Honeywell UDC3500 Specifications
UDC3500
51-52-03-40
March 2007
Page 1 of 16
Universal Digital Controller
Overview
New Power and Flexibility
The UDC3500 Universal Digital
Controller packs new powerful features
in the popular 1/4 DIN size.
Unmatched application power includes:
Infrared (IR) Configuration interface,
three universal analog inputs, two loops
of control and two Math Algorithms.
When these are combined with the
Accutune III™ tuning with fuzzy logic
overshoot suppression, the result is
price/performance leadership.
Application flexibility is assured by the
universal analog inputs, universal AC
power supply, four digital inputs, a
maximum of seven analog and digital
outputs, Infrared, RS422/485 Modbus
RTU or Ethernet 10Base-T TCP/IP
Modbus communication protocols,
simple configuration plus total field
upgrade capability for any optional
feature.
Features
• 3 Universal Analog Inputs (can be
configured to operate as 1
Universal and 4 High Level Inputs)
• 0.10% Accuracy
• Fast scanning rate (166ms)
• Up to 3 Analog Outputs
• Up to 5 Digital Outputs
• 4 Digital Inputs
• Math Functions
• Ethernet or RS-485 communication
• Cascade or 2 Loops of control
• Infrared PC & Pocket PC
configuration
• Healthwatch Maintenance Tool
• NEMA4X and IP66 front face
protection
• Multilanguage prompts
• ¼ DIN Size
• Easily Field Upgradeable
• Bright, dual displays with multi-
language prompts (in English,
French, German, Spanish, or
Italian) make the operator interface
easy to read, understand, and
operate. Simple keystrokes let you
set operating parameters that meet
your process control needs.
The UDC3500 has up to three
Universal analog inputs with a typical
accuracy of ±0.10% of full-scale input
and a typical resolution of 16 bits.
These can easily be configured to
operate as 2 Universal and 2 High
Level or as 1 Universal and 4 High
Level inputs. All analog inputs are
sampled six times per second (every
166 milliseconds). The first, or Process
Variable input, can be one of various
thermocouple, RTD, Radiamatic or
linear actuations as shown in Table 1.
Linear actuations have thermocouple,
RTD and Radiamatic transmitter
characterization capability as a
standard feature. Linear actuations
also have square root capability.
The optional second and third inputs are
isolated from each other and all other
circuits and accept the same actuations
as input one. These optional inputs can
each be split into two high level inputs.
The fourth input is enabled by first
configuring Input 2 as a 20 mA or 5 Vdc
input type (High Level Analog Input –
HLAI). Input 4 is then available as a
high level input. The fifth input is
enabled by first configuring Input 3 as a
20 mA or 5 Vdc type (HLAI). Input 5 is
then available as a high level input.
Figure 1 - UDC3500 Universal Digital Controller
Analog Inputs
All actuations and characterizations
are keyboard configurable. A separate
Cold Junction compensator is
provided for each thermocouple type
analog input, thus maximizing
accuracy. Upscale, downscale or
failsafe sensor break protection is
keyboard configurable. Square Root
Extraction, Ratio/Bias and a
configurable digital filter of 0 to 120
seconds for signal damping are
available for each input.
See Table 1 for other details.
Algorithms – Two pre-configured
algorithms are available for easy
implementation. The following
selections are available:
Feedforward Summer—Uses any
input, followed by a Ratio/Bias
calculation, summed directly with the
computed PID output value to provide
a resultant output to the final control
element (standard feature).
Feedforward Multiplier—Uses any
input, multiplied by the calculated PID
output to provide a resultant output,
which is sent to the final control
element (standard feature).
Specification
Analog Inputs (continued)
Math Functions (Option)
Honeywell Process Solutions, 512 Virginia Drive, Fort Washington, PA 19034
Printed in U.S.A. ν © Copyright 2007 — Honeywell
51-52-03-40
Page 2
Math Functions (Option)—continued
Weighted Average – Averages any two
inputs to derive the PV or SP (standard
feature).
Summer/Subtractor – Will add or
subtract up to three inputs with the result
used as the derived PV or SP.
Multiplier/Divider – Uses the analog
inputs to calculate a derived PV or SP.
Available with or without Square Root.
Input High/Low Select – Specifies the
PV or SP as the higher or lower of the
two inputs.
8 Segment Characterizers – Two 8segment characterizers are available
that can be applied to any Analog
Input, to Loop 1 Output or to Loop 2
Output. These can be linked together
to produce a single 16-segment
characterizer.
Polynomial Curve Characterizer – A
fifth order polynomial equation can be
used on any one of the analog inputs.
Totalizer – Calculates and displays the
total flow volume as measured by one of
the analog inputs or as derived by either
Math algorithm. Displayed value is eight
digits with a configurable scaling factor.
The totalizer value may be reset.
Combinational Inputs – Inputs can
be combined for use with Relative
Humidity, % Oxygen, Carbon
Potential, Dewpoint or Math
Algorithms. This controller can accept
carbon probes from Cambridge,
Marathon Monitors, Corning, A.A.A.C,
Barber Coleman, MacDhui, Bricesco
or Furnace Controls. See Table 1 for
other details.
Logic Gates – Five Logic Gates
configurable as OR, NOR, AND, NAND,
XOR, XNOR, or COMPARATOR. Each
Gate has two inputs and one output.
Logic Gates may be linked together to
perform more complex functions.
Communications
An infrared communication link is
standard on the UDC3500, which allows
a non-intrusive configuration of the
instrument via Honeywell Process
Instrument Explorer (P.I.E.) software.
RS-422/485 Modbus® RTU or Ethernet
TCP/IP Modbus communications links
are available as options. These allow
communications between the UDC3500
and a host computer or PLC. The
Second Current Output option is
mutually exclusive with the Ethernet
Communications option.
Outputs and Control
Output Types – The UDC3500 may
have as many as seven analog and
digital outputs made up of two or more of
the following types:
• Current Outputs (4-20 or 0-20 mA)
• Electromechanical Relays (5 amps)
• Solid State Relay (1 amp)
• Dual Electromechanical Relays (2
amps)
• Open Collector Output (20 mA)
Output Algorithms – The UDC3500 is
available with one or more of the
following output algorithms:
• Time Proportional provides On-Off
or Time Proportional (Relay) output.
• Current Proportional supplies
proportional direct current output for
those final control elements that
require a 4-20mA signal. Output can
be easily configured via the
keyboard for 0-20mA operation
without recalibration.
• Position Proportional positions a
reversible motor with a feedback
slidewire in proportion to the output
of the control algorithm. Requires
the Dual Relay Output option and
the Third Analog Input. Not available
on Loop 2.
• Current Proportional Duplex –
Similar to current proportional but
provides a second set of tuning
parameters and a split range current
output or a second current output
via one of the optional current
outputs, for the heat and cool zones.
• Time Proportional Duplex –
Depending on which control
algorithm you select, this duplex
output algorithm can provide On-Off
Duplex, Time Proportional Duplex,
or Three Position Step Control
(TPSC). The Time Proportional
Duplex output algorithm provides
two independent PID tuning sets
and two time proportional outputs;
one for heat zone above 50%
output, and one for cool zone below
50% output. Requires the Dual
Relay Output option.
• Current/Relay Duplex
(Relay=Heat) – A variation of
Duplex with Current active for 0 to
50% output and Relay active 50 to
100% output.
Outputs and Control (continued)
Output Algorithms, continued
• Relay/Current Duplex
(Relay=Cool) – A variation of
Duplex with Current active for 50 to
100% output and Relay active for 0
to 50% output.
Control Algorithms – Depending on
the output algorithms specified, the
controller can be configured for the
following control algorithms:
• On-Off
• PID-A
• PID-B
• PD with Manual Reset
• Three Position Step Control (TPSC)
The TPSC algorithm is a form of motor
control that does not require a feedback
slidewire linked to the motor shaft.
Similar to Position Proportional control,
TPSC uses two relays to control an
electric motor; one to drive the motor
upscale and the other to drive the motor
downscale. TPSC is an automatic backup mode to Position Proportional
Control if the feedback slidewire signal
should fail. TPSC requires the Dual
Relay Output Option. TPSC is not
available on Loop 2.
Dual Loop – Internal Cascade
(Optional) – Two independent loops or
internally cascaded loops in one device.
Includes Output Override Algorithm.
Five Control Modes – The following
control modes are available:
1. Manual (one or two loops)
2. Automatic with Local Setpoint
(one or two loops)
3. Automatic with Remote Setpoint
(one or two loops)
4. Manual Cascade
5. Automatic Cascade
Digital Inputs (Option)
Four isolated digital inputs are provided
for remote dry contact closure to select
one of the following actions:
• Manual control mode
• Local Setpoint 1
• Local Setpoint 2
• Local Setpoint 3
• Local Setpoint 4
• Remote Setpoint
• Direct controller action
• Hold SP Ramp/Program
• Run - SP Ramp/Program
• ReRun - SP Ramp/Program
• External program reset
• Select PID set 2
• Select PID set 3
• Select PID set 4
• Disable PID integral action
• PV = Input 2
• PV = Input 3
• Manual mode, failsafe output
• Disable keyboard
• Output 1 = Fixed value
• Start Timer
• Auto/Manual Station
• Initiate Tuning
• Initiate PV Hot Start
• Output 1 tracks Input 2
• PID reset feedback via Input 2
• Purge
• Auxiliary Output Purge
• Low Fire
• To Latching Manual Mode
• Reset Totalizer
• PV Hold
Digital inputs 1 and 2 can have one of
the following selections combined with
one of the above selections:
• Select PID set 2
• Direct controller action
• Local Setpoint 1
• Local Setpoint 2
• Disable Accutune
• To Run – SP Ramp/Program
Any unused current output connected to
a remote dry contact can be used to trip
an alarm relay, thus acting as an
additional digital input.
Miscellaneous Features
Auxiliary Output – Any of the three
current outputs can function as an
Auxiliary Output, which can be scaled for
0 to 100% for any range. An Auxiliary
Output can be configured to represent
any analog input, PV, active Setpoint,
Local SP1, Remote SP, Deviation, or
Control Output. The Second Current
Output option is mutually exclusive with
the Ethernet Communications option.
Miscellaneous Features (continued)
Transmitter Power – This option
provides up to 30 volts dc to power a 2wire transmitter (requires the use of
Output #2 open collector output selection
or one of the current outputs).
Four Local and one Remote Setpoints
– Each loop can be configured to provide
four Local Setpoints and one Remote
Setpoint, which can be automatically or
manually selectable either via the
keyboard or by Digital Input.
Universal Switching Power – Operates
on any line voltage from 90 to 264 Vac
50/60 Hz without jumpers. 24 Vac/dc
instrument power is available as an
option.
Four Sets of Tuning Constants – Four
sets of PID parameters can be configured
for each loop and can be selected
automatically or manually by Keyboard or
Digital Input.
Timer – This standard feature provides a
configurable time period of 0 to 99 hours,
59 minutes or units of minutes and
seconds. It can be started via the
keyboard, Alarm 2, the Real Time Clock
or by a digital input. The timer output is
Alarm 1, which energizes at the end of the
Timer Period. Alarm 1 can be
automatically reset. The Timer Period can
be changed between each batch. Status
is shown on the lower display.
Moisture Protection – The NEMA4X and
IP66 rated front face permits use in
applications where it may be subjected to
moisture, dust, or hose-down conditions.
UL and CSA approved as Type 4
protection.
Setpoint Ramp/Soak Programming
(Optional) – Enables you to program and
store up to ten Ramp and ten Soak
segments (20 total) for Setpoint
Programming (SPP). Run or Hold of
program is keyboard or remote digital
switch selectable. Each Soak Segment
may have a unique Guaranteed Soak
Deviation value. Each Ramp and Soak
Segment can be configured to use any
one of the four PID Sets.
Enhanced Setpoint Ramp/Soak
Programming (Optional) – Enables you
to program and store up to four
independent Setpoint Programs, each
with up to ten Ramp and ten Soak
segments. These can be combined to
form up to two programs with each
program having up to twenty Ramp and
twenty Soak segments (40 total). Run or
Hold of program is keyboard or remote
digital switch selectable. Each Soak
Segment may have a unique Guaranteed
Soak Deviation value. Each Ramp and
Soak Segment can be configured to use
any one of the four PID Sets.
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Miscellaneous Features (continued)
Setpoint Rate – Lets you define a
ramp rate to be applied to any local
setpoint change. A separate upscale or
downscale rate is configurable. A single
setpoint ramp is also available as an
alternative.
Output Rate Limiter – A maximum
output rate may be configured for both
the upscale and the downscale output
directions.
Data Security – Five levels of
keyboard security protect tuning,
configuration, and calibration data,
accessed by a configurable 4-digit
code. Nonvolatile EEPROM memory
assures data integrity during loss of
power.
Quality/Support – The UDC3500 is
covered by an 18-month warranty and
backed up by a toll-free phone number
for technical assistance (US Only).
Accutune III™ – This standard feature
provides a truly plug and play tuning
algorithm, which will, at the touch of a
button or through a digital input,
accurately identify and tune any
process including those with dead-time
and integrating processes. This speeds
up and simplifies start-up plus allows
retuning at any setpoint. The algorithm
used is an improved version of the
Accutune II
previous controllers. Two possibilities
are now offered when tuning your
process: Fast Tune and Slow Tune.
Fast Tune will tune the process in such
a way that the temp is reached faster, a
slight overshoot will be allowed.
Slowtune will minimize overshoot, but
it will take more time for the process
temperature to reach the target
setpoint.
Heat/Cool (Duplex Tune) will
automatically tune both the heating and
cooling sides of the process.
Fuzzy Logic – This standard feature
uses fuzzy logic to suppress process
variable overshoot due to SP changes
or externally induced process
disturbances. It operates independently
from Accutune III™ tuning. It does not
change the PID constants, but instead
temporarily modifies the internal
controller response to suppress
overshoot. This allows more aggressive
tuning to co-exist with smooth PV
response. It can be enabled or disabled
depending on the application or the
control criteria.
Diagnostic/Failsafe Outputs –
Continuous diagnostic routines detect
failure modes, trigger a failsafe output
value and identify the failure to
minimize troubleshooting time.
TM
algorithm used on
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Miscellaneous Features (continued)
HealthWatch (optional) – Consists of
three timers and three counters, each
of which can be assigned to track the
following UDC3500 controller
functions:
(3) Timers
• Total Operating Time
• Time in Manual or Automatic Mode
• Time in Alarm
• Time of Digital Input Activation
• Time in “Sooting” State
(3) Counters
• Manual Control Mode Counts
• Alarm Trip Counts
• Control Relay Actuations
• Digital Input Actuations
• Outside PV Range Limit Counts
• Failsafe Mode Counts
• Re-tune Counts
• Out of Soak-Band Counts
• Power Cycle Events
Selected Maintenance & Diagnostic data
can be accessed from the front panel or
via communications. Alarms can be
configured to activate when a desired
threshold is reached. A security code is
required to perform resetting of any of
the above listed counter or timer
functions.
Real Time Clock (optional) – A batterybacked clock feature that allows the user
to perform such things as starting a
Setpoint Program on a specific date and
time.
Auto/Manual Station Plus Back-up
Control – A UDC3500 can act as both
an Auto/Manual Station PLUS as a backup PID Controller, should the primary
loop controller fail. Since the PID control
is sometimes implemented via a PLC,
this feature provides a very cost-effective
way to insure the process does not have
to shutdown or remain in manual mode if
the PLC should fail. Switching from the
Auto/Manual Station to the back-up
control mode is accomplished using the
Digital Input option.
High Noise Immunity – The controller
is designed to provide reliable, error-free
performance in industrial environments
that often affect highly noise-sensitive
digital equipment.
CE Mark – Conformity with 73/23/EEC,
Low Voltage Directive and 89/336/EEC,
the EMC Directive as a standard feature.
Approval Body Options – CSA
certification and UL listing are available
as an option.
Indicators – Provide alarm, control
mode and temperature unit indication.
There is also indicators for which
setpoint is active, the status of the
control relays, status of the Digital
Inputs, when an Accutune III™ process
is being performed and whether a
Setpoint Program is in Run, Hold or
Guaranteed Soak mode.
Displays – During normal operation,
the upper display is dedicated to the
process variable (4-digits) 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).
You decide how the controller is to
interact with the process by selecting,
through simple keystrokes, the
functions you want.
Multi-language prompts guide the
operator step-by-step through the
configuration process assuring quick
and accurate entry of all configurable
parameters. Five languages are
available via configuration: English,
French, German, Spanish and Italian.
Decimal Point Location –
Configurable for none, one, two or three
places.
Dedicated Keys – Provide direct
access to setpoint modes and to
Setpoint Program operation to simplify
and speed operator procedures.
Operator Interface
Alarms (Option)
Up to four electromechanical alarm
relays are available to activate external
equipment when preset alarm setpoints
are reached. Each of the four alarms can
be set to monitor two independent
setpoints. Each alarm setpoint can be
either high or low alarm. The alarm type
can be selected to be either of the
inputs, the Process Variable, Deviation,
Output, Shed from communications, PV
rate of change, or to alarm on manual
mode activation. It can also be used as
an On or Off event at the beginning or
end of a Ramp/Soak segment. Each
alarm has a configurable hysteresis
configurable 0 to 100% of range.
Also available is a Diagnostic Alarm
configuration to monitor the Current
Outputs for an open circuit condition. If
any of the outputs falls below about 3.5
mA, then the Diagnostic Alarm is
activated. This configuration is in
addition to whatever alarm configuration
was selected. Effectively, the Diagnostic
Alarm can be used as an additional
Digital Input used to trip an Alarm Relay
when a Current Output circuit opens.
• Alarms 1 and 2 can be configured
as latching or non-latching.
• Alarm blocking is also available
which allows start-up without alarm
energized until after the tracked
variable first reaches the operating
region.
• PV rate of change alarm.
• Loop break alarm.
• Timer output reset.
• Diagnostic Alarm
Physical Description
General Description -The controller is
housed in a 5.8-inch (148 mm) deep,
black plastic case with a dark gray
elastomer bezel that is panel mounted in
a 1/4 DIN cutout. (See Figure 4.) The
plug-in chassis allows easy access to
the controller board and its various
option boards. All power, input, and
output wiring are connected to screw
terminals on the rear panel.
(See Figure 5.)
UL and CSA Approved Sealed Front
Face – NEMA3R and IP54, or NEMA4X
and IP66 with 4 screws. UL and CSA
approved as Type 4 moisture protection
when used with 4 screws.
AA
3200 3500
Operator Interface
Figure 2 – Front Face
Display Indicators
Upper display with 4 larger digits shows Process
Variable value (normal operation) and special
annunciator features. During Configuration, the
upper display provides guidance for the operator
through prompts (7 – characters)
OUT
Control Relay 1 through 4 annunciations.
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SP 3500
ALMALM
Func
Loop 1/2
SetupSetup
Lower
Lower
Lower
Display
Display
Display
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,
FF
Indicates either degrees Fahrenheit or Centigrade.
or
CC
the lower display provides guidance for the
operator through prompts (8-characters).
Alarm 1 through 4 annunciations.
DIDI
Digital Input 1 through 4 annunciations.
Indicates either Manual
MAN
or
or
Auto mode.
SPSP
Indicates Local Setpoint #1. The lower display also
shows other control information and other setpoints.
A bar is lighted next to the lower display when the
setpoint currently being used is shown on the lower
display.
Keys and Functions
Selects functions within each configuration
group. Switches between Loop Displays for
Two Loop and Cascade units.
Scrolls through the configuration groups.
Returns Controller to normal display from
Set Up mode. Toggles various operating
parameters for display.
Increases setpoint or output value.
Increases the configuration values or
changes functions in Configuration mode
groups.
Infrared transceiver
Man
Man
Man
Auto
Auto
Auto
SP
SP
SP
Select
Select
Select
Run
Run
Run
Hold
Hold
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)
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