
Run
Run
Run
Hold
Hold
Hold
Hold key down to cycle through configured
setpoints.
Enables Run/Hold of the SP Ramp or Program
plus Timer start.
Decreases setpoint or output value. Decreases
the configuration values or changes functions in
Configuration mode groups.
NEMA4X and IP66 screw attachment (each
corner)
10/05 UDC3500 Universal Digital Controller Product Manual 7
Introduction
1.3 Process Instrument Explorer Software
Overview
Process Instrument Explorer (P.I.E.) lets you configure your instrument on a
desktop/laptop or Pocket PC. For details see Process Instrument Explorer Manual #5152-25-131.
Features
• Create configurations with intuitive software program running on a Pocket PC, a
Desktop or a laptop computer.
• Create/edit configurations live, just connect software to the controller via a
communications port.
• Create/edit configurations offline and download to controller later via a
communications port.
• Communication types available on every UDC3500:
Infrared (standard)
RS 485 (optional)
Ethernet (optional)
• Same port types on UDC2500 and UDC3200 allow interconnectivity.
• This software is available in English, Spanish, Italian, German and French.
Figure 1-2 Screen capture of Process Instrument Explorer
running on a Pocket PC
8 UDC3500 Universal Digital Controller Product Manual 10/05
Infrared communications
The infrared connection provides a non-intrusive wireless connection with the instrument
and maintains NEMA4X AND IP66 integrity.
No need to get access to the back of the controller to communicate with the instrument,
no need to take your screw driver to wire the communication cable, no wiring mistake
possible. You can now duplicate an instrument’s configuration, upload or download a
new configuration in a matter of seconds, just by pointing your Pocket PC in the direction
of the instrument.
It takes just a few seconds to upload a configuration from an instrument. You can then
save the configuration file onto your PC or pocket PC for review, modification or
archiving. Furthermore, this software also gives you important maintenance information
on the controller: instantly, get information on the current operating parameters, digital
inputs and alarm status, identify internal or analog input problems.
Question: What if I have several controllers on the same panel? How can I be sure I am
communicating with the correct one?
Answer: The infrared port of the controller is normally “off”. You activate the infrared
port by pressing any controller’s key. You can now communicate. After 4 minutes, the
port will be shut down again. Each controller may also be assigned a different
communications address.
Introduction
Figure 1-3 Depiction of infrared communications
10/05 UDC3500 Universal Digital Controller Product Manual 9
Introduction
1.4 CE Conformity (Europe)
This product is in conformity with the protection requirements of the following European
Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC
Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be
assumed.
Product Classification: Class I: Permanently connected, panel-mounted Industrial
Control Equipment with protective earthing (grounding) (EN61010-1).
Enclosure Rating: This controller must be panel-mounted with the rear terminals
enclosed within the panel. The front panel of the controller is rated at NEMA4X and IP66
when properly installed.
Installation Category (Overvoltage Category): Category II (EN61010-1)
Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with
occasional conductivity caused by condensation. (Ref. IEC 664-1)
EMC Classification: Group 1, Class A, ISM Equipment (EN61326, emissions), Industrial
Equipment (EN61326, immunity)
Method of EMC Assessment: Technical File (TF)
Declaration of Conformity: 51453681
Deviation from the installation conditions specified in this manual, and the special
conditions for CE conformity in Subsection 2.1, may invalidate this product’s conformity
with the Low Voltage and EMC Directives.
ATTENTION
The emission limits of EN61326 are designed to provide reasonable protection
against harmful interference when this equipment is operated in an industrial
environment. Operation of this equipment in a residential area may cause harmful
interference. This equipment generates, uses, and can radiate radio frequency
energy and may cause interference to radio and television reception when the
equipment is used closer than 30 meters (98 feet) to the antenna(e). In special
cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the
electromagnetic emissions of this equipment.
WARNING
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
10 UDC3500 Universal Digital Controller Product Manual 10/05
2.1 Overview
Introduction
Installation of the UDC3500 consists of mounting and wiring the controller according to
the instructions given in this section. Read the pre-installation information, check the
model number interpretation (Subsection 2.3) and become familiar with your model
selections, then proceed with installation.
What’s in this section?
The following topics are covered in this section.
2.1 Overview 11
Installation
2 Installation
TOPIC See Page
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
2.7 Wiring Diagrams
Figure 2-4 Composite Wiring Diagram
Figure 2-5 Mains Power Supply
Figure 2-6 Input 1 Connections
Figure 2-7 Input 2 Connections
Figure 2-8 Input 3 Connections
Figure 2-9 HLAI Inputs 2 and 4
Figure 2-10 HLAI Inputs 3 and 5
Figure 2-11 Optional Analog Input Jumper Positions
Figure 2-12 First Current Output
Figure 2-13 Second Current Output
Figure 2-14 Output #2 – Electromechanical Relay Output
Figure 2-15 Output #2 – Solid State Relay Output
Figure 2-16 Output #2 – Open Collector Output
Figure 2-17 Output #2 – Third Current Output
Figure 2-18 Output #2 – Dual Relay Output for Time Duplex
Figure 2-19 Output #2 – Dual Relay Output for Position
Proportional or Three Position Step Control
Figure 2-20 RS-422/485 Communications Option
27
28
29
30
31
32
33
33
34
34
35
35
36
36
37
37
38
39
10/05 UDC3500 Universal Digital Controller Product Manual 11
Installation
Figure 2-22 Ethernet Communications Option
Figure 2-23 Digital Inputs
Figure 2-24 Optional Electromechanical Relay Outputs
Figure 2-25 Transmitter Power for 4-20 mA — 2 wire
Transmitter Using Open Collector Output
Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire
Transmitter Using Second Current Output
40
41
41
42
12 UDC3500 Universal Digital Controller Product Manual 10/05
Pre-installation Information
If the controller has not been removed from its shipping carton, inspect the carton for
damage then remove the controller.
• Inspect the unit for any obvious shipping damage and report any damage due to
transit to the carrier.
• Make sure a bag containing mounting hardware is included in the carton with the
controller.
• Check that the model number shown on the inside of the case agrees with what you
have ordered.
2.2 Condensed Specifications
Honeywell recommends that you review and adhere to the operating limits listed in Table
2-1 when you install your controller.
Table 2-1 Condensed Specifications
Analog Inputs
Analog Input Signal
Failure Operation
Stray Rejection Common Mode
Digital Inputs (Four)
(Optional)
Up to three Universal analog inputs. These can easily be configured to operate as 2
Universal and 2 High Level or as 1 Universal and 4 High Level inputs.
Accuracy:
± 0.10% of full scale typical (± 1 digit for display)
Can be field calibrated to ± 0.05% of full scale typical
16-bit resolution typical
Sampling Rate: All inputs are sampled six times per second
Temperature Stability: ± 0.0075% of Full Scale span / ˚C change—typical
Input Impedance:
0-20 and 4-20 Milliampere Inputs: 250 ohms
0-10 Volt and –1 to +1 Volt Input: 200K ohms
All Others: 10 megohms
Maximum Lead Wire Resistance:
Thermocouples: 50 ohms/leg
100 ohm, 200 ohm, 500 ohm and 1000 ohm RTD: 100 ohms/leg
100 ohm Low RTD: 10 ohms/leg
Slidewire Input for Position Proportional Control (Input 3 only):
100 ohm to 1000 ohm resistive slidewire types
Herculine
Burnout Selections: Upscale, Downscale, Failsafe or None
Thermocouple Health: Good, Failing, Failure Imminent or Failed
Failsafe Output Level: Configurable 0-100% of Output range
AC (50 or 60 Hz): 120 dB (with maximum source impedance of 100 ohms) or ± 1 LSB (least
significant bit) whichever is greater with line voltage applied.
DC: 120 dB (with maximum source impedance of 100 ohms) or a ±1 LSB whichever is
greater with 120 Vdc applied.
DC (to 1 KHz): 80 dB (with maximum source of impedance of 100 ohms) or ±1 LSB
whichever is greater with 50 Vac applied.
Normal Mode
AC (50 or 60 Hz): 60 dB (with 100 % span peak-to-peak maximum)
+30 Vdc source for external dry contacts or isolated solid-state contacts. Digital Inputs are
isolated from line power, earth ground, analog inputs and all outputs.
Models 10260 and 11280 Slidewire Emulation
Installation
Specifications
10/05 UDC3500 Universal Digital Controller Product Manual 13
Installation
Current and Auxiliary
Outputs
Output 2 Options
Three Relay Board
(Optional)
Specifications
Up to three Milliamp Outputs. These outputs provide a 0 to 21 mA current output into a
negative or positive grounded load or into a non-grounded load. Current outputs are isolated
from each other, line power, earth ground and all inputs. Outputs can easily be configured
via the keyboard to be 0 to 20 mA or 4 to 20 mA without field calibration and for either direct
or reverse action when used as a control output.
Any current output not being used as a control output can be used in an Auxiliary Output
mode. Auxiliary Outputs can be configured to represent any Analog Input, PV, Setpoint,
Deviation, or Control Output. The range of an Auxiliary Output can be scaled per the range
of the selected variable and can be set anywhere between 0 to 21 mA.
Resolution: 14 bits over 0 to 21 mA
Accuracy: 0.05% of full scale
Temperature Stability: 0.01% F.S./°C typical
Load Resistance: 0 to 1000 ohms
The First Current Output is a standard feature and is present on all instruments. The Second
Current Output is an option and is mutually exclusive with Ethernet Communications. The
Third Current Output is an option and is mutually exclusive with the other Output 2 Options
listed directly below.
Output 2 is a socket which may be populated with any one of the following output types:
Electromechanical Relay
SPDT contacts. Both Normally Open and Normally Closed contacts are brought out to the
rear terminals.
Resistive Load: 5 amps @ 120 Vac or 240 Vac or 30 Vdc
Inductive Load (cos
Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
Motor: 1/6 H.P.
Dual Electromechanical Relays
Two SPST relays. One Normally Closed contact for each relay is brought out to the rear
terminals. This option must be used as the Loop 1 output for On-Off Duplex, Time Duplex,
Three Position Step Control and Position Proportional Control applications. Instruments with
this option can have a total of five relays plus one or two current outputs.
Resistive Load: 2 amps @ 120 Vac, 240 Vac or 30 Vdc
Inductive Load (cos
Inductive Load (L/R = 7 milliseconds): 1 amp @ 30 Vdc
Solid State Relay
SPST solid-state contact consisting of a triac N.O. output with zero-crossing detection.
Resistive Load: 1.0 amp @ 25°C ambient temperature and 120 or 240 Vac
0.5 amp @ 55°C ambient temperature and 120 or 240 Vac
Inductive Load: 50 VA @ 55°C ambient temperature and 120 or 240 Vac
Minimum Load: 20 milliamps
Open Collector Output
Transistor drive for powering an external relay. Isolated from earth ground and all other
circuits except the First Current Output. Internally powered @ 30 Vdc.
Note: Applying an external power supply to this output will damage the instrument.
Maximum Sink Current: 20 mA
Overload Protection: 100 mA
Third Current Output
See above.
Three SPDT contacts. Both Normally Open and Normally Closed contacts are brought out to
the rear terminals for each relay. These relays are used for Alarm outputs or for the output of
the second control loop. They may also be used as outputs for Logic Gate functions.
Resistive Load: 5 amps @ 120 Vac or 240 Vac or 30 Vdc
Inductive Load (cosϕ = 0.4): 3 amps @ 130 Vac or 250 Vac
Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
Motor: 1/6 H.P.
ϕ
= 0.4): 3 amps @ 130 Vac or 250 Vac
ϕ
= 0.4): 1 amp @ 130 Vac or 250 Vac
14 UDC3500 Universal Digital Controller Product Manual 10/05
Specifications
Alarm Outputs
(Optional)
Isolation (Functional)
RS422/485 Modbus
RTU
Communications
Interface (Optional)
Ethernet TCP/IP
Communications
Interface (Optional)
Infrared
Communications
(Standard)
Power Consumption 24 VA maximum (90 to 264 Vac)
Power Inrush Current
Weight
A maximum of four alarm relays are available, depending upon the type and quantity of
outputs used for control purposes. Each alarm may have one or two setpoints, each of which
can be independently set as high or low alarm. Setpoints can be on any Input, Process
Variable, Deviation, Manual Mode, Failsafe, PV Rate, RSP Mode, Communication Shed, or
Output. A single adjustable hysteresis of 0.0 to 100.0% is provided. The alarm can also be
set as an ON or OFF event at the beginning of a Setpoint Program Ramp or Soak segment.
Alarm status is accessible via any communications port and is shown on the display
annunciators.
AC Power: Electrically isolated from all other inputs and outputs and earth ground to
withstand a HIPOT potential of 1900 Vdc for 2 seconds per Annex K of EN61010-1.
Analog Inputs and Outputs: Are isolated from each other and all other circuits to withstand a
HIPOT potential of 850 Vdc for 2 seconds per Annex K of EN61010-1.
Digital Inputs and Digital Outputs: Electrically isolated from all other circuits to withstand a
HIPOT potential of 850 Vdc for 2 seconds per Annex K of EN61010-1.
Relay Contacts: With a working voltage of 115/230 Vac, these are electrically isolated from
all other circuits to withstand a HIPOT potential of 345 Vdc for 2 seconds per Annex K of
EN61010-1
Baud Rate: 4800, 9600,19,200 or 38,400 baud selectable
Data Format: Floating point or integer
Length of Link:
2000 ft (600 m) max. with Belden 9271 Twinax Cable and 120 ohm termination resistors
4000 ft. (1200 m) max. with Belden 8227 Twinax Cable and 100 ohm termination resistors
Link Characteristics: Two-wire (half-duplex), multi-drop Modbus RTU protocol, 15 drops
maximum or up to 31 drops for shorter link length.
Type: 10Base-T
Length of Link: 330 ft. (100 m) maximum. Use Shielded twisted-pair, Category 5 (STP
CAT5) Ethernet cable.
Link Characteristics: Four-wire plus shield, single drop, five hops maximum
IP Address: IP Address is 10.0.0.2 as shipped from the Factory
Recommended network configuration: Use Switch rather than Hub in order to maximize
UDC Ethernet performance.
Configuration: Ethernet parameters are configured via the Process Instrument Explorer.
Email: The capability to send two different Emails is provided. These must be configured via
the Process Instrument Explorer. It is recommended that the Real Time Clock Option be
purchased for any instrument that needs to send Email.
Ethernet Communications is mutually exclusive with the Second Current Output.
Type: Serial Infrared (SIR)
Length of Link: 3 ft. (1 m) maximum for IrDA 1.0 compliant devices
Baud Rate: 19,200 or 38,400 baud selectable
18 VA maximum (24 Vac/dc)
10A maximum for 4 ms (under operating conditions), reducing to a maximum of 265 mA (90
to 264 Vac operation) or 900 mA (24 Vac/dc operation) after one second.
CAUTION
power is supplied. Otherwise, the instruments may not start up normally due to voltage drop
from the inrush current.
3 lbs. (1.3 kg)
When applying power to more than one instrument, make sure that sufficient
Installation
10/05 UDC3500 Universal Digital Controller Product Manual 15
Installation
Environmental and Operating Conditions
Parameter Reference Rated Operative
Ambient Temperature
Relative Humidity
Vibration
Frequency (Hz)
Acceleration (g)
Mechanical Shock
Acceleration (g)
Duration (ms))
Line Voltage (Vdc)
24 Vdc
Line Voltage (Vac)
90 to 240 Vac
24 Vac
Frequency (Hz)
(For Vac)
* The maximum moisture rating only applies up to 40 °C (104 °F). For higher temperatures, the RH specification is derated to
maintain constant moisture content.
25 ± 3 °C
77 ± 5 °F
10 to 55* 10 to 90* 5 to 90* 5 to 95*
0
0
0
0
+24 ± 1
120 ± 1
240 ± 2
24 ± 1
50 ± 0.2
60 ± 0.2
15 to 55 °C
58 to 131 °F
0 to 70
0.4
1
30
22 to 27
90 to 240
20 to 27
49 to 51
59 to 61
Limits
0 to 55 °C
32 to 131 °F
0 to 200
0.6
5
30
20 to 30
90 to 264
20 to 27
48 to 52
58 to 62
Transportation and Storage
–40 to 66 °C
–40 to 151 °F
0 to 200
0.5
20
30
- -
- -
- -
- -
- -
- -
16 UDC3500 Universal Digital Controller Product Manual 10/05
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