Honeywell UDC3200 User Manual

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UDC3200

Universal Digital Controller

Operator Manual

51-52-25-143

April 2008

Honeywell Process Solutions

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.

Contacts

Notices and Trademarks

April 2008

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 Honeywell Process Solutions http://hpswebhoneywell.com

http://www.honeywell.com

Telephone

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/

Honeywell Process Solutions

512 Virginia Drive

Fort Washington, PA 19034

UDC3200 is a U.S. registered trademark of Honeywell

Other brand or product names are trademarks of their respective owners.

4/08 UDC3200 Universal Digital Controller Operator Manual ii

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.

4/08 UDC3200 Universal Digital Controller Operator Manual iii

1 INTRODUCTION ...................................................................................................1

1.1 Operator Interface ...........................................................................................................................1

1.2 Function of Displays and Keys .......................................................................................................1

1.3 CE Conformity (Europe).................................................................................................................2

2 INSTALLATION.....................................................................................................5

2.1 Pre-installation Information ............................................................................................................5

2.2 Model Number Interpretation .........................................................................................................5

2.3 Control and Alarm Relay Contact Information...............................................................................6

2.4 Mounting.........................................................................................................................................7

2.5 Wiring .............................................................................................................................................9

2.5.1 Electrical Considerations .....................................................................................................9

2.6 Wiring Diagrams...........................................................................................................................10

3 CONFIGURATION...............................................................................................24

3.1 Configuration Prompt Hierarchy ..................................................................................................24

3.2 Configuration Procedure...............................................................................................................25

3.3 Tuning Set Up Group....................................................................................................................26

3.4 SP Ramp Set Up Group ................................................................................................................29

3.5 Accutune Set Up Group ................................................................................................................32

3.6 Algorithm Set Up Group...............................................................................................................33

3.7 Output Set Up Group ....................................................................................................................39

3.8 Input 1 Set Up Group....................................................................................................................42

3.9 Input 2 Set Up Group....................................................................................................................45

3.10 Control Set Up Group ...............................................................................................................48

3.11 Options Group ...........................................................................................................................53

3.12 Communications Group ............................................................................................................57

3.13 Alarms Set Up Group ................................................................................................................59

3.14 Display Set Up Group ...............................................................................................................63

4 MONITORING AND OPERATING THE CONTROLLER.....................................65

4.1 Operator Interface .........................................................................................................................65

4.2 Entering a Security Code ..............................................................................................................65

4.3 Individual key lockout ..................................................................................................................66

4.4 Monitoring Your Controller..........................................................................................................67

4.4.1 Annunciators ......................................................................................................................67

4.4.2 Viewing the operating parameters......................................................................................68

4.4.3 Diagnostic Messages..........................................................................................................69

4.5 Accutune III ..................................................................................................................................71

4.5.1 Tune for Simplex Outputs..................................................................................................72

4/08 UDC3200 Universal Digital Controller Operator Manual iv

4.5.2 Tune for Duplex (Heat/Cool) .............................................................................................73

4.5.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool) ......................................74

4.5.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool) ...........................................75

4.5.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool).............................................75

4.5.6 Error Codes ........................................................................................................................77

4.6 Fuzzy Overshoot Suppression.......................................................................................................78

5 TROUBLESHOOTING/SERVICE........................................................................79

5.1 Background Tests..........................................................................................................................79

5.2 Controller Failure Symptoms........................................................................................................81

6 SALES AND SERVICE........................................................................................82

v UDC3200 Universal Digital Controller Operator Manual 4/08

1.1 Operator Interface

1 Introduction

Figure 1-1 UDC3200 Operator Interface

1.2 Function of Displays and Keys

Table 1-1 Function of Displays and Keys

Display Indicators

32003200

SP 3200SP 3200

ALMALM

Upper display with 4 large 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 Control Relay 1 and/or

OUTOUT

2 on.

Indicates either degrees Fahrenheit or Centigrade.

MANMAN

Indicates either Manual or Auto mode.

DIDI

04/08 UDC3200 Universal Digital Controller Operator Manual 1

Indicates Digital Input 1 and/or 2 on.

Indicates Local Setpoint #1.

SPSP

Also, a bar is lighted when the setpoint being used is shown on the lower display.

Keys and Functions

FunctionFunctionFunction

SetupSetup

Selects functions within each configuration group.

Scrolls through the configuration groups.

Lower

Display

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

1.3 CE Conformity (Europe)

Man

Auto

Select

Run

Hold

Selects Manual or Auto mode.

Hold key down to cycle through configured setpoints.

Enables Run/Hold of the SP Ramp or Program plus Timer start.

Decreases setpoint or output value. Decreases the configuration values or changes functions in Configuration mode groups.

NEMA4X and IP66 screw attachment (each corner)

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: 51453663

Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Subsection 2, may invalidate this product’s

conformity with the Low Voltage and EMC Directives.

2 UDC3200 Universal Digital Controller Operator Manual 04/08

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.

04/08 UDC3200 Universal Digital Controller Operator Manual 3

2 Installation

_ _

_ _I_

_ _V_

2.1 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 Model Number Interpretation

Write your controller’s model number in the spaces provided below and circle the corresponding items in each table. This information will also be useful when you wire your controller.

Instructions

Select the desired key number. The arrow to the right marks the selection available. Make the desired selections from Tables I through VI using the column below the proper arrow. A dot ( ) denotes availability.

Key Number

_ _ _ _

KEY NUMBER - UDC3200 Single Loop Controller

Digital Controller for use with 90 to 264Vac Power DC3200 Digital Controller for use with 24Vac/dc Power DC3201

TABLE I - Specify Control Output and/or Alarms

Output #1

Output #2 and Alarm #1 or Alarms 1 and 2

TABLE II - Communications and Software Selections

Communications

Software Selections

Reserved

Infrared interface

TABLE III - Input 1 can be changed in the field using external resistors

Input 1

Input 2

-- - -_ _ _ _ _-

Current Output (4 to 20ma, 0 to 20 ma) Electro Mechanical Relay (5 Amp Form C) Solid State Relay (1 Amp) Open Collector transistor output Dual 2 Amp Relays (Both are Form A) (Heat/Cool Applications) No Additional Outputs or Alarms One Alarm Relay Only E-M Relay (5 Amp Form C) Plus Alarm 1 (5 Amp Form C Relay) Solid State Relay (1 Amp) Plus Alarm 1 (5 Amp Form C Relay) Open Collector Plus Alarm 1 (5 Amp Form C Relay)

None Auxiliary Output/Digital Inputs (1 Aux and 1 DI or 2 DI) RS-485 Modbus Plus Auxiliary Output/Digital Inputs

Base-T Ethernet (Modbus RTU) Plus Auxiliary Output/Digital Inputs

10 Standard Functions, Includes Accutune Math Option Set Point Programming (1 Program, 12 Segments) Set Point Programming Plus Math No Selection

Infrared Interface Included (Can be used with a Pocket PC)

TC, RTD, mV, 0-5V, 1-5V TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V Carbon, Oxygen or Dewpoint (Requires Input 2) None TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V Slidewire Input (Requires two Relay Outputs) _ 40

_ _

Description

IIIII IV

Selection

C _ E _ A _ T _ R _ _ 0 _ B _ E _ A _ T

0 _ _ _ 1 _ _ _ 2 _ _ _

3 _ _ _ _ 0 _ _ _ A _ _ _ B _ _ _ C _ _

_ _ 0 _ _ _ _ R

1 _ _ 2 _ _ 3 _ _ 1 6 0

_ 00 _ 10 _ 20

Availability

04/08 UDC3200 Universal Digital Controller Operator Manual 5

TABLE IV - Options

Approvals

2.3 Control and Alarm Relay Contact Information

Control Relays

ATTENTION

0 _ _ _ _ 1 _ _ _ _ _ 0 _ _ _ _ T _ _ _

_ S _ _ _

_ _ 0 _ _ _ _ _ 0 _ _ _ _ _ 0

S _ _ 0 _ C

Control relays operate in the standard control mode (that is, energized when output state is on).

Unit Power Control Relay

Alarm Relays

ATTENTION

Alarm relays are designed to operate in a failsafe mode (that is, de-energized during alarm sate). This results in alarm actuation when power is OFF or when initially applied, until the unit completes self-diagnostics. If power is lost to the unit, the alarms will de-energize and thus the alarm contacts will close.

Power

Off

Table 2-1 Control Relay Contact Information

Control Relay

Wiring

Contact

Indicator Status

N.O. Open N.C. Closed N.O.

Open

Closed

N.C.

Closed

Open

Table 2-2 Alarm Relay Contact Information

Alarm Relay

Wiring

N.O. Open Open N.C. Closed N.O. Closed Open N.C. Open

Variable NOT in Alarm State Variable in Alarm State Unit

Relay

Contact

Indicators Relay

Contact

Off

Closed

Off

Closed

Output #1 or #2

Off Off

On Off On

Indicators

Off

6 UDC3200 Universal Digital Controller Operator Manual 04/08

2.4 Mounting

Physical Considerations

The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied. Adequate access space must be available at the back of the panel for installation and servicing activities.

• Overall dimensions and panel cutout requirements for mounting the controller are

shown in Figure 2-2.

• The controller’s mounting enclosure must be grounded according to CSA standard

C22.2 No. 0.4 or Factory Mutual Class No. 3820 paragraph 6.1.5.

• The front panel is moisture rated NEMA3 and IP55 rated and can be easily

upgraded to NEMA4X and IP66.

Overall Dimensions

mm inches

Max. panel thickness 19,1 .75

9,0 0,35

92,0 + 0,8

-0,00

3,62 + 0,03

-0,00

Panel Cutout

92,0 + 0,8

-0,00

3,62 + 0,03

-0,00

Figure 2-2 Mounting Dimensions (not to scale)

17,9 0,70

113,1 4,45

90,6 3,57

108,6 4,28

04/08 UDC3200 Universal Digital Controller Operator Manual 7

Mounting Method

Before mounting the controller, refer to the nameplate on the outside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration.

Attach screws and washers here for water protection

Mounting clips

Mounting Procedure

Step Action

Mark and cut out the controller hole in the panel according to the dimension

information in Orient the case properly and slide it through the panel hole from the front.

Remove the mounting kit from the shipping container and install the kit as follows:

• For normal installation two mounting clips are required. Insert the prongs of the clips into the two holes in the top and bottom center of the case

• For water-protected installation four mounting clips are required. There are two options of where to install the mounting clips:

1) Insert the prongs of the clips into the two holes on the left and right side of the top and bottom of the case or

2) on the center on each of the four sides.

• Tighten screws to 2 lb-inch (22 N•cm) to secure the case against the panel. CAUTION: Over tightening will cause distortion and the unit may not seal properly.

For water-protected installation, install four screws with washers into the four recessed

areas in the corners of the front bezel ( through the center piercing the elastomeric material and then tighten screws to 5 lb-in (56 N•cm).

Figure 2-3 Mounting Methods

Table 2-3 Mounting Procedure

Figure 2-2.

Figure 2-3). Push the point of the screw

8 UDC3200 Universal Digital Controller Operator Manual 04/08

2.5 Wiring

2.5.1 Electrical Considerations Line voltage wiring

This controller is considered “rack and panel mounted equipment” per EN61010-1, Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements. Conformity with 72/23/EEC, the Low Voltage Directive requires the user to provide adequate protection against a shock hazard. The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals.

Mains Power Supply

This equipment is suitable for connection to 90 to 264 Vac or to 24 Vac/dc 50/60 Hz, power supply mains. It is the user’s responsibility to provide a switch and non-time delay (North America), quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuit-breaker for 90-264 Vac applications; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc applications, as part of the installation. The switch or

circuit-breaker shall be located in close proximity to the controller, within easy reach of the OPERATOR. The switch or circuit-breaker shall be marked as the

disconnecting device for the controller.

CAUTION

When applying power to multiple instruments, make certain that sufficient current is supplied. Otherwise, the instruments may not start up normally due to the voltage drop caused by the in-rush current.

Applying 90-264 Vac to an instrument rated for 24 Vac/dc will

severely damage the instrument and is a fire and smoke hazard.

Controller Grounding

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to a local ground, using a No. 12

(4 mm

) copper conductor, is recommended.

Control/Alarm Circuit Wiring

The insulation of wires connected to the Control/Alarm terminals shall be rated for the highest voltage involved. Extra Low Voltage (ELV) wiring (input, current output, and low voltage Control/Alarm circuits) shall be separated from HAZARDOUS LIVE (>30 Vac, 42.4 Vpeak, or 60 Vdc) wiring per Permissible Wiring Bundling, 2-4.

Electrical Noise Precautions

Electrical noise is composed of unabated electrical signals which produce undesirable effects in measurements and control circuits.

Digital equipment is especially sensitive to the effects of electrical noise. Your controller has built-in circuits to reduce the effect of electrical noise from various sources. If there is a need to further reduce these effects:

Table

04/08 UDC3200 Universal Digital Controller Operator Manual 9

• Separate External Wiring—Separate connecting wires into bundles

(See Permissible Wiring Bundling - Table 2-4) and route the individual bundles through separate conduit metal trays.

Use Suppression Devices—For additional noise protection, you may want to add

suppression devices at the external source. Appropriate suppression devices are commercially available.

ATTENTION

For additional noise information, refer to document number 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise Environments.

Permissible Wiring Bundling

Table 2-4 Permissible Wiring Bundling

Bundle No. Wire Functions

2 Analog signal wire, such as:

• Line power wiring

• Earth ground wiring

• Line voltage control relay output wiring

• Line voltage alarm wiring

• Input signal wire (thermocouple, 4 to 20 mA, etc.)

• 4-20 mA output signal wiring

Digital input signals

• Low voltage alarm relay output wiring

• Low voltage wiring to solid state type control circuits

• Low voltage wiring to open collector type control circuits

2.6 Wiring Diagrams

Universal Output Functionality and Restrictions

Instruments with multiple outputs can be configured to perform a variety of output types and alarms. For example, an instrument with a current output and two relays can be configured to perform any of the following:

1) Current Simplex with two alarm relays;

2) Current Duplex 100% with two alarm relays;

3) Time Simplex with one alarm relay;

4) Time Duplex with no alarm relays; or

5) Three Position Step Control with no alarm relays. These selections may all be made via the keyboard and by wiring to the appropriate output terminals; there are no internal jumpers or switches to change. This flexibility allows a customer to stock a single instrument which is able to handle a variety of applications.

Table 2-5 shows what control types and alarms are available based upon the installed outputs. In this table, when Duplex Control and Reverse Action are configured, “Output 1” is HEAT while “Output 2” is COOL. When Three Position Step Control is configured, “Output 1” is OPEN while “Output 2” is CLOSE. The Output 1/2 option “Single Relay” can be any of the following selections: Electro-Mechanical Relay, Solid-State Relay or Open Collector Output.

Table 2-5 Universal Output Functionality and Restrictions

10 UDC3200 Universal Digital Controller Operator Manual 04/08

Type

Time Simplex

Time Duplex or TPSC or Position Proportional

Current Simplex

Current Dup. 100% Current = COOL

and HEAT

Current Duplex 50%

Current = HEAT Aux Out = COOL

Current/Time Current = COOL Time = HEAT

Time/Current Time = COOL Current = HEAT

Output 1/2

Option

Single Relay Output 1 Alarm 2 Alarm 1 Not Needed Current Output INU Output 1 Alarm 1 Not Needed Dual Relay Output 1 Alarm 2 Alarm 1 Not Needed Single Relay Output 1 Output 2 Alarm 1 Not Needed Current Output INU Output 2 Output 1 Not Needed Dual Relay Outputs 1 and

Single Relay INU Alarm 2 Alarm 1 Output 1 Current Output Output 1 Alarm 2 Alarm 1 Not Needed Dual Relay INU Alarm 2 Alarm 1 Output 1 Single Relay INU Alarm 2 Alarm 1 Outputs 1 and 2 Current Output Outputs 1 and

Dual Relay INU Alarm 2 Alarm 1 Outputs 1 and 2 Single Relay N/A N/A N/A N/A Current Output Output 1 Alarm 2 Alarm 1 Output 2 Dual Relay N/A N/A N/A N/A

Single Relay * Output 1 Output 2 Alarm 1 Output 2 Current Output Output 2 Output 2 Alarm 1 Not Needed Dual Relay * Outputs 1 & 2 Alarm 2 Alarm 1 Output 2 Single Relay * Output 1 Output 2 Alarm 1 Output 1 Current Output Output 1 Output 2 Alarm 1 Not Needed Dual Relay * Outputs 1 & 2 Alarm 2 Alarm 1 Output 1

Function of

Output 1/2

Output #3 Output #4 Auxiliary Output

Alarm 2 Alarm 1 Not Needed

Function of Other Outputs Output Algorithm

TPSC = Three Position Step Control

N/A = Not Available – This output algorithm type cannot be performed with this Output 1/2

option.

INU = I

nstalled, Not Used – The installed Output 1/2 option is not used for the configured

output algorithm type.

Not Needed = Auxiliary Output is Not Needed to provide the desired output algorithm and

can be used for another purpose. With the proper configuration, Auxiliary Output could also be used as a substitute for the Current Output.

* To obtain this output algorithm type with these Output 1/2 Options: 1) Configure the

OUTALG selection as “TIME D”; 2) Configure Auxiliary Output for “OUTPUT” and; 3) Scale the Auxiliary Output as necessary for the desired output algorithm type. For these selections, the Output 1 (HEAT) and Output 2 (COOL) signals will be present both on the Auxiliary Output and on the two relays normally used for Time Duplex.

04/08 UDC3200 Universal Digital Controller Operator Manual 11

Wiring the Controller

L1 L2/N

4 5 6 7 8 9

11 12 13 14 15 16 17

19 20 21 22

23 24 25 26 27

See table for callout details

Figure 2-4 Composite Wiring Diagram

Callout Details

1 AC/DC Line Voltage Terminals. See Figure 2-5. 2 Output 3 Terminals. See Figure 2-8 through Figure 2-14. 3 Output 4 Terminals. See Figure 2-8 through Figure 2-14. 4 Outputs 1 and 2 Terminals. See Figure 2-8 through Figure 2-14. 5 Input #2 Terminals. See Figure 2-7. 6 Input #1 Terminals. See Figure 2-6. 7 Aux. Output and Digital Inputs Terminals. See Figure 2-17. 8 Communications Terminals. See Figure 2-15 and Figure 2-16.

12 UDC3200 Universal Digital Controller Operator Manual 04/08

Earth

C/DC

Line

Voltage

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is

Ground

Hot

Neutral

L2/N

4 5 6

7 8 9

12 13

14 15 16 17

19 20 21 22 23 24 25 26 27

installed, shall be in accordance with National and local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to local ground using a No. 12 (4 mm conductor is recommended. Before powering the controller, see “Prelimnary Checks” in this section of the Product Manual.

It is the user’s responsibility to provide a switch and non-time delay (North America), quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuitbreaker for 90-264 Vac applications; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc applications, as part of the instal lat ion.

) copper

CAUTION

Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely

damage the instrument and is a fire and smoke hazard.

Figure 2-5 Mains Power Supply

04/08 UDC3200 Universal Digital Controller Operator Manual 13

Input #1

Millivolt or Volts

–

Xmitter

RTD

Power

Supply

250

except 0-10 Volts

2627+

–

source

mV or

Volt

source

+ –

Thermocouple Differential

Use Thermocouple

–+

extension wire only

R + –

–

– +

Thermocouple

Use Thermocouple extension wire only

+ –

0-10 Volts Milliamps

25 26

R +

–

100K

0–10

Volt

source

100K

–

The 250 ohm resistor for milliamp inputs or the voltage divider for 0-10 Volt inputs are supplied with the controller when those inputs are specified. These items must be installed prior to start up when the controller is wired. For 0-20 mA applications, the resistor should be located at the transmitter terminals if Burnout detection is desired.

Splice and tape this junction between the two thermocouples. This junction may be located anywhere between the thermocouples and the instrument terminals, it does not need to be close to the other thermocouple junctions. Both thermocouples must be of the same type. For best accuracy, the two thermocouples should be matched or, preferably, made from the same batch of wire.

This controller does not produce a steady current for burnout detection. For that reason, when a thermocouple is used in parallel with another instrument, it may be desirable to configure the burnout selection for this controller to “NOFS” and use the burnout current from the other instrument to also drive this controller.

The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450°F / 232°C.

R +

–

+ –

Figure 2-6 Input 1 Connections

14 UDC3200 Universal Digital Controller Operator Manual 04/08

Input #2

Thermocouple RTD

Use Thermocouple

Use Thermocouple extension wire only

extension wire only

22 23

23 24

+ –

–

Xmitter

–

Power

Supply

250

0-10 Volts Milliamps

100K

0–10

Volt

source

100K

–

Millivolt or Volts

except 0-10 Volts

source

2324+

–

–+

+ –

–

source

mV or

Volt

source

–

Thermocouple Differential

Use Thermocouple

Use Thermocouple extension wire only

extension wire only

+ –

– –

– +

R +

–

22 23

R +

+ –

–

Slidewire Input

(for Position Proportional Control or Three Position Step Control )

Open

Wiper

The 250 ohm resistor for milliamp inputs or the voltage divider for 0-10 Volt inputs are supplied

The 250 ohm resistor for milliamp inputs or the voltage divider for 0-10 Volt inputs are supplied with the controller when those inputs are specified. These items must be installed prior to start

with the controller when those inputs are specified. These items must be installed prior to start

with the controller when those inputs are specified. These items must be installed prior to start up when the controller is wired. For 0-20 mA applications, the resistor should be located at the

up when the controller is wired. For 0-20 mA applications, the resistor should be located at the

up when the controller is wired. For 0-20 mA applications, the resistor should be located at the transmitter terminals if Burnout detection is desired.

transmitter terminals if Burnout detection is desired.

Splice and tape this junction between the two thermocouples. This junction may be located

Splice and tape this junction between the two thermocouples. This junction may be located anywhere between the thermocouples and the instrument terminals, it does not need to be close

anywhere between the thermocouples and the instrument terminals, it does not need to be close

anywhere between the thermocouples and the instrument terminals, it does not need to be close to the other thermocouple junctions. Both thermocouples must be of the same type. For best

to the other thermocouple junctions. Both thermocouples must be of the same type. For best

to the other thermocouple junctions. Both thermocouples must be of the same type. For best accuracy, the two thermocouples should be matched or, preferably, made from the same batch

accuracy, the two thermocouples should be matched or, preferably, made from the same batch

accuracy, the two thermocouples should be matched or, preferably, made from the same batch of wire.

of wire.

This controller does not produce a steady current for burnout detection. For that reason, when a

thermocouple is used in parallel with another instrument, it may be desirable to configure the

thermocouple is used in parallel with another instrument, it may be desirable to configure the burnout selection for this controller to “NOFS” and use the burnout current from the other

burnout selection for this controller to “NOFS” and use the burnout current from the other

burnout selection for this controller to “NOFS” and use the burnout current from the other instrument to also drive this controller.

instrument to also drive this controller.

Input 2 is used to measure the Slidewire Input for Position Proportional Control.

22 2324+

2324+

–

xxxx

Figure 2-7 Input 2 Connections

04/08 UDC3200 Universal Digital Controller Operator Manual 15

Load Supply Power

Time Simplex

Output

Relay#1

L2/N

Relay Load

To terminal

4 or 6

4 5 6 7

Relay Load

To terminal

7 or 9

8 9

N.C. N.O.

Time Duplex

N.C.

N.O.

larm

Relay#2

larm

Relay#1

20 21 22 23 24 25 26 27

Relay Load

To terminal

19 or 21

Load Supply Power

Output

Relay#1

L2/N

Relay Load

To terminal

4 or 6

4 5 6 7

Relay Load

To terminal

7 or 9

8 9

N.C. N.O.

N.C.

N.O.

Output Relay#2

larm

Relay#1

20 21 22 23 24 25 26 27

Relay Load

To terminal

19 or 21

Load Supply

Power

larm #2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay Option is used.

Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc.

Customer should size fuses accordingly. Us e Fast Blo fuses only.

Figure 2-8 Electromechanical Relay Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

16 UDC3200 Universal Digital Controller Operator Manual 04/08

Load Supply Power

Relay Load

To terminal

4 or 6

Relay Load

To terminal

7 or 9

Dummy Resistor

Relay Load

To terminal

7 or 9

Time Simplex

Dummy Resisto r

Output

Relay#1

L2/N 4 5

6 7 8

N.C. N.O.

larm

Relay#2

larm

Relay#1

N.O.

20 21 22 23 24 25 26 27

Relay Load

Load Supply

Power

Time Duplex

L2/N 4 5

Output

Relay#1

Output Relay#2

N.O.

6 7 8

N.C. N.O.

larm

Relay#1

N.O.

20 21 22 23 24 25 26 27

Dummy Resisto r

Relay Load

Load Supply

Power

If the load current is less than the minimum rated value of 20 mA, then there may be residual voltage across both

ends of the load even if the relay is turned off. Use a dummy resistor as shown to counteract this. The total current through the resistor and the the load must exceed 20 mA. Solid State Relays are zero-crossing type.

Solid State relays are rated at 1 Amp at 25°C and derated linearly to 0.5 Amp at 55°C. Customer should size

fuse accordingly. Use Fast Blo fuses only.

Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc.

Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-9 Solid State Relay Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

04/08 UDC3200 Universal Digital Controller Operator Manual 17

Load

Supply Power

Load

Supply Power

Customer Supplied Electromechanical relay

–

Load

Supply Power

Relay Load

To terminal

4 or 6

Relay Load

To terminal

7 or 9

Customer Supplied Solid-State relay

Relay Load

To terminal

7 or 9

Time Simplex

Customer Supplied

–

larm

20 21 22 23

–

Customer Supplied Solid-State relay

24 25

26 27

Output #1

L2/N 4 5 6 7 8 9

N.C. N.O.

Relay#2

larm

Relay#1

Time Duplex

Output #1

L2/N 4

+ –

5 6 7 8 9

Output #2

–

N.C. N.O.

larm

Relay#1

–

21 22 23 24 25 26 27

–

Customer Supplied Solid-State relay

Electromechanical relay

–

Customer Supplied Electromechanical relay

–

CAUTION

larm #2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay option is used.

Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.

Open collector outputs are internally powered at +30 Vdc. Connecting an external power supply will damage the controller.

Figure 2-10 Open Collector Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

18 UDC3200 Universal Digital Controller Operator Manual 04/08

Load

Relay Load

Supply Power

Load

Relay Load

Supply Power

Dual Electromechanical relays are rated at 2 Amps @120 Vac or 240 Vac or 30 Vdc. Customer should size

fuses accordingly. Use Fast Blo fuses only. Electromechanical relays are rated at 5 Amps @120 Vac or 240 Vac or 30 Vdc.

Customer should size fuses accordingly. Use Fast Blo fuses only.

Time Duplex with a Dual Relay Board

larm

N.O.

19 20 21

22 23 24 25 26 27

To terminal

4 or 6

To terminal

7 or 9

Out Relay#2

Out Relay#1

L2/N 4 5 6 7 8

N.C.

Relay#2

N.O.

N.C.

larm

Relay#1

N.O.

Figure 2-11 Dual Electromechanical Relay Option Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

Cool Relay Load

Heat Relay Load

Load Supply

Power

Current Output

4–20 mA

larm

20 21 22 23 24 25 26 27

L2/N

Load Supply Power

Relay Load

To terminal

4 or 6

5 6

Load

Supply Power

When the instrument has the Current Output as shown, no Alarms are available when using the Time Proportional Duplex or Three Position Step Control Output Algorithms, as these outputs require both available relays.

Electromechanical relays are rated at 5 Amps @120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly. Use Fast Blo fuses only.

Relay Load

To terminal

7 or 9

8 9

N.C.

Relay#2

N.O.

N.C. N.O.

larm

Relay#1

–

Figure 2-12 Current Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

Controller Load

0-1000 ohms

04/08 UDC3200 Universal Digital Controller Operator Manual 19

Figure 2-13 Position Proportional or Three Position Step Control

Connection, Models DC3200-EE or DC3200-AA

Figure 2-14 Position Proportional or Three Position Step Control

Connections, Model DC3200-R_

20 UDC3200 Universal Digital Controller Operator Manual 04/08

16 SHLD

17 D+ (B) 18 D– (A)

SHLD

D+

D–

COMMUNICATION MASTER

D+ (B)

SHLD D– (A)

120 OHMS

Connect shield

TO OTHER

COMMUNICATION

CONTROLLERS

D+D–

120 OHMS ON LAS T LEG

Do not run the communications lines in the same conduit as AC power.

Use shielded twisted pair cables (Belden 9271 Twinax or equivalent).

to ground at one end only.

Figure 2-15 RS-422/485 Communications Option Connections

COMMUNICATION MASTER

OR SWITCH

TXD+ TXD-

RXD–

TXD+ TXD-

RXD–

RXD-

TXD+

RXD-

TXD+

RXD+SHLD

TXD–SHLD

RXD+SHLD

TXD–SHLD

14 SHLD

14 SHLD 15 RXD +

15 RXD +

15 RXD+

–

16 RXD

16 RXD-

17 TXD +

17 TXD+

–

18 TXD-

18 TXD

Do not run the communications lines in the same conduit as AC

power. Correct connections may require the use of an Ethernet

power. Correct connections may require the use of an Ethernet cross-over cable.

cross-over cable.

cross-over cable. Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.

Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.

Use Switch rather than Hub to maximize performance.

RXD

333

Figure 2-16 Ethernet Communications Option Connections

Figure 2-16 and Table 2-6 shows how to connect a UDC to a MDI Compliant Hub or

Switch utilizing a straight-through cable or for connecting a UDC to a PC utilizing a crossover cable.

04/08 UDC3200 Universal Digital Controller Operator Manual 21

Table 2-6 Terminals for connecting a UDC to a MDI Compliant Hub or Switch

UDC Terminal UDC Signal Name RJ45 Socket Pin # Switch Signal

Name

Position 14 Shield Shield Shield

Position 15 RXD- 6 TXD-

Position 16 RXD+ 3 TXD+

Position 17 TXD- 2 RXD-

Position 18 TXD+ 1 RXD+

Table 2-7 shows how to connect a UDC directly to a PC utilizing a straight-through cable (wiring the UDC cable this way makes the necessary cross-over connections)

Table 2-7 Terminals for connecting a UDC directly to a PC utilizing a straight-

through cable

UDC Terminal UDC Signal Name RJ45 Socket Pin # PC Signal Name

Position 14 Shield Shield Shield

Position 15 RXD- 2 TXD-

Position 16 RXD+ 1 TXD+

Position 17 TXD- 6 RXD-

Position 18 TXD+ 3 RXD+

Digital

Input #1

Digital

Input #2

12 13

Auxiliary Output

Connect shield to ground at one end only.

uxiliary

Load

0 - 1000

10 11 12 13

Digital Inputs

Connect shield to ground at one end only.

uxiliary Output and Digital Input 2 are mutually exclusive.

Figure 2-17 Auxiliary Output and Digital Inputs Option Connections

22 UDC3200 Universal Digital Controller Operator Manual 04/08

2 Wire Transmitter

5 +

250

6 -

If necessary, install a zener diode here to reduce voltage at the

transmitter. A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc.

Configure:

2S1TY = NONE 2S2TY = NONE

26 + 27 -

INPUT 1OUTPUT 3

Figure 2-18 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open

Collector Alarm 2 Output

2 Wire Transmitter

Configure:

AUXOUT = OUT

uxiliary Output Calibration

250

12 +

13 -

UXILIARY OUTPUT

If necessary, install a zener diode here to reduce voltage at the

transmitter. A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc.

ZEROVAL = 16383 SPANVAL = 16383

26 + 27 -

INPUT 1

Figure 2-19 Transmitter Power for 4-20 mA — 2 Wire Transmitter

Using Auxiliary Output

04/08 UDC3200 Universal Digital Controller Operator Manual 23

3 Configuration

3.1 Configuration Prompt Hierarchy

Set Up Group

TUNING

PROP BD or

GAIN

CYC SEC or

CYC SX3

GAINVALn RATE MIN RSET MIN or

CYC2 SEC or

CYC2 SX3

SECURITY LOCKOUT AUTO MAN SP SEL RUN HOLD

Function Prompts

RSET RPM

MAN RSET PROPBD2 or

GAIN 2

RATE2MIN RSET2MIN

RSET2RPM

SPRAMP

ACCUTUNE

ALGORTHM

OUT ALG

INPUT1

INPUT2

CONTRL

SP RAMP TIME MIN FINAL SP SP RATE EU/HR UP EU/HR DN EUHRUP2 EUHRDN2 SP PROG STRT SEG END SEG RAMPUNIT RECYCLES SOAK DEV PROG END STATE

KEYRESET HOTSTART SEGxRAMP

FUZZY ACCUTUNE DUPLEX AT ERROR

CONT ALG TIMER PERIOD START LOW DISP INP ALG1 MATH K CALC HI

CALC LO ALG1 INA ALG1 INB ALG1 INC PCT CO PCT H2 ALG1BIAS

OUT ALG RLYSTATE RLY TYPE CUR OUT LOW VAL HIGH VAL CO RANGE MOTOR TI

IN1 TYPE XMITTER1 IN1 HIGH IN1 LOW RATIO 1 BIAS IN1 FILTER 1 BURNOUT1

EMISSIV1

IN2 TYPE XMITTER2 IN2 HIGH IN2 LOW RATIO 2 BIAS IN2 FILTER 2 BURNOUT2

EMISSIV2

PV SOURC PID SETS SW VALUE LSP'S RSP SRC AUTOBIAS SP TRACK PWR MODE

PWR OUT SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP PCT/M DN OUTHiLIM

OUTLoLIM I Hi LIM I Lo LIM DROPOFF DEADBAND OUT HYST FAILSAFE FAILMODE

MAN OUT AUTO OUT PBorGAIN MINorRPM

SEGxRATE

SEGx SP*

* x = 1 to 12. Program concludes after segment 12

OPTIONS

COM

ALARMS

DISPLAY

CALIB

AUX OUT LOW VAL HIGH VAL CORANGE DIG1 INP DIG1 COM DIG2 INP DIG2 COM

Com ADDR ComSTATE IR ENABLE BAUD TX DELAY WSFLOAT SHEDENAB SHEDTIME

SHEDMODE SHEDSP UNITS CSP RATO CSP BIAS LOOPBACK

A1S1TYPE A1S1 VAL A1S1 H L A1S1 EV A1S2 TYPE A1S2 VAL A1S2 H L A1S2 EV A2S1TYPE A2S1 VAL A2S1 H L A2S1 EV A2S2TYPE A2S2 VAL A2S2 H L A2S2 EV

AL HYST ALM OUT1 BLOCK DIAGNOST

DECIMAL TEMPUNIT PWR FREQ RATIO 2 LANGUAGE

USED FOR FIELD CALIBRATION

24 UDC3200 Universal Digital Controller Operator Manual 04/08

3.2 Configuration Procedure

Introduction

Each of the Set Up groups and their functions are pre-configured at the factory. If you want to change any of these selections or values, follow the procedure in Table 3-1. This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt.

Procedure

ATTENTION

The prompting scrolls at a rate of 2/3 seconds when the SET UP or FUNCTION key is held in. Also,

Step Operation Press Result

Select any Set

Select a Function

Enter the Value

Exit Configuration

or keys will move group prompts forward or backward at a rate twice as fast.

Table 3-1 Configuration Procedure

Enter Set Up

Mode

Up Group

Parameter

Change the

Value or

Selection

or Selection

SetupSetup

FunctionFunctionFunction

Lower

Display

Upper Display = SETUP Lower Display = TUNING (This is the first Set Up Group title)

Sequentially displays the other Set Up group titles. You can also use the

directions. Stop at the Set Up group title that describes the group of parameters you want to configure. Then proceed to the next step.

Upper Display = the current value or selection for the first function

Lower Display = the first Function prompt within that Set Up group.

Sequentially displays the other function prompts of the Set Up group you have selected. Stop at the function prompt that you want to change, then proceed to the next step.

Increments or decrements the value or selection that appears for the selected function prompt. If you change the value or selection of a parameter while in Set Up mode but then decide not to enter it, press the configuration. This “recall” procedure does not work for a Field Calibration process. Field Calibration is a one-way operation.

Enters value or selection made into memory after another key is pressed.

Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made. If you do not press any keys for 30 seconds, the controller times out and reverts to the mode and associated display used prior to entry into Set Up mode.

or keys to scan the Set Up groups in both

prompt of the selected Set Up group.

MAN/AUTO key once. This will recall the original

04/08 UDC3200 Universal Digital Controller Operator Manual 25

3.3 Tuning Set Up Group

Function

Prompt

Lower Display

PROP BD

GAIN

RATE MIN

Selections or

Range of Setting

Upper Display

0.1 to 9999 % or

0.001 to 1000

0.00 to 10.00 minutes

Parameter Definition

PROPORTIONAL BAND (simplex) is the percent of the range of

the measured variable for which a proportional controller will produce a 100 % change in its output.

GAIN is the ratio of output change (%) over the measured variable change (%) that caused it.

G = 100 / %PB where PB is the proportional band(in %) If the PB is 20 %, then the Gain is 5. And, at those settings, a 3 %

change in the error signal (SP-PV) will result in a 15 % change in the controller's output due to proportional action. If the Gain is 2, then the PB is 50 %.

Also defined as "HEAT" Gain on Duplex models for variations of Heat/Cool applications.

The selection of Proportional Band or Gain is made in the CONTROL parameter group under prompt PBorGAIN.

RATE action, in minutes, affects the controller's output whenever the deviation is changing; and affects it more when the deviation is changing faster.

RSET MIN

RSET RPM

MAN RSET

PROPBD2

GAIN 2

0.02 to 50.00

–100 to +100

(in % output)

0.1 to 9999 % or

0.001 to 1000

RSET MIN = Reset in Minutes per Repeat RSET RPM = Reset in Repeats per Minute

RESET (or Integral Time) adjusts the controller's output in

accordance with both the size of the deviation (SP–PV) and the time that it lasts. The amount of the corrective action depends on the value of Gain. The Reset adjustment is measured as how many times proportional action is repeated per minute or how many minutes before one repeat of the proportional action occurs.

Used with control algorithm PID-A or PID-B. Also defined as "HEAT" Reset on Duplex models for variations of Heat/Cool applications.

ATTENTION The selection of whether Minutes per Repeat or Repeats per Minute is used is made in the CONTROL parameters group under the prompt MINorRPM.

MANUAL RESET is only applicable if you use control algorithm PD WITH MANUAL RESET in the Algorithm Set Up group. Because a proportional controller will not necessarily line out at setpoint, there will be a deviation (offset) from setpoint. This eliminates the offset and lets the PV line out at setpoint.

ATTENTION Bias is shown on the lower display. PROPORTIONAL BAND 2 or GAIN 2, RATE 2, and RESET 2

parameters are the same as previously described for “Heat” except that they refer to the cool zone tuning constants on duplex models or the second set of PID constants, whichever is pertinent.

RATE2MIN

26 UDC3200 Universal Digital Controller Operator Manual 04/08

0.00 to 10.00 minutes

This is the same as above except that it applies to Duplex models for the "COOL" zone of Heat/Cool applications or for the second set of PID constants.

Function

Prompt

Lower Display

RSET2MIN

RSET2RPM

CYC SEC

CYC SX3

CYC2 SEC

CYC2 SX3

Selections or

Parameter Definition

Range of Setting

Upper Display

0.02 to 50.00 These are the same as above except that they apply to Duplex

models for the "COOL" zone of Heat/Cool applications or for the second set of PID constants.

1 to 120

CYCLE TIME (HEAT) determines the length of one time proportional output relay cycle. Defined as "HEAT" cycle time for Heat/Cool applications.

CYC SEC—Electromechanical relays CYC SX3—Solid state relays

ATTENTION Cycle times are in either second or 1/3-second

increments depending upon the configuration of RLY TYPE in the Output Algorithm Set Up group.

1 to 120

CYCLE TIME 2 (COOL) is the same as above except it applies to Duplex models as the cycle time in the "COOL" zone of Heat/Cool applications or for the second set of PID constants.

CYC2 SEC—Electromechanical relays CYC2 SX3—Solid state relays

ATTENTION Cycle times are in either second or 1/3-second

increments depending upon the configuration of RLY TYPE in the Output Algorithm Set Up group.

SECURITY

LOCKOUT

0 to 9999

NONE CALIB

+ CONF

+ VIEW

MAX

SECURITY CODE—The level of keyboard lockout may be changed in the Set Up mode. Knowledge of a security code may be required to change from one level to another. This configuration should be copied and kept in a secure location.

NOTE: The Security Code is for keyboard entry only and is not available via communications.

ATTENTION Can only be changed if LOCKOUT selection is NONE.

LOCKOUT applies to one of the functional groups: Configuration, Calibration, Tuning, Accutune. DO NOT CONFIGURE UNTIL ALL

CONFIGURATION IS COMPLETE. NONE—No lockout; all groups are read/write. CALIB—All groups are available for read/write except for the

Calibration and Keyboard Lockout groups. + CONF—Tuning, SP Ramp, and Accutune groups are read/write.

All other groups are read only. Calibration and Keyboard Lockout groups are not available.

+ VIEW—Tuning and Setpoint Ramp parameters are read/write. No other parameters are viewable.

MAX—Tuning and Setpoint Ramp parameters are available for read only. No other parameters are viewable.

04/08 UDC3200 Universal Digital Controller Operator Manual 27

Function

Prompt

Lower Display

AUTO MAN

RUN HOLD

SP SEL

Selections or

Range of Setting

Upper Display

DISABLE

ENABLE

DISABLE

ENABLE

DISABLE

ENABLE

Parameter Definition

MANUAL/AUTO KEY LOCKOUT—Allows you to disable the

Manual/Auto key

DISABLE ENABLE

ATTENTION Can only be viewed if LOCKOUT is configured for

NONE.

RUN/HOLD KEY LOCKOUT—Allows you to disable the Run/Hold key, for either SP Ramp or SP Program. The Run/Hold key is never disabled when used to acknowledge a latched alarm 1

DISABLE ENABLE

ATTENTION Can only be viewed if LOCKOUT is configured for

NONE.

SETPOINT SELECT KEY LOCKOUT—Allows you to disable the Setpoint Select key

DISABLE ENABLE

ATTENTION Can only be viewed if LOCKOUT is configured for

NONE.

28 UDC3200 Universal Digital Controller Operator Manual 04/08

3.4 SP Ramp Set Up Group

Function

Prompt

Lower Display

SP RAMP

SP Program must be disabled for SP Ramp prompts to appear

TIME MIN

FINAL SP

Selections or

Range of Setting

Upper Display

DISABLE ENABLE

0 to 255 minutes

Within setpoint limits

Parameter Definition

SINGLE SETPOINT RAMP—Make a selection to enable or disable

the setpoint ramp function. Make sure you configure a ramp time and a final setpoint value.

SP Programming must be disabled.

DISABLE SETPOINT RAMP—Disables the setpoint ramp option. ENABLE SETPOINT RAMP—Allows the single setpoint ramp

prompts to be shown. SETPOINT RAMP TIME—Enter the number of minutes desired to

reach the final setpoint. A ramp time of “0” implies an immediate change of setpoint.

SETPOINT RAMP FINAL SETPOINT—Enter the value desired for the final setpoint. The controller will operate at the setpoint set here when ramp is ended.

ATTENTION If the ramp is on HOLD, the held setpoint can be changed by the ▲ and ▼ keys. However, the ramp time remaining and original ramp rate is not changed. Therefore, when returning to RUN mode, the setpoint will ramp at the same rate as previous to the local setpoint change and will stop if the final setpoint is reached before the time expires. If the time expires before the final setpoint is reached, it will jump to the final setpoint.

HOTSTART

SP RATE

EU/HR UP

DISABLE ENABLE

0 to 9999 in engineering units per hour

ATTENTION SP RAMP and SP RATE will cause the SP portion of Accutune to abort. PV Tune will continue to function normally. Ramp is placed into HOLD while tuning (TUNE configuration).

DISABLE—LSP1 is used as the initial ramp setpoint. ENABLE—Current PV value is used as the initial ramp setpoint.

SETPOINT RATE—Lets you configure a specific rate of change for

any local setpoint change.

DISABLE SETPOINT RATE—Disables the setpoint rate option. ENABLE SETPOINT RATE—Allows the SP rate feature.

SP Rate operates only when both SP Ramp and SP Programing are in HOLD mode or when both SP Ramp and SP Programming are disabled.

RATE UP—Rate up value. When making a setpoint change, this is the rate at which the controller will change from the original setpoint up to the new one. The ramping (current) setpoint can be viewed as SPn in the lower display.

Entering a 0 will imply an immediate step change in Setpoint (i.e., no rate applies).

04/08 UDC3200 Universal Digital Controller Operator Manual 29

Function

Prompt

Lower Display

EU/HR DN

SP PROG

(optional

feature)

STRT SEG

END SEG

RAMPUNIT

Selections or

Range of Setting

Upper Display

0 to 9999 in engineering units per hour

RATE DOWN—Rate down value. When making a setpoint change, this is the rate at which the controller will change from the original setpoint down to the new one. The ramping (current) setpoint can be viewed as SPn in the lower display.

Entering a 0 will imply an immediate step change in Setpoint (i.e., no rate applies).

DISABLE ENABLE

SETPOINT RAMP/SOAK PROGRAM—Available only with controllers that contain this option.

SP RAMP must be disabled.

DISABLE—Disables setpoint programming. ENABLE—Enables setpoint programming.

SP Ramp must be disabled for SP Program prompts to appear. If SP Rate is enabled, it does not operate while an SP Program is running

1 to 11 Start Segment Number 2 to 12 even

End Segment Number, always end in a soak segment (2, 4, ... 12)

numbers

TIME EU/MIN EU/HR

RAMPUNIT—Engineering Units for Ramp Segments TIME in hours: minutes

RATE in Enineering units per minute RATE in Enineering units per hour

Parameter Definition

RECYCLES SOAK DEV

PROG END

STATE

KEYRESET

HOTSTART

SEG1RAMP or

SEG1RATE

SEG2 SP

0 to 99 recycles Number of Program Recycles 0 to 99

Guaranteed Soak Deviation Value The number selected will be the PV value (in engineering units) above or below the setpoint outside of which the timer halts.

LASTSP F SAFE

DISABLE

Program Termination State Hold at last setpoint in the program Manual mode/Failsafe output

Program State at Program End

HOLD DISABLE

Reset/Rerun SP Program ToBEGIN RERUN

DISABLE

Hot Start ENABLE

0-99 hours.0-59 minutes

Segment #1 Ramp Time or

Segment #1 Ramp Rate Engineering units/minute or Engineering

Select TIME, EU/MIN, or EU/HR at prompt RAMPUNIT. All

ramps will use the same selection.

units/hour Within the Setpoint

Segment #2 Soak Setpoint Value limits

30 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

SEG2TIME

SEG3RAMP or

SEG3RATE

SEG4 SP

SEG4TIME

SEG5RAMP or

SEG5RATE

SEG6 SP

SEG6TIME

SEG7RAMP or

SEG7RATE

SEG8 SP

SEG8TIME

SEG9RAMP or

SEG9RATE

SG10 SP

SG10TIME

SG11RAMP or

SG11RATE

SG12 SP

SG12TIME

Selections or

Range of Setting

Upper Display

0-99 hours.0-59 minutes

Selections are same as above.

Parameter Definition

Segment #2 Soak Duration

Same as above

04/08 UDC3200 Universal Digital Controller Operator Manual 31

3.5 Accutune Set Up Group

Function

Prompt

Lower Display

FUZZY

ACCUTUNE

DISABLE

DUPLEX

This prompt

only appears

when a Duplex

Control

Algorithm has

been

configured

Selections or

Range of Setting

Upper Display

DISABLE ENABLE

TUNE

MANUAL

AUTO

Parameter Definition

FUZZY OVERSHOOT SUPPRESSION—Can be enabled or

disabled independently of whether Demand Tuning or SP Tuning is

enabled or disabled.

DISABLE—Disables Fuzzy Overshoot Suppression.

ENABLE—The instrument uses Fuzzy Logic to suppress or

minimize any overshoot that may occur when PV approaches SP. It

will not recalculate any new tuning parameters.

ACCUTUNE III

DISABLE —Disables the Accutune function.

DEMAND TUNING—If TUNE is selected, and tuning is initiated

through the operator interface or digital input (if configured), the

algorithm calculates new tuning parameters and enters them into

the tuning group. This tuning requires no process knowledge and

does not require line out for initialization.

DUPLEX ACCUTUNING III – These prompts only appear when a

duplex output type has been configured.

MANUAL – Tune manually using LSP 1 and LSP 2 values. LSP 1

is used to derive tuning parameters associated with HEAT (output

> 50 %). LSP 2 is used to derive tuning parameters associated

with COOL (output < 50 %).

AUTOMATIC – Tuning is performed automatically on both HEAT

and COOL sequentially. LSP 1 is used for HEAT tuning and LSP 2

is used for COOL tuning. To initiate tuning, either LSP 1 or LSP 2

must be in use.

AT ERROR (Read Only)

DISABLE

NONE RUNNING

ABORT

SP2

DISABLE – The current SetPoint is used to derive a single set of

blended tuning parameters. This tuning is performed over the

range of the output limits similar to Simplex Tuning. The Tuning

Parameters derived are placed into both the HEAT and COOL tune

sets (PID 1 and PID 2).

ACCUTUNE ERROR STATUS—When an error is detected in the

Accutune process, an error prompt will appear.

NONE—No errors occurred during last Accutune procedure.

RUNNING—An Accutune process is still active checking process

gain, even though “T” is not lit. It does not affect keyboard

operation.

CURRENT ACCUTUNE PROCESS ABORTED—Caused by one

of the following conditions: changing to manual mode, digital input

detected, in heat region of output but a cool output was calculated,

or vice versa.

SP2—LSP2 not configured or a Setpoint other than LSP1 or LSP2

is in use.

32 UDC3200 Universal Digital Controller Operator Manual 04/08

3.6 Algorithm Set Up Group

Function

Prompt

Lower Display

CONT ALG

Selections or

Range of Setting

Upper Display

ON-OFF

Parameter Definition

The CONTROL ALGORITHM lets you select the type of control

that is best for your process.

ON/OFF is the simplest control type. The output can be either ON

(100 %) or OFF (0 %). The Process Variable (PV) is compared with

the setpoint (SP) to determine the sign of the error (ERROR = PV–

SP). The ON/OFF algorithm operates on the sign of the error

signal.

In Direct Acting Control, when the error signal is positive, the

output is 100 %; and when the error signal is negative, the output is

0 %. If the control action is reverse, the opposite is true. An

adjustable overlap (Hysteresis Band) is provided between the on

and off states.

ATTENTION Other prompts affected: OUT HYST

DUPLEX ON/OFF is an extension of this algorithm when the output

is configured for a Duplex control algorithm. It allows the operation

of a second ON/OFF output. There is a deadband between the

operating ranges of the two inputs and an adjustable overlap

(hysteresis) of the on and off states of each output. Both Deadband

and Hysteresis are separately adjustable. With no relay action the

controller will read 50 %.

ATTENTION Other prompts affected: OUT HYST and

DEADBAND

PID A ATTENTION

PID A should not be used for Proportional only action; i.e., no integral (reset) action. Instead, use PD+MR with rate set to 0.

PID B

PID A is normally used for three-mode control. This means that the

output can be adjusted somewhere between 100 % and 0 %. It

applies all three control actions—Proportional (P), Integral (I), and

Derivative (D)—to the error signal.

Proportional (Gain)

proportion to the error signal (the difference between Process

Variable and Setpoint).

Integral (Reset

the error and the time the error has existed. (The amount of

corrective action depends on the value of proportional Gain.)

Derivative (Rate)

to the rate of change of the error. (The amount of corrective action

depends on the value of proportional Gain.)

PID B—Unlike the PID A equation, the controller gives only an

integral response to a setpoint change, with no effect on the output

due to the gain or rate action, and it gives full response to PV

changes. Otherwise controller action is as described for the PID A

equation. See note on PID A.

—Regulates the controller’s output in

)—Regulates the controller’s output to the size of

—Regulates the controller’s output in proportion

04/08 UDC3200 Universal Digital Controller Operator Manual 33

Function

Prompt

Lower Display

CONT ALG (continued)

Selections or

Range of Setting

Upper Display

PD+MR

3PSTEP

Parameter Definition

PD WITH MANUAL RESET is used whenever integral action is not

wanted for automatic control. The equation is computed with no

integral contribution. The MANUAL RESET, which is operator

adjustable, is then added to the present output to form the

controller output.

Switching between manual and automatic mode will be bumpless.

If you select PD with Manual Reset you can also configure the

following variations:

• PD (Two Mode) control,

• P (Single Mode) control.

Set Rate (D) to 0.

ATTENTION Other prompts affected: MAN RSET in the Tuning

Set Up group

THREE POSITION STEP—The Three Position Step Control

algorithm allows the control of a valve (or other actuator) with an

electric motor driven by two controller relay outputs; one to move

the motor upscale, the other downscale without a feedback

slidewire linked to the motor shaft. The deadband is adjustable in

the same manner as the duplex output algorithm.

TIMER

DISABLE ENABLE

The Three Position Step Control algorithm provides an output

display (OUT) which is an estimated motor position, since the

motor is not using any slidewire feedback. Although this output

indication is only an approximation, it is “corrected” each time the

controller drives the motor to one of its stops (0 % or 100 %). It

avoids all the control problems associated with the feedback

slidewire (wear, dirt, noise). When operating in this algorithm, the

estimated OUT display is shown to the nearest percent (i.e., no

decimal). This selection forces the Output Algorithm selection to

“POSITON”.

Refer to the Operation section for motor position displays.

As a customer configurable option, when a second input board is

installed, the motor slidewire can be connected to the controller.

The actual slidewire position is then shown on the lower display as

POS. This value is used for display only. It is NOT used in the

Three Position Step algorithm. To configure this option, set Input

2 actuation to SLIDEW and then calibrate Input 2.

ATTENTION Other prompts affected: DEADBAND

TIMER allows you to enable or disable the timer option.

The timer option allows you to configure a timeout period and to

select timer start by either the keyboard (RUN/HOLD key) or Alarm

2. A digital input can also be configured to start the timer.

When the timer is enabled, it has exclusive control of the alarm 1

relay; any previous alarm configuration is ignored. At timeout, the

timer is ready to be re-activated by whatever action has been

configured. Alarm 1 is activated at the end of the timeout period.

34 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

PERIOD

Selections or

Range of Setting

Upper Display

0:00 to 99:59

Parameter Definition

PERIOD allows you to configure the length of timeout period (from

0 to 99 hours: 59 minutes).

START

LOW DISP

KEY ALARM 2

TI REM E TIME

START allows you to select whether the timer starts with the

keyboard (Run/Hold key) or Alarm 2.

LOW DISP allows you to select whether time remaining (TI REM)

or elapsed time (E TIME) is displayed for the timer option.

The time is shown on the lower display in HH:MM format along with

a rotating “clock” character.

• If the “clock” rotation is clockwise, elapsed time is indicated.

• If the “clock” rotation is counterclockwise, time remaining is indicated.

INPUT MATH ALGORITHMS—Controllers with two inputs are provided with one input algorithm. Unless otherwise noted, these selections are provided only as part of the Math Options package. Each algorithm can be configured to provide a derived (calculated) PV or a derived Remote Setpoint. Up to three inputs may be applied to the calculation. See Inputs A, B, and C for definitions per equation.

All algorithms operate in engineering units except Feedforward (F FWRD) which operates in percent of output units.

ATTENTION When the Input C configuration is set to NONE, the value of Input C used in the functions is automatically set to 1.0, except for the Summer algorithm, where it is set to 0.0.

INP ALG1

INPUT ALGORITHM 1 has the following selections from which to

choose:

NONE W AVG

(See Note 2) (Standard feature

NONE—No algorithm configured WEIGHTED AVERAGE—When you configure for Weighted

Average, the controller will compute a PV or SP for the control algorithm from the following equation:

on controllers with two analog inputs)

Alg1 = [(InpA x Ratio A + Bias A) + (K x InpB x Ratio B + Bias B)] / (1 + K)] + Alg1Bias F FWRD (Standard feature

on controllers with two analog inputs)

FEEDFORWARD SUMMER—Feedforward uses Input A, following a Ratio and Bias calculation as a value summed directly with the PID computed output value and sent, as an output value, to the final control element.

This algorithm will only function in automatic mode and is not used for Three Position Step Control applications.

The following formula applies:

Controller Output = PID Output + (Input A x Ratio A + Bias A ) x (100 / Input A Range) FFWDMu

(Standard feature on controllers with two analog inputs)

FEEDFORWARD MULTIPLIER—Feedforward uses Input A, following a Ratio and Bias calculation as a value multiplied directly with the PID computed output value and sent, as an output value, to the final control element.

This algorithm will only function in automatic mode and cannot be used for Three Position Step Control applications.

The following formula applies:

04/08 UDC3200 Universal Digital Controller Operator Manual 35

Controller Output = PID Output x (Input A x Ratio A + Bias A ) / Input A Range

Function

Prompt

Lower Display

Selections or

Range of Setting

Upper Display

SUMMER (See Note 2)

Parameter Definition

SUMMER WITH RATIO AND BIAS—The following formula

applies:

Alg1=(InpAxRatioA+BiasA)+(InpBxRatioB+BiasB)+(InpCxRatioC+BiasC)+Alg1Bias

HI SEL (See Note 2)

INPUT HIGH SELECT WITH RATIO AND BIAS—This selection specifies the PV or SP as the higher of Input 1 or Input 2. The following formula applies:

Alg1 = higher of (Input A x Ratio A + Bias A) or (Input B x Ratio B + Bias B)

LO SEL (See Note 2)

INPUT LOW SELECT WITH RATIO AND BIAS—This selection specifies the PV or SP as the lower of Input 1 or Input 2. The following formula applies:

√MuDIV (See Note 1)

Alg1 = lower of (Input A x Ratio A + Bias A) or (Input B x Ratio B + Bias B)

MULTIPLIER DIVIDER WITH SQUARE ROOT—The following formula applies:

Alg1=K*SqRt{(InpAxRatioA+BiasA)x(InpCxRatioC+BiasC)/(InpB*RatioB+BiasB)}

x (CalcHi-CalcLo)+Alg1Bias

√MULT (See Note 1)

MULTIPLIER WITH SQUARE ROOT—The following formula applies:

Alg1 =K x Sq.Rt.{(InputA x Ratio A + Bias A) x (InputB x Ratio B + Bias B) x (InputC x Ratio C + Bias C)}

x (Calc Hi – Calc Lo) + Alg1Bias

MuDIV

MULTIPLIER DIVIDER—The following formula applies:

(See Note 1)

Alg1 = K x [{(Input A x Ratio A + Bias A) x (Input C x Ratio C + Bias C)} / (Input B x Ratio B + Bias B)]

x (Calc Hi – Calc Lo) + Alg1Bias

MULT

MULTIPLIER—The following formula applies:

(See Note 1)

Alg1 = K x [(Input A x Ratio A + Bias A) x (Input C x Ratio C + Bias C) x (Input B x Ratio B + Bias B)]

x (Calc Hi – Calc Lo) + Alg1Bias

CARB A

CARBON POTENTIAL A—Make this selection if you have a Cambridge or Marathon monitor type Zirconium Oxide sensor. See Note 3.

CARB B

CARBON POTENTIAL B—Make this selection if you have a Corning type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1380 to 2000°F. See Note

CARB C

CARBON POTENTIAL C—Make this selection if you have an A.A.C.C. type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1380 °F to 2000 °F. See Note 3.

CARB D

CARBON POTENTIAL D—Make this selection if you have a Barber Coleman, MacDhui, or Bricesco type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1380 to 2000°F. See Note 3.

36 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

Selections or

Range of Setting

Upper Display

FCC

Parameter Definition

CARBON POTENTIAL FCC—Make this selection if you have a

Furnace Controls Corp Accucarb type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1380 °F to 2000 °F. See Note 3.

DEW PT

DEWPOINT OF CARBONIZING ATMOSPHERE—Use this selection if you are using any Zirconium Oxide Carbon Probe and you want to measure the atmosphere in terms of Dewpoint. The range is –50 °F to 100 °F or –48 °C to 38 °C. This algorithm requires a temperature range within the region of 1000 °F to 2200 °F and a minimum carbon probe value of 800 millivolts.

OXYGEN

PERCENT OXYGEN RANGE—Make this selection if you are using a Zirconium Oxide Oxygen Probe to measure Percent of Oxygen in a range of 0 to 40 % O

. This algorithm requires a temperature

range within the region of 800 °F to 3000 °F.

ATTENTION The Carbon and Dewpoint selections will automatically set the first input actuation to Carbon. The Oxygen selection will automatically set the first input actuation to Oxygen. Input 2 can be any input actuation, but it is normally a type K, R or S thermocouple input, depending upon the probe type selected. All calculations are performed by the Controller with Percent Carbon shown as the PV display. The actual value of each analog input may be viewed on the lower display. For all Carbon Types, if the value of Percent Carbon falls below 0.1% - such as can happen when the Carbon Probe voltage output falls below 900 mVdc – then the Controller will continue to update the PV display, but the accuracy is unspecified. Likewise, if the measured temperature falls outside of the specified ranges as noted above for the Carbon, Oxygen and Dewpoint input types, then the Controller will continue to update the PV display, but the accuracy is unspecified. For the Dewpoint algorithm, if the Carbon Sensor voltage falls below 800 mVdc, then the Dew Point is calculated as if the sensor voltage was at 800 mVdc.

MATH K

CALC HI

CALC LO

ALG1 INA

0.001 to 1000 floating

–999. To 9999. Floating (in engineering units)

INPUT 1 INPUT 2 OUTPUT

WEIGHTED AVERAGE RATIO OR MASS FLOW ORIFICE CONSTANT (K) FOR MATH SELECTIONS—Only applicable for

algorithms W AVG or General Math selections √MuDIV, √MULT, MuDIV, or MULT.

CALCULATED VARIABLE HIGH SCALING FACTOR FOR INPUT ALGORITHM 1—Used only when either Summer, Input

Hi/Lo, or one of the General Math functions was selected as the Input Algorithm. See Note 2.

CALCULATED VARIABLE LOW SCALING FACTOR FOR INPUT ALGORITHM 1—Used only when either Summer, Input Hi/Lo, or

one of the General Math functions was selected as the Input Algorithm. See Note 2.

ALGORITHM 1, INPUT A SELECTION will represent one of the available selections.

Input 1 Input 2 Output – Should not be used for Three Position Step Control applications)

04/08 UDC3200 Universal Digital Controller Operator Manual 37

Function

Prompt

Lower Display

ALG1 INB

ALG1 INC

PCT CO

Selections or

Range of Setting

Upper Display

INPUT 1 INPUT 2 OUTPUT

NONE INPUT 1 INPUT 2 OUTPUT

0.020 to 0.350 (fractional percent of CO)

Parameter Definition

ALGORITHM 1, INPUT B SELECTION will represent one of the

available selections.

Input 1 Input 2 Output – Should not be used for Three Position Step Control applications)

ALGORITHM 1, INPUT C SELECTION will represent one of the

available selections.

None Input 1 Input 2 Output – Should not be used for Three Position Step Control applications)

PERCENT CARBON is only applicable when Carbon Potential is

selected. Enter the value in percent carbon monoxide that is applicable for the enriching gas used in fractional form.

FOR EXAMPLE: Natural Gas = 20.0 % CO, then setting is 0.200 Propane Gas = 23.0 % CO, setting is 0.230

ALG1 BIAS

-999 to 9999 floating (in

INPUT ALGORITHM 1 BIAS—Does not apply to selections: FFWRD, FFWDMU, HISEL or LOSEL.

engineering units)

PCT H2

1.0 to 99.0 (% H2)

HYDROGEN CONTENT FOR DEWPOINT is only applicable when Dewpoint is selected. Enter a value for the percentage of Hydrogen content that is applicable.

Math Algorithm Notes:

1. Calculation ranges for the Math Algorithms are set via CALC HI and CALC LO parameters and are between –999. and 9999. The SP High and Low values (SP Range) are independent of these settings and can be any value between –999. and 9999.

2. The CALC HI and CALC LO values determine the range limits for the SP High and Low values for the Weighted Average, Summer, Hi Select and Low Select algorithms.

3. If the Ratio for Input 2 is set to 0.0, then a constant value may be used for the Input 2 value via the Input 2 Bias setting. For this configuration, the Input 2 low range and the Sooting diagnostic messages are disabled.

38 UDC3200 Universal Digital Controller Operator Manual 04/08

3.7 Output Set Up Group

Function

Prompt

Lower Display

OUT ALG

Selections or

Range of Setting

Upper Display

TIME

CURRENT

POSITON

Parameter Definition

The OUTPUT ALGORITHM lets you select the type of output you want. Not applicable with Control algorithm prompt 3PSTEP. Selections are hardware dependent.

ATTENTION For all Duplex Output forms, PID heat parameters apply for controller output greater than 50 %; PID cool parameters apply for controller output less than 50 %.

TIME SIMPLEX—This output algorithm uses Digital Output 1 for Time Proportional Control. The output is updated per the Loop sampling rate selection. Time Proportional Output has a resolution of 4.44 msec. Cycle Time is adjustable from 1 to 120 seconds.

CURRENT SIMPLEX—Type of output using one 4 mA to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 1000 ohms. This signal can easily be configured for 4-20 mA or 0-20 mA operation via the CO RANGE configuration, below.

POSITION PROPORTIONAL—Type of output using two relays and a motor that has a 100 to 1000 ohms feedback slidewire.

This output algorithm selection forces Input 2 to the SLIDEW selection when the Control Algorithm is any selection other than 3PSTEP.

ATTENTION Other prompts affected: DEADBAND, IN2 TYPE

TIME D

OUT RNG

CUR D

CUR TI

TI CUR

TIME DUPLEX—This output algorithm uses Digital Outputs 1 and 2 for Duplex Time Proportional Control. The outputs are updated per the Loop sampling rate selection. Time Proportional Output has a resolution of 4.44 msec. Cycle Time is adjustable from 1 second to 120 seconds.

CURRENT DUPLEX is similar to current simplex but uses a second current output. The second output is usually scaled so that zero and span correspond with 0 % and 50 % output (cool zone). When the output is 0 % to 50 %, the controller uses tuning parameter set #2, when the output is 50 % to 100 % it uses set #1.

ATTENTION Other prompts affected: OUT RNG CURRENT/TIME DUPLEX is a variation of duplex with current

active for 0 % to 50 % output (tuning set 2) and time is active 50 % to 100 % output (tuning set 1). Relay controls heat, current controls cool.

ATTENTION Other prompts affected: OUT RNG TIME CURRENT DUPLEX is similar to CUR TI except that current

is active for 50 % to 100 % and time is active for 0 % to 50 %. Relay controls cool, current controls heat.

ATTENTION Other prompts affected: OUT RNG CURRENT DUPLEX RANGE ALGORITHM — Used with Output

Algorithm selections CUR D, CUR TI, or TI CUR.

04/08 UDC3200 Universal Digital Controller Operator Manual 39

50 PCT

CURRENT DUPLEX RANGE (SPLIT)—This setting should be

Function

Prompt

Lower Display

Selections or

Range of Setting

Upper Display

100PCT

Parameter Definition

used for Relay/Current and Current/Relay Duplex Outputs. It can also be used for Current Duplex when an Auxiliary Output board is present. This enables the normal control current output to provide heat control and the auxiliary current output to provide cool control. To enable this:

• AUX OUT in the Options Set Up group must be selected for Output.

• The Auxiliary Current Output is scaled as desired for 0-50 % controller output.

• Deadband for this configuration only applies to the Current Output. The Auxiliary Output must have the Deadband scaled in.

FOR EXAMPLE: If a 2 % Deadband is desired, then enter 2.0 for the Deadband

selection in the Control Algorithm group. This will apply Deadband to the Current Output. In the Options group, set the Auxiliary Output LOW VAL selection to 49.0 and the HIGH VAL selection to

0.0.

CURRENT DUPLEX RANGE (FULL) enables the Current Output

to provide both heat and cool functions for control over 0-100 % of the controller output. The PID heat parameters apply when the output is greater than 50 % and the PID cool parameters apply when the output is less than 50 %. The second current output is not required for this type of duplex operation.

RLYSTATE

RLY TYPE

1OF 2OF

1ON 2OF

1OF 2ON

1ON 2ON

MECHAN

SOL ST

DIGITAL OUTPUT STATUS AT 0 % OUTPUT allows the following selections:

1OF 2OF Output 1 de-energized Output 2 de-energized

1ON 2OF Output 1 energized Output 2 de-energized

1OF 2ON Output 1 de-energized Output 2 energized

1ON 2ON Output 1 energized Output 2 energized

RELAY CYCLE TIME INCREMENT selection is used only for Time Simplex and Duplex output configurations. This configuration sets the increment size of the relay cycle times in the Tuning and Tuning 2 Set Up groups.

ELECTROMECHANICAL RELAY—Cycle time in one-second increments.

SOLID STATE RELAY—Cycle time in 1/3 second increments. This is useful for solid state relay applications that require shorter cycle times. DO NOT use this setting unless cycle times of less than 1 second are required.

ATTENTION The Lockout selection must be set to NONE in order to view this selection.

40 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

MOTOR TI

CUR OUT

LOW VAL

Selections or

Range of Setting

Upper Display

5 to 1800 seconds

DISABLE INPUT 1 INPUT 2 PV DEV OUTPUT SP LSP RSP IN ALG 1

Low Scale Value within the range of the selected variable to represent the minimun output (0 or 4 mA)

Parameter Definition

MOTOR TIME – Appears only when “POSITON” is selected as the

Output algorithm. This is the time it takes the motor to travel from 0 to 100% (fully closed to fully open). This time can usually be found on the nameplate of the motor.

CURRENT OUTPUT – If Current Output #1 is not used to perform one of the above output algorithms, it may be used to perform an Auxiliary Output function.

DISABLE INPUT 1 INPUT 2 PV (Process Variable) DEVIATION OUTPUT SETPOINT LOCAL SETPOINT REMOTE INPUT ALGORITHM 1

CURRENT OUTPUT LOW SCALING FACTOR—Used only when CUR OUT is any selection other than DISABLE. This is a value in engineering units used to represent all CUR OUT parameters except Output.

For Output, this is a value in percent and can be any value between –5 % and +105 %. However, keep in mind that relay output types can only be scaled 0 % to 100 %.

HIGH VAL

CO RANGE

High Scale Value within the range of the selected variable to represent the maximum output (20 mA)

4-20mA 0-20mA

CURRENT OUTPUT HIGH SCALING FACTOR—Used only when CUR OUT is any selection other than DISABLE. This is a value in engineering units used to represent all CUR OUT parameters except Output.

For Output, this is a value in percent and can be any value between –5 % and +105 %. However, keep in mind that relay output types can only be scaled 0 % to 100 %.

CURRENT OUTPUT RANGE allows the user to easily select 4-20 mA output or 0-20 mA output operation without the need for recalibration of the instrument.

ATTENTION Changing the Current Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values.

04/08 UDC3200 Universal Digital Controller Operator Manual 41

3.8 Input 1 Set Up Group

Function

Prompt

Lower Display

IN1 TYPE

ATTENTION

Changing the input type will result in the loss of Field Calibration values and will restore Factory Calibration values.

Selections or

Range of Setting

Upper Display

DISABLE B TC E TC H E TC L J TC H J TC M J TC L K TC H K TC M K TC L NNM H NNM L NIC H NIC L R TC S TC T TC H T TC L W TC H W TC L 100 PT 100 LO 200 PT 500 PT RAD RH RAD RI 0-20mA 4-20mA 0-10mV 0-50mV 0-100mV 0-5 V 1-5 V 0-10 V TC DIFF CARBON OXYGEN

Parameter Definition

INPUT 1 ACTUATION TYPE – This selection determines what

actuation you are going to use for Input 1.

DISABLE—Disables Input. B TC—B Thermocouple E TC H—E Thermocouple High E TC L—E Thermocouple Low J TC H—J Thermocouple High J TC M—J Thermocouple Med J TC L—J Thermocouple Low K TC H—K Thermocouple High K TC M—K Thermocouple Med K TC L—K Thermocouple Low NNM H—Ni-Ni-Moly Thermocouple High NNM L—Ni-Ni-Moly Thermocouple Low NIC H—Nicrosil-Nisil Thermocouple High NIC L—Nicrosil-Nisil Thermocouple Low R TC—R Thermocouple S TC—S Thermocouple T TC H—T Thermocouple High T TC L—T Thermocouple Low W TC H—W5W26 Thermocouple High W TC L—W5W26 Thermocouple Low 100 PT—100 Ohm RTD High 100 LO—100 Ohm RTD Low 200 PT—200 Ohm RTD 500 PT—500 Ohm RTD RAD RH—Radiamatic RH RAD RI—Radiamatic RI 0-20mA—0 to 20 Milliamperes 4-20mA—4 to 20 Milliamperes 0-10mV—0 to 10 Millivolts 0-50mV—0 to 50 Millivolts 0-100mV—0 to 100 Millivolts 0-5 V—0 to 5 Volts 1-5 V—1 to 5 Volts 0-10 V—0 to 10 Volts TC DIFF—Thermocouple Differential Carbon—Carbon Probe Input Oxygen—Oxygen Probe Input

42 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

XMITTER

Selections or

Range of Setting

Upper Display

B TC E TC H

E TC L J TC H J TC M J TC L K TC H K TC M K TC L NNM H NNM L NIC H NIC L R TC S TC T TC H T TC L W TC H W TC L 100 PT 100 LO 200 PT 500 PT RAD RH RAD RI LINEAR SQROOT

Parameter Definition

TRANSMITTER CHARACTERIZATION—This selection lets you

instruct the controller to characterize a linear input to represent a non-linear one. If characterization is performed by the transmitter itself, then select LINEAR.

ATTENTION Prompt only appears when a linear actuation is selected at prompt IN1 TYPE.

FOR EXAMPLE: If input 1 is a 4 to 20 mA signal, but the signal represents a type K H thermocouple, then configure K TC H and the controller will characterize the 4 to 20 mA signal so that it is treated as a type K thermocouple input (high range).

Parameter definitions are the same as in IN1 TYPE.

IN1 HIGH

IN1 LOW

RATIO 1

BIAS IN1

FILTER 1

–999. To 9999. Floating (in engineering units)

–20.00 to 20.00 Floats to 3 decimal places

–999. to 9999. (in engineering units)

0 to 120 seconds No filter = 0

INPUT 1 HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization.

Scale the #1 input signal to the display value you want for 100 %. ATTENTION The control setpoint will be limited by the range of

units selected here. INPUT 1 LOW RANGE VALUE in engineering units is displayed

for all inputs but can only be configured for linear or square root transmitter characterization. Scale the #1 input signal to the display value you want for 0 %. See example above.

ATTENTION The control setpoint will be limited by the range of units selected here.

RATIO ON INPUT 1—Select the Ratio value you want on Input 1.

BIAS ON INPUT 1 — Bias is used to compensate the input for drift

of an input value due to deterioration of a sensor, or some other cause. Select the bias value you want on Input 1.

FILTER FOR INPUT 1—A software digital filter is provided for Input 1 to smooth the input signal. You can configure the first order lag time constant from 1 to 120 seconds. If you do not want filtering, enter 0.

04/08 UDC3200 Universal Digital Controller Operator Manual 43

Function

Prompt

Lower Display

BURNOUT

Selections or

Range of Setting

Upper Display

NONE

DOWN

Parameter Definition

BURNOUT PROTECTION (SENSOR BREAK) provides most input types with upscale or downscale protection if the input fails.

NO BURNOUT—Pre-configured Failsafe output (selected in the

CONTROL Set up Group) applied if failed input is detected (does not apply for an input out of range). Diagnostic message IN1 FAIL is intermittently flashed on the lower display.

UPSCALE BURNOUT will force the Input 1 signal to the full scale value when the sensor fails. Diagnostic message IN1 FAIL intermittently flashed on the lower display.

The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 1 signal developed by the Burnout circuitry.

DOWNSCALE BURNOUT will force the Input 1 signal to the lower range value when the sensor fails. Diagnostic message IN1 FAIL intermittently flashed on the lower display.

The controller remains in Automatic control mode and adjusts the controller output signal in response to the lower range Input 1 signal developed by the Burnout circuitry.

EMISSIV1

NO FS

NO FAILSAFE— This selection does not provide input failure detection and should only be used when a thermocouple input is connected to another instrument which supplies the Burnout current. (For this selection, no burnout signal is sent to the sensor.)

ATTENTION For Burnout to function properly on a 0-20 mA input type (or a 0-5V type that uses a dropping resistor), the dropping resistor must be remotely located (across the transmitter terminals). Otherwise, the input at the instrument terminals will always be 0 mA (i.e., within the normal operating range) when the 0-20 mA line is opened.

0.01 to 1.00

EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator. Available only for Radiamatic inputs.

44 UDC3200 Universal Digital Controller Operator Manual 04/08

3.9 Input 2 Set Up Group

Function Prompt

Lower Display

IN2 TYPE

ATTENTION

Changing the input type will result in the loss of Field Calibration values and will restore Factory Calibration values.

Selecting Position Proportional Control in the Output Setup Group forces Input 2 to the Slidewire Selection.

Selections or

Range of Setting

Upper Display

Parameter

Definition

INPUT 2 ACTUATION TYPE – This selection

determines what actuation you are going to use for Input 2.

Applications)

XMITTER2

04/08 UDC3200 Universal Digital Controller Operator Manual 45

B TC E TC H E TC L J TC H J TC M J TC L K TC H K TC M K TC L NNM H NNM L NIC H NIC L R TC

S TC T TC H T TC L W TC H W TC L 100 PT 100 LO 200 PT 500 PT RAD RH RAD RI LINEAR SQROOT

TRANSMITTER CHARACTERIZATION—This selection lets you instruct the controller to characterize a linear input to represent a non-linear one.

ATTENTION Prompt only appears when a linear actuation is selected at prompt IN2 TYPE.

Parameter definitions are the same as in IN2 TYPE.

Function Prompt

Lower Display

IN2 HIGH

IN2 LOW

RATIO 2

BIAS IN2

FILTER 2

Selections or

Range of Setting

Upper Display

–999. To 9999. Floating (in engineering units)

–20.00 to 20.00 Floats to 3 decimal places

–999. to 9999. (in engineering units)

0 to 120 seconds No filter = 0

Parameter

Definition

INPUT 2 HIGH RANGE VALUE in engineering units

is displayed for all inputs but can only be configured for linear or square root transmitter characterization

See the example in IN1 HI. INPUT 2 LOW RANGE VALUE in engineering units

is displayed for all inputs but can only be configured for linear or square root transmitter characterization.

See the example in IN1 HI RATIO ON INPUT 2—Select the Ratio value you

want on Input 1. BIAS ON INPUT 2 — Bias is used to compensate

the input for drift of an input value due to deterioration of a sensor, or some other cause. Select the bias value you want on Input 1.

FILTER FOR INPUT 2—A software digital filter is provided for Input 1 to smooth the input signal. You can configure the first order lag time constant from 1 to 120 seconds. If you do not want filtering, enter 0.

BURNOUT

NONE

DOWN

BURNOUT PROTECTION (SENSOR BREAK) provides most input types with upscale or downscale protection if the input fails.

NO BURNOUT—If Input 2 is being used in the Control Algorithm (such as the PV or RSP input parameter), then the pre-configured Failsafe output (selected in the CONTROL Set up Group) is applied when a failed input is detected (does not apply for an input out of range). Diagnostic message IN2 FAIL is intermittently flashed on the lower display.

UPSCALE BURNOUT will force the Input 2 signal to the full scale value when the sensor fails. Diagnostic message IN2 FAIL intermittently flashed on the lower display.

The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 2 signal developed by the Burnout circuitry.

DOWNSCALE BURNOUT will force the Input 2 signal to the lower range value when the sensor fails. Diagnostic message IN2 FAIL intermittently flashed on the lower display.

The controller remains in Automatic control mode and adjusts the controller output signal in response to the lower range Input 2 signal developed by the Burnout circuitry.

46 UDC3200 Universal Digital Controller Operator Manual 04/08

Function Prompt

Lower Display

EMISSIV2

Selections or

Range of Setting

Upper Display

NO FS

0.01 to 1.00

Parameter

Definition

NO FAILSAFE—This selection does not provide

input failure detection and should only be used when a thermocouple input is connected to another instrument which supplies the Burnout current. (For this selection, no burnout signal is sent to the sensor.)

04/08 UDC3200 Universal Digital Controller Operator Manual 47

3.10 Control Set Up Group

Function

Prompt

Lower Display

PV SOURCE

PID SETS

PID SETS (continued)

SW VALUE

LSP’S

Selections or

Range of Setting

Upper Display

INPUT 1 INPUT 2 IN ALG1

1 ONLY

2KEYBD

Lower

Display

2PV SW

2SP SW

Value in engineering units within PV or SP range limits

1 ONLY TWO

THREE

PROCESS VARIABLE SOURCE —Selects the source of the Process Variable.

INPUT 1 INPUT 2 INPUT ALGORITHM 1

NUMBER OF TUNING PARAMETER SETS—This selection lets

you choose one or two sets of tuning constants (gain, rate, and reset). NOTE: The Tuning Group is automatically configured to have two PID sets when a Duplex Control Algorithm is configured.

ONE SET ONLY—Only one set of tuning parameters is available. Configure the values for: Gain (proportional band), Rate, Reset Time, and Cycle Time (if time proportional is used).

TWO SETS KEYBOARD SELECTABLE—Two sets of tuning parameters can be configured and can be selected at the operator interface or by using the Digital Inputs.

Press this key until you see PID SET1 or PID SET2 then press

Rate, Reset, Cycle Time, Gain #2, Rate #2, Reset #2, Cycle #2 Time

TWO SETS PV AUTOMATIC SWITCHOVER—When the process variable is GREATER than the value set at prompt SW VALUE (Switchover Value), the controller will use Gain, Rate, Reset, and Cycle Time. The active PID SET can be read in the lower display. When the process variable is LESS than the value set at prompt SW VALUE, the controller will use Gain#2, Rate#2, Reset#2, and Cycle#2 Time. The active PID SET can be read in the lower display.

TWO SETS SP AUTOMATIC SWITCHOVER—When the setpoint is GREATER than the value set at prompt SW VALUE (Switchover Value), the controller will use Gain, Rate, Reset, and Cycle. When the setpoint is LESS than the value set at prompt SW VALUE, the controller will use Gain #2, Rate #2, Reset #2, and Cycle #2.

ATTENTION Other prompts affected: SW VALUE AUTOMATIC SWITCHOVER VALUE—This is the value of

Process Variable or Setpoint at which the controller will switch from Tuning Constant Set #2 to Set #1.

LOCAL SETPOINT SOURCE—This selection determines what your local setpoint source will be.

LOCAL SETPOINT—The setpoint entered from the keyboard. TWO LOCAL SETPOINTS—This selection lets you switch

between two local setpoints using the THREE LOCAL SETPOINTS—This selection lets you switch

between three local setpoints using the

Parameter Definition

or to switch between sets. Configure the values for: Gain,

Select

key.

Select

key

48 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

RSP SRC

AUTOBIAS

SP TRACK

PWR MODE

PWR OUT

For Three

Position Step

Control Only

Selections or

Range of Setting

Upper Display

NONE INPUT 2 IN ALG1

DISABLE ENABLE

NONE

PV RSP

MANUAL

A LSP

A RSP

AM SP AM LSP

Parameter Definition

REMOTE SETPOINT SOURCE—This selection determines what

your remote setpoint source will be when toggled by the SP Select key or Digital Input.

NONE—No remote setpoint. INPUT 2—Remote Setpoint is Input 2. IN AL1—Remote Setpoint using Input 1 algorithm.

ATTENTION To cycle through the available local setpoints and

remote setpoint, press and hold in the

Select

key. When the key is released, the setpoint selection currently displayed will be the new setpoint selection.

AUTOBIAS is used for bumpless transfer when transferring from local setpoint to remote setpoint. Auto Bias calculates and adds a bias to remote setpoint input each time a transfer is made. Only available if no tracking is selected.

DISABLE—Disables auto bias. ENABLE—Enables auto bias.

SETPOINT TRACKING—The local setpoint can be configured to

track either PV or RSP as listed below. Not configurable when Auto Bias is set.

ATTENTION For selections other than NONE, LSP is stored in nonvolatile memory only when there is a mode change; i.e., when switching from RSP to LSP or from Manual to Automatic. If power is lost, then the current LSP value is also lost.

NO TRACKING—If local setpoint tracking is not configured, the LSP will not be altered when transfer from RSP to LSP is made.

PV—Local setpoint tracks the PV when in manual. RSP—Local setpoint tracks remote setpoint when in automatic.

When the controller transfers out of remote setpoint, the last value of the remote setpoint (RSP) is inserted into the local setpoint.

POWER UP CONTROLLER MODE RECALL—This selection determines which mode and setpoint the controller will use when the controller restarts after a power loss.

MANUAL, LSP—At power-up, the controller will use manual mode with the local setpoint displayed.

AUTOMATIC MODE, LAST LSP—At power-up, the controller will use automatic mode with the last local setpoint used before power down displayed.

AUTOMATIC MODE, LAST RSP—At power-up, the controller will use automatic mode with the last remote setpoint used before power down displayed.

LAST MODE/LAST SETPOINT used before power down. LAST MODE/LAST LOCAL SETPOINT on power down. THREE POSITION CONTROL STEP OUTPUT START-UP

MODE—This selection determines what position the motor will be in when powered up or in the failsafe position.

04/08 UDC3200 Universal Digital Controller Operator Manual 49

Function

Prompt

Lower Display

(Note 3)

SP HiLIM

(Note 4)

SP LoLIM

(Note 4) ACTION

OUT RATE

PCT/M UP

PCT/M DN

OUTHiLIM

OUTLoLIM

I Hi LIM (Note 5) I Lo LIM (Note 5)

DROPOFF

(Note 5)

Selections or

Range of Setting

Upper Display

LAST

F’SAFE

0 to 100 % of PV span in engineering units

DIRECT

REVERSE

ENABLE DISABLE

0 to 9999 % per minute

0 % to 100 % –5 % to 105 %

0 % to 100 % –5 % to 105 % Within the range of

the output limits Within the range of

the output limits –5 to 105 % of

output

Parameter Definition

LAST OUTPUT—At power-up in automatic mode, the motor

position will be the last one prior to power down. When the unit goes into FAILSAFE, it will stay in automatic mode; motor will not be driven to the configured failsafe position.

FAILSAFE OUTPUT—At power-up in manual mode, the motor will be driven to either the 0 % or 100 % output position, whichever is selected at prompt FAILSAFE. For Burnout/None, when the unit goes into FAILSAFE, it will go to manual mode; motor will be driven to the configured failsafe position.

SETPOINT HIGH LIMIT—This selection prevents the local and remote setpoints from going above the value selected here. The setting must be equal or less than the upper range of the PV.

SET POINT LOW LIMIT—This selection prevents the local and remote setpoints from going below the value selected here. The setting must be equal or greater than the lower range of the PV.

CONTROL OUTPUT DIRECTION—Select direct or reverse output action.

DIRECT ACTING CONTROL—The controller’s output increases as the process variable increases.

REVERSE ACTING CONTROL—The controller’s output decreases as the process variable increases.

OUTPUT CHANGE RATE—Enables or disables the Output Change Rate. The maximum rate is set at prompt PCT/M UP or PCT/M DN. Only available for PID-A, PID-B, PD+MR control algorithms.

ENABLE—Allows output rate. DISABLE—Disables output rate.

OUTPUT RATE UP VALUE—This selection limits the rate at which

the output can change upward. Enter a value in percent per minute. Appears only if OUT RATE is enabled. “0” means no output rate applied.

OUTPUT RATE DOWN VALUE—This selection limits the rate at which the output can change downward. Enter a value in percent per minute. Appears only if OUT RATE is enabled. “0” means no output rate.

HIGH OUTPUT LIMIT—This is the highest value of output beyond which you do not want the controller automatic output to exceed.

For relay output types. For current output types. LOW OUTPUT LIMIT—This is the lowest value of output below

which you do not want the controller automatic output to exceed. For relay output types.

For current output types. HIGH RESET LIMIT—This is the highest value of output beyond

which you do not want reset action to occur LOW RESET LIMIT—This is the lowest value of output beyond

which you do not want reset action to occur. CONTROLLER DROPOFF VALUE—Output value below which

the controller output will drop off to the low output limit value set in prompt OUTLoLIM.

50 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

DEADBAND

OUT HYST

FAILMODE

FAILSAFE

SW FAIL

MAN OUT

AUTO OUT

PBorGAIN

Selections or

Range of Setting

Upper Display

–5.0 to 25.0 %

0.0 to 25.0 %

0.5 to 5.0 %

0.0 to 100.0 % of PV span

NoLATCH

LATCH

0 to 100 %

0 PCT 100 PCT

0 to 100 %

PB PCT

GAIN

Parameter Definition

DEADBAND is an adjustable gap between the operating ranges of

output 1 and output 2 in which neither output operates (positive value) or both outputs operate (negative value).

Time Duplex On-Off Duplex Position Proportional and Three Position Step

HYSTERESIS (OUTPUT RELAY) is an adjustable overlap of the ON/OFF states of each control output. This is the difference between the value of the process variable at which the control outputs energize and the value at which they de-energize.

Only applicable for ON/OFF control.

FAILSAFE MODE NON LATCHING—Controller stays in last mode that was being

used (automatic or manual); If unit was in Automatic mode, then the output goes to the failsafe value. (NOTE 1, NOTE 2)

LATCHING—Controller goes to manual mode; If unit was in Automatic mode, then the output goes to the failsafe value. (NOTE

2) FAILSAFE OUTPUT VALUE—The value used here will also be

the output level when you have Communications SHED set to failsafe or when NO BURNOUT is configured and Input 1 fails.

ATTENTION Applies for all output types except Three Position Step Control.

THREE POSITION STEP FAILSAFE OUTPUT 0 PCT—Motor goes to closed position. 100 PCT—Motor goes to open position.

Position Proportional motor position when slidewire fails.

0 PCT—Motor goes to closed position. 100 PCT—Motor goes to open position. ATTENTION PWR OUT must be configured for FSAFE. POWER-UP PRESET MANUAL OUTPUT—At power-up, the

controller will go to manual and the output to the value set here. (NOTE 1)

POWER-UP PRESET AUTOMATIC OUTPUT—At power-up, the controller will begin its automatic control at the output value set here. (NOTE 1)

PROPORTIONAL BAND UNITS—Select one of the following for the Proportional (P) term of the PID algorithm:

PROPORTIONAL BAND selects units of percent proportional band for the P term of the PID algorithm. Where: PB % = 100 % FS GAIN

GAIN selects the unitless term of gain for the P term of the PID algorithm. Where: GAIN = 100 % FS PB%

04/08 UDC3200 Universal Digital Controller Operator Manual 51

Function

Prompt

Lower Display

MINUTESorRP

Selections or

Range of Setting

Upper Display

Parameter Definition

RESET UNITS—Selects units of minutes per repeat or repeats per

minute for the I term of the PID algorithm. 20 Repeats per Minute = 0.05 Minutes per Repeat.

RPM

REPEATS PER MINUTE—The number of times per minute that the proportional action is repeated by reset.

MINUTES

MINUTES PER REPEAT—The time between each repeat of the

proportional action by reset. NOTE 1: Does not apply to Three Position Step Control. NOTE 2: If controller is in Manual mode when a failure occurs, then the output will maintain its value. NOTE 3:These selections appear when:

A) Control Algorithm is selected for 3PSTEP. B) Control Algorithm is selected for PD+MR and Output Algorithm is selected for Position

Proportional. NOTE 4: The local setpoint will automatically adjust itself to be within the setpoint limit range. For example, if SP = 1500 and the SP HiLIM is changed to 1200, the new local setpoint will be 1200.

NOTE 5: Reset limits and Dropoff are not displayed when Three Position Step Control is configured.

52 UDC3200 Universal Digital Controller Operator Manual 04/08

3.11 Options Group

Function

Prompt

Lower Display

AUX OUT

ATTENTION

Prompts for the Auxiliary Output Selection appear only if one of the Auxiliary Output boards is installed.

Selections or

Range of Setting

Upper Display

DISABLE INPUT 1 INPUT 2 PV

DEV

Parameter

Definition

AUXILIARY OUTPUT SELECTION

This selection provides an mA output representing one of several control parameters. The display for auxiliary output viewing will be in engineering units for all but output. Output will be displayed in percent.

ATTENTION Other prompts affected by these selections: 4mA VAL and 20mA VAL.

ATTENTION Output cannot be configured when Three Position Step Control is used.

NO AUXILIARY OUTPUT INPUT 1—This represents the configured range of input 1. INPUT 2 represents the value of the configured range of input 2. PROCESS VARIABLE—Represents the value of the Process

Variable. PV = Input XxRatioX + BiasX DEVIATION (PROCESS VARIABLE MINUS SETPOINT)—

Represents –100 % to +100 % of the selected PV span in engineering units.

Zero deviation will produce a center scale (12 mA or 50 %) output. A negative deviation equal in magnitude to the Auxiliary Output High Scaling Factor will produce a low end output (4 mA or 0 %) output. A positive deviation equal in magnitude to the Auxiliary Output Low Scaling Factor will produce a high end output (20 mA or 100 %).

CO RANGE

OUTPUT

LSP 1

RSP

IN ALG1

4-20mA 0-20mA

OUTPUT—Represents the displayed controller output in percent (%). Cannot be used with Three Position Step Control.

SETPOINT—Represents the value of the setpoint currently in use (LSP1, LSP2, LSP3, RSP or CSP) and is shown in the same units as those used by the PV.

LOCAL SETPOINT ONE—Auxiliary output represents Local Setpoint 1 regardless of active setpoint.

REMOTE SETPOINT – Represents the configured RSP regardless of the active SetPoint.

INPUT ALGORITHM 1 OUTPUT—Represents the output from input algorithm 1.

AUXILIARY CURRENT OUTPUT RANGE—Allows the user to easily select 4-20mA output or 0-20mA output operation without the need for recalibration of the instrument.

ATTENTION Changing the Auxiliary Current Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values.

04/08 UDC3200 Universal Digital Controller Operator Manual 53

Function

Prompt

Lower Display

LOW VAL

HIGH VAL

DIG INP1

TO MAN

Selections or

Range of Setting

Upper Display

Low Scale Value within the range of the selected variable to represent the minimun output (0 or 4 mA)

High Scale Value within the range of the selected variable to represent the maximum output (20 mA)

NONE

Parameter

Definition

AUXILIARY OUTPUT LOW SCALING FACTOR— This is a value

in engineering units used to represent all AUX OUT parameters except Output.

For Output, this is a value in percent and can be any value between –5 % and +105 %. However, keep in mind that relay output types can only be scaled 0 % to 100 %.

AUXILIARY OUTPUT HIGH SCALING FACTOR— This is a value in engineering units used to represent all AUX OUT parameters except Output.

For Output, this is a value in percent and can be any value between –5 % and +105 %. However, keep in mind that relay output types can only be scaled 0 % to 100 %.

DIGITAL INPUT 1 SELECTIONS—All selections are available for Input 1. The controller returns to its original state when contact opens, except when overruled by the keyboard.

NO DIGITAL INPUT SELECTIONS TO MANUAL—Contact closure puts the affected loop into manual

mode. Contact open returns controller to former mode.

TO LSP

TO 2SP

TO 3SP

TO DIR

TO HOLD

TO PID2 PV 2IN

TO LOCAL SETPOINT—When a remote setpoint is configured, contact closure puts the controller into local setpoint 1. When contact opens, the controller returns to former operation—local or remote setpoint—unless SP Select key is pressed while digital input is active. If this happens, the controller will stay in the local setpoint mode when contact opens.

TO LOCAL SETPOINT TWO—Contact closure puts the controller into local setpoint 2.

TO LOCAL SETPOINT THREE—Contact closure puts the controller into local setpoint 3.

TO DIRECT ACTION—Contact closure selects direct controller action.

TO HOLD—Contact closure suspends Setpoint Program or Setpoint Ramp. When contact reopens, the controller starts from the Hold point of the Ramp/Program unless the Ramp/Program

Run

Hold

was not previously started via the

key.

This selection applies to either loop.

TO PID2—Contact closure selects PID Set 2. PV=INPUT 2—Contact closure selects PV = Input 2.

RERUN

RERUN--Allows the Setpoint Programmer to be reset to the initial segment of its current cycle, unit stays in previous mode.

54 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

Selections or

Range of Setting

Upper Display

TO RUN

ToBEGIN

STOP I

MAN FS

Parameter

Definition

RUN—Contact closure starts a stopped SP Ramp or Program.

Upper left character blinks “R”. Reopening the contact puts controller in HOLD mode.

This selection applies to either loop. EXTERNAL SP PROGRAM RESET—Contact closure resets SP

Program back to the beginning of the first segment in the program and places the program in the HOLD mode. Program cycle number is not affected. Reopening switch has no effect.

This selection applies to either loop. ATTENTION Once the last segment of the setpoint program has

timed out, the controller enters the mode of action specified in the configuration data and the program cannot be reset to the beginning of the first segment by digital input closure.

INHIBIT INTEGRAL (RESET)—Contact closure disables PID Integral (Reset) action.

MANUAL FAILSAFE OUTPUT—Controller goes to Manual mode, output goes to the Failsafe value.

ATTENTION This will cause a bump in the output when switching from Automatic to Manual. The switch back from Manual to Automatic is bumpless. When the switch is closed, the output can be adjusted from the keyboard.

TO LOCK

TO Aout

KEYBOARD LOCKOUT—Contact closure disables all keys. Lower display shows LOCKED if a key is pressed.

AUTOMATIC OUTPUT—Contact closure sends output to the value set at Control prompt AUTO OUT when the controller is in the Automatic mode. Reopening the contact returns the controller to the normal output.

ATTENTION Does not apply to Three Position Step Control.

TIMER

TIMER—Contact closure starts timer, if enabled. Reopening the switch has no effect.

AM STA

TO AUTO/MANUAL STATION—Contact closure causes the control loop to perform as follows: PV = Input 2 Action = Direct Control algorithm = PD+MR PID SET = 2 SP = LSP 2

TO TUNE

INITIATE LIMIT CYCLE TUNING—Contact closure starts the tuning process. The lower display shows TUNE ON. Opening the contact has no effect.

SP Init

SETPOINT INITIALIZATION—Contact closure forces the setpoint to the current PV value. Opening the contact has no effect.

04/08 UDC3200 Universal Digital Controller Operator Manual 55

Function

Prompt

Lower Display

TO RSP

RST FB

Selections or

Range of Setting

Upper Display

TRACK

To PURGE

Lo FIRE

MAN LAT

PV Hold

Parameter

Definition

OUTPUT TRACKS INPUT 2—Contact closure allows Output to

track Input 2. While the switch is open, the output is in accordance with its pre-defined functionality. When the switch is closed, the output value (in percent) will track the Input 2 percent of range value. When the switch is reopened, the output will start at this last output value and normal PID action will then take over control. The transfer is bumpless.

TO REMOTE SETPOINT—Contact closure selects the Remote setpoint.

EXTERNAL RESET FEEDBACK—Contact closure allows Input 2 to override the internal reset value.

TO PURGE—Contact closure forces the loop to Manual mode with the output set to the Output High Limit configuration. MAN lights and the Output value is shown on the lower display. Opening the switch has no effect.

ATTENTION Does not apply to Three Position Step Control. LOW FIRE—Contact closure forces the loop to Manual mode with

the output set to the Output Low Limit configuration. MAN lights and the Output value is shown on the lower display. Opening the switch has no effect.

ATTENTION Does not apply to Three Position Step Control. MANUAL LATCHING—Contact closure transition forces the loop

to Manual mode. Opening the switch has no effect. If the MAN/AUTO key is pressed while the switch is closed, the loop will return to Automatic mode.

PROCESS VARIABLE HOLD—when the switch is closed, PV is frozen at last value. When switch opens, PV resumes.

DIG 1COMB

DIG INP2

DIG2COMB

DISABLE +PID2 +TO DIR

+TO SP2 +DIS AT

+TO SP1 +RUN

Same selections as for Digital Inp 1

Same selections as Digital Input 1 Combinations

DIGITAL INPUT 1 COMBINATION SELECTIONS —This selection allows the specified function to occur in addition to the one chosen for DIG IN 1.

DISABLE—Disables combination function. PLUS PID2—Contact closure selects PID Set 2. PLUS DIRECT ACTION—Contact closure selects direct controller

action. PLUS SETPOINT 2—Contact closure puts the controller into SP2. PLUS DISABLE ADAPTIVE TUNE—Contact closure disables

Accutune process. PLUS SETPOINT 1—Contact closure puts the controller into SP1. PLUS RUN SETPOINT PROGRAM/RAMP—Contact closure

starts SP Program/Ramp if enabled.

DIGITAL INPUT 2 SELECTIONS

DIGITAL INPUT 2 COMBINATIONS

56 UDC3200 Universal Digital Controller Operator Manual 04/08

3.12 Communications Group

Function

Prompt

Lower Display

Com ADDR

ComSTATE

IR ENABLE

BAUD

Selections or

Range of Setting

Upper Display

1 to 99

DISABLE MODBUS

DISABLE ENABLE

4800 9600 19200 38400

Parameter

Definition

COMMUNICATIONS STATION ADDRESS—This is a number that

is assigned to a controller that is to be used with the communications option. This number will be its address.

COMMUNICATIONS SELECTION DISABLE—Disables RS-485 communications option. MODBUS—Enables RS-485 Modbus RTU communication port.

IR ENABLE–Disable/Enables IR communications port. ATTENTION If there are no IR communications transactions for

four minutes, then the IR port automatically shuts down. It can be re-enabled by pressing any key on the front panel.

BAUD RATE is the transmission speed in bits per second. This value is used for both RS-485 and IR Communications, but for IR Communications, values below 19200 baud are interpreted as being 19200 baud.

4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD

TX DELAY

WS FLOAT

SHED ENAB

SHEDTIME

1 to 500 milliseconds

FP_B FP_BB FP_L FP_LB

DISABLE ENABLE

0 to 255

TX DELAY—Configurable response-delay timer allows you to force the instrument to delay its response for a time period of from 1 to 500 milliseconds compatible with the host system hardware/software.

Defines word/byte order of floating point data for communications. Byte values:

0 1 2 3 seeeeeee emmmmmmm mmmmmmmm mmmmmmmm

Where: s = sign, e = exponent, m = mantissa bit

0 1 2 3 1 0 3 2 3 2 1 0 2 3 0 1

SHED ENABLE—Disables/enables shed functionaliy. Applies to Modbus protocol only.

SHED TIME—The number that represents how many sample periods there will be before the controller sheds from communications. Each period equals 1/3 seconds; 0 equals No shed.

Note: If ComSTATE is set to MODBUS or MB3K and if SHEDENAB is set to DISABL, Shed Time will not be configurable.

SHEDMODE

SHED CONTROLLER MODE AND OUTPUT LEVEL—Determines

the mode of local control you want when the controller is shed from

04/08 UDC3200 Universal Digital Controller Operator Manual 57

the communications link.

Function

Prompt

Lower Display

SHED SP

Selections or

Range of Setting

Upper Display

LAST

TO MAN

FSAFE

TO AUTO

TO LSP TO CSP

Parameter

Definition

LAST—SAME MODE AND OUTPUT—The controller will return to

the same mode (manual or automatic) at the same output level that it had before shed.

TO MAN—MANUAL MODE, SAME OUTPUT—The controller will return to manual mode at the same output level that it had before shed.

FSAFE—MANUAL MODE, FAILSAFE OUTPUT—The controller will return to manual mode at the output value selected at Control prompt FAILSAFE.

TO AUTO—AUTOMATIC MODE, LAST SP—The controller will return to the automatic mode and the last setpoint used before shed.

SHED SETPOINT RECALL Note: If SHEDENAB=DISABLE, this prompt will not be

configurable.

TO LSP—Controller will use last local or remote setpoint used. TO CSP—When in “slave” mode, the controller will store the last

host computer setpoint and use it at the Local setpoint. When in “monitor” mode, the controller will shed to the last instrument Local or Remote setpoint used, and the LSP is unchanged.

UNITS

CSP RATO

CSP BIAS

LOOPBACK

ENG PERCENT –20.0 to 20.0 –999. to 9999.

(engineering units)

DISABLE ENABLE

COMPUTER SETPOINT UNITS ENG — Engineering units PERCENT — Percent of PV range COMPUTER SETPOINT RATIO—Computer setpoint ratio. COMPUTER SETPOINT BIAS—Computer setpoint bias in

Engineering Units. LOCAL LOOPBACK tests the RS-485 communications port. It is

not used for any other communications port. DISABLE—Disables the Loopback test.

ENABLE—Allows loopback test. The instrument goes into

Loopback mode in which it sends and receives its own message. The instrument displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running. The instrument will go into manual mode when LOOPBACK is enabled with the output at the Failsafe value. The test will run until the operator disables it here, or until power is turned off and on.

ATTENTION The instrument does not have to be connected to the external communications link in order to perform this test. If it is connected, only one instrument should run the loopback test at a time. The host computer should not be transmitting on the link while the loopback test is active.

58 UDC3200 Universal Digital Controller Operator Manual 04/08

3.13 Alarms Set Up Group

Function

Prompt

Lower Display

A1S1 VAL

A1S2 VAL

A2S1 VAL

A2S2 VAL

A1S1TYPE

Selections or

Range of Setting

Upper Display

Value in engineering units

Parameter Definition

ALARM 1 SETPOINT 1 VALUE—This is the value at which you

want the alarm type chosen in prompt A1S1TYPE to actuate. The value depends on what the setpoint has been configured to represent. No setpoint is required for alarms configured for Communications SHED. For SP Programming the value is the segment number for which the event applies.

This prompt does not appear for “Alarm on Manual” type alarm. For example: A1S1TYPE = MANUAL.

ALARM 1 SETPOINT 2 VALUE—This is the value at which you want the alarm type chosen in prompt A1S2TYPE to actuate.

The details are the same as A1S1 VAL. ALARM 2 SETPOINT 1 VALUE—This is the value at which you

want the alarm type chosen in prompt A2S1TYPE to actuate. The details are the same as A1S1 VAL. ALARM 2 SETPOINT 2 VALUE—This is the value at which you

want the alarm type chosen in prompt A2S2TYPE to actuate. The details are the same as A1S1 VAL.

ALARM 1 SETPOINT 1 TYPE—Select what you want Setpoint 1 of Alarm 1 to represent. It can represent the Process Variable, Deviation, Input 1, Input 2, Output, and if you have a model with communications, you can configure the controller to alarm on SHED. If you have setpoint programming, you can alarm when a segment goes ON or OFF.

NONE INPUT 1 INPUT 2 PV DEV OUTPUT SHED EV ON EV OFF MANUAL REM SP F SAFE PV RATE DIG INP 1 DIG INP 2 DEV 2 BREAK TCWARN TCFAIL PVHOLD

ATTENTION NOTE 1. When the controller is configured for Three Position Step Control, alarms set for Output will not

function. NOTE 2. Alarm 1 is not available if the Timer is enabled because Alarm 1 is dedicated to Timer output.

NO ALARM INPUT 1 INPUT 2 PROCESS VARIABLE DEVIATION OUTPUT (NOTE 1) SHED FROM COMMUNICATIONS EVENT ON (SP PROGRAMMING) EVENT OFF (SP PROGRAMMING) ALARM ON MANUAL MODE (NOTE 2) REMOTE SETPOINT FAILSAFE PV RATE OF CHANGE DIGITAL INPUT 1 ACTUATED (NOTE 7) DIGITAL INPUT 2 ACTUATED (NOTE 7) DEVIATION FROM LSP 2 (NOTE 3) LOOP BREAK (NOTE 4) THERMOCOUPLE WARNING (NOTE 5) THERMOCOUPLE FAIL (NOTE 6) PV HOLD

NOTE 3. This Deviation Alarm is based upon deviation from the 2nd Local Setpoint or Remote SP

04/08 UDC3200 Universal Digital Controller Operator Manual 59

Function

Prompt

Lower Display

Selections or

Range of Setting

Upper Display

Parameter Definition

regardless of whichever SP is active. NOTE 4. Loop Break monitors the control loop to determine if it is working. When enabled, the control

output is checked against the minimum and maximum output limit settings. When the output reaches one of these limits, a timer begins. If the timer expires and the output has not caused the PV to move by a predetermined amount, then the alarm activates, thus signalling that the loop is broken. The loop break timer value must be configured by the operator as the AxSx VAL entry. This value is in seconds with a range of 0 to 3600 seconds. A setting of 0 is equivalent to an instantaneous loop break when the output reaches one of its limit values.

The amount of PV Movement required is determined by the “UNITS” setting in the Display Setup Group. For the Degrees F configuration, the PV must move by 3° in the desired direction in the time allowed. For the Degrees C configuration, the PV must move by 2° in the desired direction in the time allowed. For the “NONE” selection, the PV must move 1% of the PV range in the time allowed.

Loop Break alarms do not have a HIGH/LOW State configuration, they are always assumed to be a HIGH state alarm.

NOTE 5. Thermocouple Warning means that the instrument has detected that the Thermocouple Input is starting to fail. Not valid for other input types.

NOTE 6. Thermocouple Failing means that the instrument has detected that the Thermocouple Input is in imminent danger of failing. Not valid for other input types.

NOTE 7: For the Digital Input selections, DIG INP1 can be either enabled or disabled in the Options Group (See Sub-Section

3.11), but DIG INP2 must be enabled in the Options Group for the alarm to

function properly.

A1S1 H L

A1S1 EV

A1S2TYPE

HIGH LOW

BEGIN END

Same as A1S1 TYPE

If Setpoint Programming is disabled or if the Alarm Type is not configured for Event On/Off:

ALARM 1 SETPOINT 1 STATE—Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm High or Low.

HIGH ALARM LOW ALARM

If Setpoint Programming is enabled and if the Alarm Type is configured for Event On/Off:

ALARM 1 SEGMENT EVENT 1—Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm the beginning or end of a segment in setpoint Ramp/Soak programming.

BEGINNING OF SEGMENT END OF SEGMENT

ATTENTION Alarms configured for events will not operate on

Setpoint Program segments of zero length. ALARM 1 SETPOINT 2 TYPE—Select what you want Setpoint 2

of Alarm 1 to represent. The selections are the same as A1S1TYPE.

A1S2 H L

HIGH

ALARM 1 SETPOINT 2 STATE—Same as A1S1 H L.

LOW

60 UDC3200 Universal Digital Controller Operator Manual 04/08

Function

Prompt

Lower Display

A1S2 EV

A2S1TYPE

A2S1 H L

A2S1 EV

A2S2TYPE

Selections or

Range of Setting

Upper Display

BEGIN END

Same as A1S1 TYPE

HIGH LOW

BEGIN END

Same as A1S1 TYPE

Parameter Definition

ALARM 1 SEGMENT EVENT 2—Same as A1S1 EV.

ALARM 2 SETPOINT 1 TYPE—Select what you want Setpoint 1

of Alarm 2 to represent. The selections are the same as A1S1TYPE.

ATTENTION Not available with Relay Duplex or Position

Proportional output types unless using Dual Relay PWA.

ALARM 2 SETPOINT 1 STATE—Same as A1S1 H L.

ALARM 2 SEGMENT EVENT 1—Same as A1S1 EV.

ALARM 2 SETPOINT 2 TYPE—Select what you want Setpoint 2

of Alarm 2 to represent. The selections are the same as A1S1TYPE.

ATTENTION Not applicable with Relay Duplex or Position

Proportional output types unless using Dual Relay PWA.

A2S2 H L

A2S2 EV

ALHYST

ALM OUT1

HIGH LOW

BEGIN END

0.0 to 100.0 % of span or full output as appropriate

NoLATCH LATCH

ALARM 2 SETPOINT 2 STATE—Same as A1S1 H L.

ALARM 2 SEGMENT EVENT 2—Same as A1S1 EV.

ALARM HYSTERESIS—A single adjustable hysteresis is

provided on alarms such that when the alarm is OFF it activates at exactly the alarm setpoint; when the alarm is ON, it will not deactivate until the variable is 0.0 % to 100 % away from the alarm setpoint.

Configure the hysteresis of the alarms based on INPUT signals as a % of input range span.

Configure the hysteresis of the alarm based on OUTPUT signals as a % of the full scale output range.

LATCHING ALARM OUTPUT 1—Alarm output 1 can be configured to be Latching or Non-latching.

NoLATCH —Non-latching

LATCH—Latching

ATTENTION When configured for latching, the alarm will stay

active after the alarm condition ends until the RUN/HOLD key is pressed.

BLOCK

ALARM BLOCKING—Prevents nuisance alarms when the

controller is first powered up. The alarm is suppressed until the parameter gets to the non-alarm limit or band. Alarm blocking affects both alarm setpoints.

04/08 UDC3200 Universal Digital Controller Operator Manual 61

Function

Prompt

Lower Display

DIAGNOST

Selections or

Range of Setting

Upper Display

DISABLE ALARM 1 ALARM 2 ALARM12

DISABLE ALARM 1 ALARM 2

Parameter Definition

DISABLE—Disables blocking ALARM 1—Blocks alarm 1 only ALARM 2—Blocks alarm 2 only ALARM12—Blocks both alarms

ATTENTION When enabled on power up or initial enabling via

configuration, the alarm will not activate unless the parameter being monitored has not been in an alarm condition for a minimum of one control cycle (167 ms).

DIAGNOSTIC—Monitors the Current Output and/or Auxiliary Output for an open circuit condition. If either of these two outputs falls below about 3.5 mA, then an Alarm is activated. This configuration is in addition to whatever was selected for AxSxTYPE.

DISABLE—Disables Diagnostic Alarm ALARM 1—Alarm 1 is diagnostic alarm ALARM 2—Alarm 2 is diagnostic alarm

62 UDC3200 Universal Digital Controller Operator Manual 04/08

3.14 Display Set Up Group

Function

Prompt

Lower Display

DECIMAL

TEMP UNIT

Selections or

Range of Setting

Upper Display

NONE ONE TWO THREE

DEG F DEG C NONE

Parameter Definition

DECIMAL POINT LOCATION—This selection determines where

the decimal point appears in the display.

NONE—No Decimal Place—fixed, no auto-ranging ONE—One Place TWO—Two Places THREE—Three Places

ATTENTION Auto-ranging will occur for selections of one, two or

three decimal places. For example, should the instrument be configured for two decimal places and the PV exceeds 99.99, then the display will change to a single decimal place so that values of

100.0 and above can be shown. TEMPERATURE UNITS—This selection will affect the indication

and operation.

DEG F—Degrees Fahrenheit – Degrees F Annunciator lighted DEG C—Degrees Centigrade – Degrees C Annunciator lighted NONE—No temperature annunciators lighted. Upper and Lower

Displays will show temperature in Degrees Fahrenheit when inputs are configured for Thermocouple or RTD types.

PWR FREQ

RATIO 2

LANGUAGE

60 HZ 50 HZ

DISABLE ENABLE

ENGLISH FRENCH GERMAN SPANISH ITALIAN

POWER LINE FREQUENCY—Select whether your controller is operating at 50 or 60 Hertz.

ATTENTION For controllers powered by +24 Vdc, this configuration should be set to the AC line frequency used to produce the +24 Vdc supply.

Incorrect setting of this parameter may cause normal mode noise problems in the input readings.

INPUT 2 RATIO—This enables the Ratio for Input 2 to be set from the front panel. Input 2 must be installed and enabled for this configuration to operate.

DISABLE—Disables setting Ratio 2 from front panel. ENABLE—Allows the Ratio for Input 2 to be set through the

keyboard. LANGUAGE—This selection designates the prompt language. ENGLISH

FRENCH GERMAN SPANISH ITALIAN

04/08 UDC3200 Universal Digital Controller Operator Manual 63

4 Monitoring and Operating the Controller

4.1 Operator Interface

Introduction

Figure 4-1 is a view of the Operator Interface.

Figure 4-1 Operator Interface

4.2 Entering a Security Code

Introduction

The level of keyboard lockout may be changed in the Set Up mode. However, knowledge of a security code number (0 to 9999) may be required to change from one level of lockout to another. When a controller leaves the factory, it has a security code of 0 which permits changing from one lockout level to another without entering any other code number.

Procedure

If you require the use of a security code, select a number from 0001 to 9999 and enter it when the lockout level is configured as NONE. Thereafter, that selected number must be used to change the lockout level from something other than NONE.

ATTENTION Write the number on the Configuration Record Sheet in the

configuration section so you will have a permanent record.

04/08 UDC3200 Universal Digital Controller Operator Manual 65

Table 4-1 Procedure to Enter a Security Code

Step Operation Press Result

Enter Set Up

Mode

Select any Set

Up Group

Security Code

Entry

SetupSetup

FunctionFunctionFunction

4.3 Individual key lockout

There are three keys that can be disabled to prevent unauthorized changes to the

parameters associated with these keys. First set the “Lock” prompt to NONE.

These keys are:

Run

Hold

Key - you can disable the Run/Hold key for Set Point

Upper Display = SET UP Lower Display = TUNING

Upper Display = 0 Lower Display = SECUR

To enter a four digit number in the upper display

(0001 to 9999)

This will be your security code.

Programming at configuration Set Up group prompt “Tuning,” function prompt “RN HLD.”

See Subsection 3.3 - Tuning Parameters Set Up Group prompts to enable or disable

these keys.

Key error

When a key is pressed and the prompt “Key Error” appears in the lower display, it will be for one of the following reasons:

Man

Auto

Key - you can disable the Auto/Manual key at configuration

Set Up, group prompt “Tuning”, function prompt “AUTOMA”

Select

Key - you can disable the Set Point Select function key at

configuration Set Up group prompt “Tuning,” function prompt “SP SEL.”

• Parameter not available or locked out

• Not in setup mode, press SET UP key first

• Individual key locked out.

66 UDC3200 Universal Digital Controller Operator Manual 04/08

4.4 Monitoring Your Controller

4.4.1 Annunciators

The following annunciator functions have been provided to help monitor the controller:

Table 4-2 Annunciators

Annunciator Indication

ALM 1 2

OUT 1 2 DI 1 2

A or MAN

[None], F or C

A visual indication of each alarm Blinking 1 indicates an alarm latched condition. The blinking will

continue even after the alarm condition ends until it is acknowledged by pressing the RUN/HOLD key.

A visual indication of the control relays A visual indication of each Digital Input

A visual indication of the mode of the controller)

A—Automatic Mode MAN—Manual Mode

A visual indication of the temperature units

[None]—No temperature unit annunciator

F—Degrees Fahrenheit

C—Degrees Celsius A visual Lamp to indicate when the lower display is showing the Active

Setpoint (Local 1, Local 2, Local 3, Remote Setpoint or Computer Setpoint)

The upper left digit of the display is used to show other annunciator functions

T—Accutuning in process C—Computer overide active

O—Output override active

04/08 UDC3200 Universal Digital Controller Operator Manual 67

4.4.2 Viewing the operating parameters

Press the LOWER DISPLAY key to scroll through the operating parameters. The lower display will show only those parameters and their values that apply to your specific model.

Table 4-3 Lower Display Key Parameter Prompts

Lower Display Description

OUT XX.X

SP XXXX 2SP XXXX 3SP XXXX

RSP XXXX

1IN XXXX 2IN XXXX

POS XX CSP XXXX DEV XXXX

PIDSET X

ET HR.MN

OTR HR.MN

RAMPXXXM

SPN XXXX SETPOINT NOW—Current Setpoint when SP Rate is enabled. The SP XXXX display

XXRAHR.MN

XXSKHR.MN

RECYC XX

To BEGIN

RERUN

AUX XXXX

BIA XXXX

TUNE OFF

DO FAST

DO SLOW

OUTPUT—Output value is shown in percent with one decimal point for all output types except Three Position Step Control (TPSC). For TPSC, when no slidewire is connected, this display is an estimated motor position and is shown with no decimal point. For Position Proportional Control, if the slidewire fails, then the instrument automatically switches over to TPSC and the OUT display changes with it.

LOCAL SETPOINT #1—Also current setpoint when using SP Ramp. LOCAL SETPOINT #2 LOCAL SETPOINT #3 REMOTE SETPOINT INPUT 1—Used only with combinational input algorithms. INPUT 2 SLIDEWIRE POSITION—Used only with TPSC applications that use a slidewire input. COMPUTER SETPOINT—When SP is in override. DEVIATION—Maximum negative display is –999.9. TUNING PARAMETER —where X is either 1 or 2. ELAPSED TIME—Time that has elapsed on the Timer in Hours.Minutes. TIME REMAINING—Time remaining on the Timer in Hours.Minutes. The “O” is a

rotating clock face. SETPOINT RAMP TIME—Time remaining in the Setpoint Ramp in minutes.

shows the “target” or final setpoint value. RAMP SEGMENT NUMBER AND TIME REMAINING—Set Point Programming

display. XX is the current segment number and HR.MN is the time remaining for this segment in Hours.Minutes.

SOAK SEGMENT NUMBER AND TIME REMAINING— Set Point Programming display. XX is the current segment number and segment in Hours.Minutes.

NUMBER OF SP PROGRAM RECYCLES REMAINING RESET SP PROGRAM TO START OF FIRST SEGMENT RESET SP PROGRAM TO START OF CURRENT SEGMENT AUXILIARY OUTPUT—Displayed only when output algorithm is not Current Duplex. BIAS—Displays the manual reset value for algorithm PD+MR. LIMIT CYCLE TUNING NOT RUNNING—Appears when Accutune is enabled but not

operating. Limit Cycle Tuning with the objective of producing quarter-damped tuning parameters.

This tuning may result in PV overshoot of the SP setting. Limit Cycle Tuning with the objective of producing damped or Dahlin tuning

parameters, depending upon the detected process deadtime. The tuning parameters calculated by this selection are aimed at reducing PV overshoot of the SP setting.

HR.MN is the time remaining for this

68 UDC3200 Universal Digital Controller Operator Manual 04/08

4.4.3 Diagnostic Messages

The UDC3200 performs background tests to verify data and memory integrity. If there is a malfunction, a diagnostic message will be shown on the lower display. In the case of more than one simultaneous malfunction, only the highest priority diagnostic message will be displayed. Table 4-4 shows the error messages in order by priority.

Table 4-4 Diagnostic Messages

Prompt Description

EE FAIL

FAILSAFE

INP1FAIL

INP2FAIL

SW FAIL

CONF ERR

SOOTING IN1 RNG

IN2 RNG PV LIMIT

Unable to write to nonvolatile memory. A subsequent successful write to nonvolatile memory removes this message.

This error message appears whenever the controller goes into a failsafe mode of operation. Failsafe operation occurs when an analog input fails or when configuration is corrupted.

Two consecutive failures of input 1 integration or input value is outside of Out-of-Range limits.

Two consecutive failures of input 2 integration or input value is outside of Out-of-Range limits.

Slidewire input failure. Position Proportional Control automatically switched to Three Position Step Control.

Configuration Errors—Low limit greater than high limit for PV, SP, Reset, or Output.

Carbon Potential Problem—Percent Carbon outside of “sooting boundary.” Input 1 Out-of-Range—Input is outside of the High or Low Limits.

Out-of-range criteria: Linear range: ± 10 % Characterized range: ± 1 %

Input 2 Out-of-Range—Same criteria as Input 1. PV beyond limits—PV outside of PV Hi/Low Limits.

PV = (PV source x PV source ratio) + PV source bias

FAILSAFE RV LIMIT

SEG ERR

CAL MTR SW FAIL

TC1 WARN TC2 WARN TC1 FAIL TC2 FAIL OUT1FAIL OUT2FAIL

Failsafe—Check inputs or configuration. Remote Variable beyond limits—RSP outside of SP Hi/Low Limits.

RV = (RV source x RV source ratio) + RV source bias Segment Error—SP Program starting segment number is less than ending

segment number. Slidewire not calibrated. Perform Slidewire calibration. Position Proportional slidewire input failure.

The Thermocouple on Input 1 is starting to burnout. The Thermocouple on Input 2 is starting to burnout. Thermocouple on Input 1 is in imminent danger of burning out. Thermocouple on Input 2 is in imminent danger of burning out. Current Output is less than 3.5 mA. Current Output 2 is less than 3.5 mA.

04/08 UDC3200 Universal Digital Controller Operator Manual 69

IN 2

Remote SP

Local SP

LSP1

To RSP

RSP

Source

LSP2

In Alg1

LSP3

Source

IN 1

Ratio

Bias

• •

Source

INPUT

ALGORITHM 1

FEEDFORWARD

To RSP

CONTROL

ALGORITHM

INPUT A ONLY

FEEDFO RWARD

SUMMER OR

MULTIPLIER

1 2

INPUT A

INPUT B

INPUT C

IN 2

Ratio

Bias

• •

•

To RSP

Input 1

Input 2

Output 1

Input 1

Input 2

Output 1

Input 1

Input 2

Output 1

Manual Mode

Output

OUTPUT

To Final

Control

Element

Figure 4-2 Functional Overview Block Diagram of the UDC3200 Controller

70 UDC3200 Universal Digital Controller Operator Manual 04/08

4.5 Accutune III

Introduction

Accutune III (TUNE) may be used for self-regulating and single integrating processes. This autotuning method is initiated on-demand, typically at initial start-up.

There are no other requirements necessary, such as prior knowledge to the process dynamics or initial or post tune process line-out to setpoint or manual output.

Also, the setpoint value is not required to change in order to initiate the tuning process, but the controller must be in the Automatic mode to start tuning. The process need not be in a static (lined out) state and may be dynamic (changing with a steady output).

Configuration check

Make sure:

• TUNE has been enabled see to Subsection 3.5 - Accutune Set Up Group for

details.

Tuning indicators

A “T” will show in the leftmost alphanumeric of the upper display until tuning is completed.

04/08 UDC3200 Universal Digital Controller Operator Manual 71

Operation

The Accutune III algorithm provides user-friendly, on-demand tuning in this controller. No knowledge of the process is required at start-up. The operator simply initiates the tuning while in the automatic mode.

Once Accutune III has been enabled in the TUNE setup group, either “SLOW” or “FAST” tuning may be used. Which one is used is selected via the lower display during normal operation.

For the SLOW selection, the controller calculates conservative tuning constants with the objective of minimizing overshoot. If the controller determines that the process has appreciable dead time, it will automatically default to use Dahlin Tuning, which produces very conservative tuning constants. The SLOW selection may be useful for TPSC and Position Proportional applications, as it reduces “hunt” problems for the motor. This selection is also recommended for applications that have significant deadtimes.

For the FAST selection, the controller calculates aggressive tuning constants with the objective of producing quarter damped response. Depending upon the process, this selection will usually result in some overshoot. For this reason, it may be desireable to enable the FUZZY tune selection. See Section 4.6. When Fuzzy tune is enabled, it will work to suppress or eliminate any overshoot that may occur as a result of the calculated tuning parameters as the PV approaches the setpoint. This selection is best suited for processes with a single lag or for those that do not have any appreciable deadtime. FUZZY tuning does not work well for processes that have appreciable deadtime.

The Accutune III tuning process will cycle the controller’s output two full cycles between the low and high output limits while allowing only a very small Process Variable change above and below the SP during each cycle. A “T” shows in the upper display until tuning is completed.

At the end of the tuning process, the controller immediately calculates the tuning constants and enters them into the Tuning group, and begins PID control with the correct tuning parameters. This works with any process, including integrating type processes, and allows retuning at a fixed setpoint.

4.5.1 Tune for Simplex Outputs

After “TUNE” has been enabled, you can start Accutune as shown in Table 4-5.

Table 4-5 Procedure for Starting “TUNE”

Step Operation Press Result

Configure LSP1

Switch to “Automatic” Mode

Lower

Display

Man

Auto

Until SP (Local Setpoint 1) shows in the lower display.

Until LSP1 is to the desired value.

Until the “A” indicator is lighted (on controllers with Manual option).

72 UDC3200 Universal Digital Controller Operator Manual 04/08

Show Tuning Prompt

Lower

Display

Until “TUNE OFF” is shown on lower display.

Initiate Tuning

Tuning in operation

Lower

Display

Select “DO SLOW” or “DO FAST” in lower display.

Upper display will show a “T” as long as ACCUTUNE process is operating. When process completes, tuning parameters are calculated and lower display will show “NO TUNE” prompt.

ATTENTION

The Accutune process may be aborted at any time by changing the lower display back to “NoTUNE” or by switching the controller into Manual Mode.

4.5.2 Tune for Duplex (Heat/Cool)

Accutune for applications using Duplex (Heat/Cool) control.

The controller must be configured to have two local setpoints unless Blended Tuning is desired (see below). During tuning, the Accutune III process assumes that Local Setpoint 1 will cause a Heating demand (output above 50%), and the tuning parameters calculated for that setpoint are automatically entered as PID SET 1. Likewise, Accutune III assumes that Local Setpoint 2 will cause a Cooling demand (output less than 50%), and the tuning parameters calculated for that setpoint are automatically entered as PID SET 2.

Configuration Check for Duplex

See Subsection 3.5 - Accutune Set Up Group for details.

Make sure:

• TUNE has been enabled

• DUPLEX has been configured to Manual, Automatic or Disabled

04/08 UDC3200 Universal Digital Controller Operator Manual 73

4.5.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool)

Used when DUPLEX has been configured for AUTOMATIC. This is the preferred selection for most Heat/Cool applications when tuning a new chamber. This selection will sequentially perform both Heat and Cool tuning without further operator intervention.

Table 4-6 Procedure for Using AUTOMATIC TUNE at Start-up for Duplex

Control

Step Operation Press Result

Configure LSP1

Configure LSP2

Switch to “Automatic” Mode

Show Tuning Prompt

Lower

Display

Lower

Display

Man

Auto

Lower

Display

Initiate Tuning

Tuning in operation

Lower

Display

Until SP (Local Setpoint 1) shows in the lower display.

Until LSP1 is a value within the Heat Zone (output above 50%).

Until 2SP (Local Setpoint 2) shows in the lower display.

Until LSP2 is a value within the Cool Zone (output below 50%).

Until the “A” indicator is lighted (on controllers with Manual option).

Until “TUNE OFF” is shown on lower display.

Select “DO SLOW” or “DO FAST” in lower display.

Upper display will show a “T” as long as ACCUTUNE process is operating. When process completes, tuning parameters are calculated and lower display will show “NO TUNE” prompt.

74 UDC3200 Universal Digital Controller Operator Manual 04/08

4.5.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool)

When DUPLEX has been configured for DISABLE. This is the preferred selection for Heat/Cool applications which use a highly insulated chamber (a chamber which will lose heat very slowly unless a cooling device is applied). Only one local setpoint (LSP 1) is needed for this selection.

This selection results in performance tuning over the full range utilizing both Heat and Cool outputs to acquire blended tune values that are then applied to both Heat and Cool tuning parameters. Both PID sets are set to the same values.

Table 4-7 Procedure for Using BLENDED TUNE at Start-up for Duplex Control

Step Operation Press Result

Configure LSP1

Switch to “Automatic” Mode

Show Tuning Prompt

Initiate Tuning

Tuning in operation

Lower

Display

Man

Auto

Lower

Display

Lower

Display

Until SP (Local Setpoint 1) shows in the lower display.

Until the Setpoint is to the desired value.

Until the “A” indicator is lighted (on controllers with Manual option).

Until “TUNE OFF” is shown on lower display.

Select “DO SLOW” or “DO FAST” in lower display.

Upper display will show a “T” as long as ACCUTUNE process is operating. When process completes, tuning parameters are calculated and lower display will show “NO TUNE” prompt.

4.5.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool)

When DUPLEX has been configured for MANUAL. This selection should be used when tuning is needed only for the HEAT zone or only for the COOL zone but not both. If Local Setpoint 1 is used, then the controller will perform a HEAT zone tune. If Local Setpoint 2 is used, then the controller will perform a COOL zone tune.

Table 4-8 Procedure for Using MANUAL TUNE for Heat side of Duplex Control

Step Operation Press Result

04/08 UDC3200 Universal Digital Controller Operator Manual 75

Configure LSP1

Switch to “Automatic” Mode

Lower

Display

Man

Auto

Until SP (Local Setpoint 1) shows in the lower display.

Until LSP1 is a value within the Heat Zone (output above 50%).

Until the “A” indicator is lighted (on controllers with Manual option).

Step Operation Press Result

Show Tuning Prompt

Initiate Tuning

Tuning in operation

Lower

Display

Lower

Display

Until “TUNE OFF” is shown on lower display.

Select “DO SLOW” or “DO FAST” in lower display.

Upper display will show a “T” as long as ACCUTUNE process is operating. When process completes, tuning parameters are calculated and lower display will show “NO TUNE” prompt.

Table 4-9 Procedure for Using MANUAL TUNE for Cool side of Duplex Control

Step Operation Press Result

Configure LSP2

Switch to “Automatic” Mode

Lower

Display

Man

Auto

Until 2SP (Local Setpoint 2) shows in the lower display.

Until LSP2 is a value within the Cool Zone (output below 50%).

Until the “A” indicator is lighted (on controllers with Manual option).

Show Tuning Prompt

Initiate Tuning

Tuning in operation

Lower

Display

Lower

Display

Until “TUNE OFF” is shown on lower display.

Select “DO SLOW” or “DO FAST” in lower display.

Upper display will show a “T” as long as ACCUTUNE process is operating. When process completes, tuning parameters are calculated and lower display will show “NO TUNE” prompt.

76 UDC3200 Universal Digital Controller Operator Manual 04/08

4.5.6 Error Codes

Table 4-10 Procedure for Accessing Accutune Error Codes

Step Operation Press Result

Select Accutune

Set-up Group

Go to Error Code

Prompt

Error Code

(Upper Display)

RUNNING

NONE

ID FAIL

SetupSetup

FunctionFunctionFunction

Upper Display = SETUP Lower Display = ACCUTUNE

Upper Display = (an error code) Lower Display = AT ERROR

Table 4-11 lists all the error codes, definitions, and fixes.

Table 4-11 Accutune Error Codes

Definition

ACCUTUNE RUNNING NO ERRORS OCCURRED

DURING LAST ACCUTUNE PROCEDURE

PROCESS IDENTIFICATION FAILURE Autotune has aborted because an illegal value of GAIN, RATE, or reset was calculated.

Fix

The Accutune process is still active (Read Only) None

• Illegal Values – try Accutune again.

• untunable process -- contact local application engineer.

ABORT

SP2

CURRENT ACCUTUNE PROCESS ABORTED caused by the following conditions:

a. Operator changed to Manual mode

b. Digital Input detected c. In Heat region of output

and a Cool output calculated or vice versa.

LSP2 not enabled or LSP1 or LSP2 not in use (only applies to Duplex Tuning)

Aborting Accutune

To abort Accutune and return to the last previous operation (SP or output level), press

MAN-AUTO key to abort the Accutune process or increment from the “DO SLOW” or

“DO FAST” prompt to the “TUNE OFF” prompt.

Completing Accutune

When Accutune is complete, the calculated tuning parameters are stored in their proper memory location and can be viewed in the TUNING Set up Group, and the

Try Accutune again

Enable LSP2 and configure the desired LSP1 and LSP2 setpoints.

04/08 UDC3200 Universal Digital Controller Operator Manual 77

controller will control at the local setpoint using these newly calculated tuning constants.

4.6 Fuzzy Overshoot Suppression

Introduction

Fuzzy Overshoot Suppression minimizes Process Variable overshoot following a setpoint change or a process disturbance. This is especially useful in processes which experience load changes or where even a small overshoot beyond the setpoint may result in damage or lost product.

How it works

The Fuzzy Logic in the controller observes the speed and direction of the PV signal as it approaches the setpoint and temporarily modifies the internal controller response action as necessary to avoid an overshoot. There is no change to the PID algorithm, and the fuzzy logic does not alter the PID tuning parameters. This feature can be independently Enabled or Disabled as required by the application to work with the Accutune algorithm. Fuzzy Tune should not be enabled for processes that have an appreciable amount of deadtime.

Configuration

To configure this item, refer to Section 3 - Configuration:

Set Up Group “ACCUTUNE” Function Prompt “FUZZY” Select “ENABLE” or “DISABLE” - Use or .

78 UDC3200 Universal Digital Controller Operator Manual 04/08

5 Troubleshooting/Service

5.1 Background Tests

The UDC3200 performs ongoing background tests to verify data and memory integrity. If there is a malfunction, a diagnostic message will be displayed (blinking) in the lower display. In the case of simultaneous malfunctions, the messages will appear in sequence in the lower display.

Diagnostic messages may be suppressed (stop the blinking) by pressing the RUN/HOLD key. The messages will still be available for viewing by pressing the LOWER DISPLAY key.

Table 5-1 Background Tests

Lower

Display

EE FAIL

FAILSAFE

INP1 RNG

INP1FAIL

INP2 RNG

Reason for Failure How to Correct the Problem

Unable to write to non-volatile memory. Anytime you change a parameter and it is not accepted, you will see E FAIL.

This error message shows whenever the controller goes into a failsafe mode of operation. This will happen if:

• RAM test failed

• Configuration test failed

• Calibration test failed

• Burnout configured for none and the input failed.

Input 1 out of range. The process input is outside the range limits.

Two consecutive failures of input 1 integration; i.e., cannot make analog to digital conversion. This will happen if:

• Upscale or Downscale burnout is selected and the input is open

• Input not configured correctly for the sensor being used

• Input source is grossly out of range.

Input 2 out of range. The remote input is outside the range limits.

1. Check the accuracy of the parameter and re-enter.

2. Try to change something in configuration.

3. Run through Read STATUS tests to re-write to EEPROM.

1. Run through STATUS check to determine the reason for the failure.

2. Press the the lower display.

3. Press the pass or fail, then run through the STATUS codes a second time to see if the error cleared.

1. Make sure the range and actuation are configured properly.

2. Check the input source.

3. Restore the factory calibration.

4. Field calibrate.

1. Make sure the actuation is configured correctly. See Section

2. Make sure the input is correct and that it has not burned-out (opened).

3. Check for gross over-ranging with a multimeter.

4. Restore factory calibration.

Same as INP1RNG above.

SET UP key until STATUS appears in

FUNCTION key to see whether the tests

3 - Configuration.

INP2FAIL

CONF ERR

04/08 UDC3200 Universal Digital Controller Operator Manual 79

Two consecutive failures of input 2 integration. i.e., cannot make analog to digital conversion.

• PV low limit is > PV high limit

• SP low limit is > SP high limit

• Output low limit > Output high limit

Same as INP1FAIL above.

1. Check the configuration for each item and

reconfigure if necessary.

Lower

Display

PV LIMIT

RV LIMIT

SEGERR

CAL MTR SW FAIL SOOTING

TCx WARN

Reason for Failure How to Correct the Problem

PV out of range. PV = INP1 x RATIO1+ INP1 BIAS

The result of the formula shown below is beyond the range of the remote variable.

RV = INP2 X RATIO + BIAS

Setpoint Program start segment number is less than ending segment number.

Slidewire calibration never performed. Field Calibrate the slidewire. Position Proportional slidewire input failure. Check the slidewire.

Percent Carbon falls outside sooting boundary

Thermocouple on Input x (1 or 2) is starting to burnout.

1. Make sure the input signal is correct.

2. Make sure the Ratio and Bias settings are correct.

3. Recheck the calibration. Use Bias of 0.0

1. Make sure the input signal is correct.

2. Make sure the Ratio2 and Bias2 settings are correct.

3. Recheck the calibration. Use a Ratio2 of 1.0 and a Bias2 of 0.0.

Check SP Program configuration, subsection 3.4 Set up Group SPPROG function prompts “STRSEG” and “ENDSEG”.

Check process for correct operation.

This diagnostic message means that the controller has detected that the thermocouple is starting to burnout. This error message may also be created if the resistance of the wires used to connect the thermocouple to the instrument is above 100 ohms.

TCxFAIL

CURFAIL

AXFAIL

The Thermocouple on Input x (1 or 2) is in imminent danger of burning out.

Current Output is less than 3.5 mA. The current output is open circuit. Check the field

Auxiliary Output is less than 3.5 mA. The auxiliary output is open circuit. Check the field

This diagnostic message means that the controller has detected that the thermocouple will soon fail. User should consider replacing the thermocouple as soon as possible. This message will also be generated if the resistance of the wires used to connect the thermocouple to the instrument is above 180 ohms.

wiring.

80 UDC3200 Universal Digital Controller Operator Manual 04/08

5.2 Controller Failure Symptoms

Upper

Display

Blank Blank Off None Power Failure

OK OK Current

OK OK Position

OK OK Time Proportional

OK OK OK External Alarm

Display does not change when a key is pressed Keyboard

Controller fails to go into “Slave” operation during communications Communications

Lower

Display

Displayed

Output

disagrees

with Controller

Output

Indicators Controller

Output

Controller

Output

disagrees

with Displayed

Output

function does

not operate

properly

Probable

Cause

Proportional Output

Proportional or

TPSC Output

Output

Current/Time

Proportional Output

Malfunction in

alarm output

Malfunction

Failure

OK Displayed

Auxiliary Output

Other symptoms

If a set of symptoms or prompts other than the one you started with appears while troubleshooting, re-evaluate the symptoms. This may lead to a different troubleshooting procedure.

If the symptom still persists, refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system.

Output

disagrees with

Controller

Auxiliary Output

disagrees

with Displayed

Auxiliary Output

04/08 UDC3200 Universal Digital Controller Operator Manual 81

6 Sales and Service

For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor, contact one of the offices below.

ARGENTINA

Honeywell S.A.I.C. Belgrano 1156 Buenos Aires Argentina Tel. : 54 1 383 9290

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VENEZUELA

HONEYWELL CA APARTADO 61314 1060 CARACAS VENEZUELA Tel. : 58 2 239 021

82 UDC3200 Universal Digital Controller Operator Manual 04/08

Honeywell Process Solutions

512 Virginia Drive Fort Washington, PA 19034

51-52-25-143 Rev. 1 0408 Printed in USA http://hpsweb.honeywell.com

Honeywell UDC3200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contacts

Symbol Definitions

Contents

1.1 Operator Interface

1 Introduction

1.2 Function of Displays and Keys

1.3 CE Conformity (Europe)

2 Installation

2.1 Pre-installation Information

2.2 Model Number Interpretation

2.3 Control and Alarm Relay Contact Information

2.4 Mounting

2.5 Wiring

2.5.1 Electrical Considerations Line voltage wiring

2.6 Wiring Diagrams

3 Configuration

3.1 Configuration Prompt Hierarchy

3.2 Configuration Procedure

3.3 Tuning Set Up Group

3.4 SP Ramp Set Up Group

3.5 Accutune Set Up Group

3.6 Algorithm Set Up Group

3.7 Output Set Up Group

3.8 Input 1 Set Up Group

3.9 Input 2 Set Up Group

3.10 Control Set Up Group

3.11 Options Group

3.12 Communications Group

3.13 Alarms Set Up Group

3.14 Display Set Up Group

4 Monitoring and Operating the Controller

4.1 Operator Interface

4.2 Entering a Security Code

4.3 Individual key lockout

4.4 Monitoring Your Controller

4.4.1 Annunciators

4.4.2 Viewing the operating parameters

4.4.3 Diagnostic Messages

4.5 Accutune III

4.5.1 Tune for Simplex Outputs

4.5.2 Tune for Duplex (Heat/Cool)

4.5.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool)

4.5.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool)

4.5.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool)

4.5.6 Error Codes

4.6 Fuzzy Overshoot Suppression

5 Troubleshooting/Service

5.1 Background Tests

5.2 Controller Failure Symptoms

6 Sales and Service