UDC3500
Universal Digital Controller
Product Manual
51-52-25-120
Revision 4
March 2012
Honeywell Process Solutions
Notices and Trademarks
Copyright 2012 by Honeywell
Revision 4 March 2012
While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied
warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be
stated in its written agreement with and for its customers.
In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and
specifications in this document are subject to change without notice.
Honeywell, PlantScape, Experion PKS, and TotalPlant are registered trademarks of Honeywell International Inc.
Other brand or product names are trademarks of their respective owners.
Honeywell Process Solutions
1860 West Rose Garden Lane
Phoenix, Arizona 85027
.
ii UDC3500 Universal Digital Controller Product Manual March 2012
About This Document
Abstract
This document provides descriptions and procedures for the Installation, Configuration, Operation, and Troubleshooting of
your UDC3500 Controller.
Revision Information
Document Name
UDC3500 Universal Digital Controller
Product Manual
Input Voltage change 51-52-25-120 4 March 2012
Document ID Revision
Number
Publication Date
References
The following list identifies all documents that may be sources of reference for material discussed in this p ublication.
Document Title
Process Instrument Explorer manual 51-52-25-131
How to Apply Digital Instrumentation in Severe Electrical Noise
Environments.
Modbus RTU Serial Communications User Manual 51-52-25-66
MODBUS Messaging on TCP/IP Implementation Guide. 51-52-25-121
51-52-05-01
March 2012 UDC3500 Universal Digital Controller Product Manual iii
Support and Contact info
United States and Canada
Contact: Honeywell Process Solution
Global Technical Support - Phone: 001-800-423-9883
Customer Service (HFS) - Phone: 001-800-343-0228
Outside United States - Phone: 001-215-641-3610
Calls are answered by dispatcher between 6:00 am and 4:00 pm Mountain Standard Time.
Emergency calls outside normal working hours are received by an answering service and returned
within one hour.
Email support: ask-ssc@honeywell.com
Mail: Honeywell Process Solutions
1860 West Rose Garden Lane,
Phoenix, Arizona 85027
For more contact details for Europe, Asia, North and South Americas, please see back page.
World Wide Web
Honeywell Process Solutions Support Online:
www.honeywellprocess.com/
Elsewhere
Call your nearest Honeywell office.
Training Classes
Honeywell Automation College:
http://www.automationcollege.com
iv UDC3500 Universal Digital Controller Product Manual March 2012
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.
The Canadian Standards mark means the equipment has been tested and meets
applicable standards for safety and/or performance.
For radio equipment used in the European Union in accordance with the R&TTE
Directive the CE Mark and the notified body (NB) identification number is used when
the NB is involved in the conformity assessment procedure. The alert sign must be
used when a restriction on use (output power limit by a country at certain
frequencies) applies to the equipment and must follow the CE marking.
March 2012 UDC3500 Universal Digital Controller Product Manual v
Contents
1 INTRODUCTION ................................................................................................... 1
1.1 Overview.........................................................................................................................................1
1.2 Operator Interface...........................................................................................................................6
1.2.1 Function of Displays and Keys............................................................................................7
1.3 Process Instrument Explorer Software............................................................................................8
1.4 CE Conformity (Europe)...............................................................................................................10
2 INSTALLATION...................................................................................................11
2.1 Overview.......................................................................................................................................11
2.2 Condensed Specifications.............................................................................................................13
2.3 Model Number Interpretation.......................................................................................................17
2.4 Control and Alarm Relay Contact Information.............................................................................20
2.5 Mounting.......................................................................................................................................21
2.6 Wiring...........................................................................................................................................23
2.6.1 Electrical Considerations ...................................................................................................23
2.7 Wiring Diagrams...........................................................................................................................25
3 CONFIGURATION...............................................................................................45
3.1 Overview.......................................................................................................................................45
3.2 Configuration Prompt Hierarchy ..................................................................................................47
3.3 Configuration Procedure...............................................................................................................51
3.4 Loop 1 Tuning Set Up Group.......................................................................................................52
3.5 Loop 2 Tuning Set Up Group.......................................................................................................56
3.6 SP Ramp Set Up Group ................................................................................................................59
3.7 SP Program 2 Set Up Group.........................................................................................................65
3.8 SP Program 3 Set Up Group.........................................................................................................68
3.9 SP Program 4 Set Up Group.........................................................................................................71
3.10 Accutune Set Up Group ............................................................................................................ 74
3.11 Algorithm Set Up Group...........................................................................................................79
3.12 Math Set Up Group ...................................................................................................................94
3.13 Logic Gates Set Up Group ......................................................................................................100
3.14 Output Set Up Group...............................................................................................................107
3.15 Input 1 Set Up Group ..............................................................................................................118
3.16 Input 2 Set Up Group ..............................................................................................................122
3.17 Input 3 Set Up Group ..............................................................................................................125
3.18 Input 4 Set Up Group ..............................................................................................................128
vi UDC3500 Universal Digital Controller Product Manual March 2012
3.19 Input 5 Set Up Group ..............................................................................................................131
3.20 Control Set Up Group .............................................................................................................134
3.21 Control 2 Set Up Group ..........................................................................................................143
3.22 Options Set Up Group.............................................................................................................150
3.23 Communications Set Up Group...............................................................................................162
3.24 Alarms Set Up Group..............................................................................................................166
3.25 Real Time Clock Set Up Group...............................................................................................174
3.26 Maintenance Set Up Group.....................................................................................................175
3.27 Display Set Up Group .............................................................................................................178
3.28 Read Maintenance Set Up Group............................................................................................180
3.29 Time Events Set Up Group .....................................................................................................181
3.30 P.I.E. Tool Ethernet and Email Configuration Screens...........................................................183
3.31 Configuration Record Sheet....................................................................................................186
4 MONITORING AND OPERATING THE CONTROLLER...................................194
4.1 Overview.....................................................................................................................................194
4.2 Operator Interface.......................................................................................................................195
4.3 Entering a Security Code............................................................................................................195
4.4 Lockout Feature..........................................................................................................................196
4.5 Monitoring Your Controller........................................................................................................198
4.5.1 Annunciators ....................................................................................................................198
4.5.2 Viewing the operating parameters....................................................................................199
4.5.3 Diagnostic Messages........................................................................................................200
4.6 Start Up Procedure for Operation...............................................................................................201
4.7 Control Modes ............................................................................................................................202
4.7.1 Mode Definitions .............................................................................................................202
4.7.2 What happens when you change modes...........................................................................203
4.8 Setpoints......................................................................................................................................203
4.9 Timer...........................................................................................................................................205
4.10 Accutune III.............................................................................................................................206
4.10.1 Tune for Simplex Outputs............................................................................................208
4.10.2 Tune for Duplex (Heat/Cool) .......................................................................................209
4.10.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool).................................210
4.10.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool)......................................211
4.10.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool).......................................212
4.10.6 ACCUTUNE Error Codes............................................................................................213
4.11 Fuzzy Overshoot Suppression.................................................................................................214
4.12 Using Two Sets of Tuning Constants......................................................................................215
4.13 Input Math Algorithms............................................................................................................217
4.14 Logic Gate Operation..............................................................................................................219
4.15 Digital Input Option (Remote Switching)...............................................................................222
March 2012 UDC3500 Universal Digital Controller Product Manual vii
4.16 Auto/Manual Station ...............................................................................................................227
4.17 Two Loops of Control.............................................................................................................231
4.18 Configuring Two Loops of Control.........................................................................................234
4.19 Monitoring Two Loops of Control..........................................................................................235
4.20 Operating Two Loops of Control............................................................................................236
4.21 Alarm Setpoints.......................................................................................................................237
4.22 Three Position Step Control Algorithm...................................................................................239
4.23 Setting a Failsafe Output Value for Restart After a Power Loss.............................................240
4.24 Setting Failsafe Mode..............................................................................................................241
4.25 Carbon Potential, Oxygen and Dewpoint Algorithms.............................................................241
4.26 Healthwatch.............................................................................................................................244
4.27 Setpoint Rate/Ramp/Program Overview.................................................................................244
4.28 Setpoint Rate ...........................................................................................................................245
4.29 Setpoint Ramp.........................................................................................................................245
4.30 Setpoint Ramp/Soak Programming.........................................................................................247
4.31 P.I.E. Tool Maintenance Screens ............................................................................................262
4.32 Configuring your Ethernet Connection...................................................................................272
5 INPUT CALIBRATION.......................................................................................279
5.1 Overview.....................................................................................................................................279
5.2 Minimum and Maximum Range Values.....................................................................................280
5.3 Preliminary Information..............................................................................................................282
5.4 Input Set Up Wiring....................................................................................................................284
5.4.1 Thermocouple Inputs Using an Ice Bath..........................................................................284
5.4.2 Thermocouple Inputs Using a Thermocouple Source......................................................285
5.4.3 RTD Inputs.......................................................................................................................286
5.4.4 Radiamatic, Millivolts, Volts, Carbon, Oxyg en or Thermocouple Differential Inputs....287
5.4.5 0 to 10 Volts or –1 to 1 Volts...........................................................................................289
5.4.6 Milliamperes ....................................................................................................................290
5.4.7 Dual High Level Voltage Inputs ......................................................................................291
5.4.8 Dual High Level Milliamperes Inputs..............................................................................292
5.5 Input Calibration Procedure........................................................................................................293
5.6 Restore Input Factory Calibration...............................................................................................295
6 OUTPUT CALIBRATION...................................................................................297
6.1 Overview.....................................................................................................................................297
6.2 First Current Output Calibration.................................................................................................298
6.3 Second Current Output Calibration.............................................................................................300
6.4 Third Current Output Calibration ...............................................................................................302
6.5 Position Proportional and Three Position Step Output Calibration............................................304
6.6 Restore Factory Output Calibration............................................................................................307
viii UDC3500 Universal Digital Controller Product Manual March 2012
7 TROUBLESHOOTING/SERVICE......................................................................309
7.1 Overview.....................................................................................................................................309
7.2 Troubleshooting Aids..................................................................................................................310
7.3 Power-up Tests............................................................................................................................312
7.4 Status Tests.................................................................................................................................312
7.5 Background Tests and Diagnostic Messages..............................................................................313
7.6 Controller Failure Symptoms......................................................................................................318
7.7 Troubleshooting Procedures .......................................................................................................319
7.7.1 Procedure #1 – Power ......................................................................................................320
7.7.2 Procedure #2 – Current Outputs.......................................................................................320
7.7.3 Procedure #3 – Position Proportional ..............................................................................322
7.7.4 Procedure #4 – Time Proportional ...................................................................................325
7.7.5 Procedure #5 – Current/Time or Time Current/Proportional...........................................326
7.7.6 Procedure #6 – Alarm Relays ..........................................................................................327
7.7.7 Procedure #7 – Keyboard.................................................................................................328
7.7.8 Procedure #8 – Analog Input ...........................................................................................329
7.7.9 Procedure #9 – RS-485 ....................................................................................................330
7.7.10 Procedure #10 – Ethernet .............................................................................................332
7.7.11 Procedure #11 – Email .................................................................................................333
7.8 Restoring Factory Configuration ................................................................................................334
7.9 Software Upgrades......................................................................................................................335
8 PARTS LIST......................................................................................................337
8.1 Exploded View............................................................................................................................337
8.2 Removing the chassis..................................................................................................................339
9 MODBUS RTU FUNCTION CODES..................................................................340
9.1 Overview.....................................................................................................................................340
9.2 General Information....................................................................................................................340
9.3 Function Code 20 (14h) - Read Configuration Reference Data..................................................342
9.3.1 Read Configuration Examples .........................................................................................344
9.4 Function Code 21 (15h) - Write Configuration Reference Data.................................................346
9.4.1 Write Configuration Examples ........................................................................................348
10 MODBUS READ, WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION
CODES........................................................................................................................349
10.1 Overview.................................................................................................................................349
10.2 Reading Control Data..............................................................................................................352
10.3 Read Software Options Status.................................................................................................353
10.4 Miscellaneous Read Onlys......................................................................................................354
10.4.1 Register Addresses for Read Onlys..............................................................................354
10.4.2 SetPoint Program Read Only Information....................................................................354
March 2012 UDC3500 Universal Digital Controller Product Manual ix
10.5 Setpoints..................................................................................................................................355
10.6 Using a Computer Setpoint (Overriding Controller Setpoint) ................................................357
10.7 Configuration Parameters........................................................................................................360
10.7.1 Tuning Loop 1..............................................................................................................360
10.7.2 Tuning Loop2...............................................................................................................362
10.7.3 SP Ramp/Rate/Program #1...........................................................................................363
10.7.4 Setpoint Program #2.....................................................................................................369
10.7.5 Setpoint Program #3.....................................................................................................375
10.7.6 Setpoint Program #4.....................................................................................................381
10.7.7 Accutune.......................................................................................................................387
10.7.8 Algorithm .....................................................................................................................389
10.7.9 Math..............................................................................................................................394
10.7.10 Logic.............................................................................................................................397
10.7.11 Output Algorithms........................................................................................................401
10.7.12 Input 1...........................................................................................................................403
10.7.13 Input 2...........................................................................................................................405
10.7.14 Input 3...........................................................................................................................407
10.7.15 Input 4...........................................................................................................................409
10.7.16 Input 5...........................................................................................................................411
10.7.17 Control..........................................................................................................................413
10.7.18 Control Loop 2.............................................................................................................416
10.7.19 Options.........................................................................................................................419
10.7.20 Communications...........................................................................................................423
10.7.21 Alarms..........................................................................................................................425
10.7.22 Maintenance .................................................................................................................429
10.7.23 Time Event...................................................................................................................432
10.7.24 Display..........................................................................................................................434
10.7.25 Clock ............................................................................................................................435
10.8 Modbus RTU Exception Codes...............................................................................................436
11 FURTHER INFORMATION................................................................................438
11.1 Modbus RTU Serial Communications ....................................................................................438
11.2 Modbus Messaging on Ethernet TCP/IP.................................................................................438
11.3 How to Apply Digital Instrumentation in Severe Electrical Noise Environments..................438
12 INDEX................................................................................................................439
13 SALES AND SERVICE.............................. ERROR! BOOKMARK NOT DEFINED.
x UDC3500 Universal Digital Controller Product Manual March 2012
Tables
Table 2-1 Condensed Specifications ____________________________________________________ 13
Table 2-2 Control Relay Contact Information _____________________________________________ 20
Table 2-3 Alarm Relay Contact Information ______________________________________________ 20
Table 2-4 Mounting Procedure _________________________________________________________ 22
Table 2-5 Permissible Wiring Bundling__________________________________________________ 24
Table 2-6 Single or Cascade Loop Controller – Loop 1 Output Functionality and Restrictions _______ 26
Table 2-7 Dual Loop Controller – Loop 2 Output Functionality and Restrictions __________________ 27
Table 2-8 Terminals for connecting a UDC to a MDI Compliant Hub or Switch utilizing a cross-over cable
______________________________________________________________________________ 41
Table 2-9 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable________ 42
Table 3-1 Configuration Topics ________________________________________________________ 45
Table 3-2 Configuration Prompt Hierarchy _______________________________________________ 47
Table 3-3 Configuration Procedure _____________________________________________________ 51
Table 3-4 TUNING Group Function Prompts _____________________________________________ 52
Table 3-5 TUNING 2 Group Function Prompts____________________________________________ 56
Table 3-6 SPRAMP Group Function Prompts_____________________________________________ 60
Table 3-7 SP PROG2 Group Function Prompts____________________________________________ 65
Table 3-8 SP PROG3 Group Function Prompts____________________________________________ 68
Table 3-9 SP PROG4 Group Function Prompts____________________________________________ 71
Table 3-10 ACCUTUNE Group Function Prompts_________________________________________ 75
Table 3-11 ALGORTHM Group Function Prompts ________________________________________ 79
Table 3-12 MATH Group Function Prompts______________________________________________ 94
Table 3-13 LOGIC Group Function Prompts _____________________________________________ 100
Table 3-14 OUTPUT Group Function Prompts ___________________________________________ 107
Table 3-15 INPUT 1 Group Function Prompts ___________________________________________ 118
Table 3-16 INPUT 2 Group Function Prompts ___________________________________________ 122
Table 3-17 INPUT 3 Group Function Prompts ___________________________________________ 125
Table 3-18 INPUT 4 Group Function Prompts ___________________________________________ 128
Table 3-19 INPUT 5 Group Function Prompts ___________________________________________ 131
Table 3-20 CONTROL Group Function Prompts__________________________________________ 134
Table 3-21 CONTROL2 Group Function Prompts_________________________________________ 143
Table 3-22 OPTION Group Function Prompts ___________________________________________ 150
Table 3-23 Communications Group Function Prompts _____________________________________ 162
Table 3-24 ALARMS Group Function Prompts __________________________________________ 167
Table 3-25 CLOCK Group Function Prompts ____________________________________________ 174
Table 3-26 MAINTENANCE Group Function Prompts ____________________________________ 175
Table 3-27 DISPLAY Group Function Prompts __________________________________________ 178
Table 3-28 READ MAINTENANCE Group Function Prompts ______________________________ 180
Table 3-29 TIME EVT Group Function Prompts _________________________________________ 181
Table 3-30 Configuration Record Sheet _________________________________________________ 186
Table 4-1 Procedure to Enter a Security Code____________________________________________ 196
Table 4-2 Annunciators _____________________________________________________________ 198
Table 4-3 Lower Display Key Parameter Prompts_________________________________________ 199
Table 4-4 Procedure for Starting Up the Controller________________________________________ 201
Table 4-5 Control Mode Definitions ___________________________________________________ 202
Table 4-6 Changing Control Modes____________________________________________________ 203
Table 4-7 Procedure for Changing the Local Setpoints _____________________________________ 204
Table 4-8 Procedure for Switching Between Setpoints _____________________________________ 204
March 2012 UDC3500 Universal Digital Controller Product Manual xi
Table 4-9 Procedure for Starting “TUNE”_______________________________________________ 208
Table 4-10 Procedure for Using AUTOMATIC TUNE at Start-up for Duplex Control ____________ 210
Table 4-11 Procedure for Using BLENDED TUNE at Start-up for Duplex Control_______________ 211
Table 4-12 Procedure for Using MANUAL TUNE for Heat side of Duplex Control ______________ 212
Table 4-13 Procedure for Using MANUAL TUNE for Cool side of Duplex Control______________ 212
Table 4-14 Procedure for Accessing Accutune Error Codes _________________________________ 213
Table 4-15 Accutune Error Codes _____________________________________________________ 213
Table 4-16 Set Up Procedure _________________________________________________________ 215
Table 4-17 Procedure for Switching PID SETS from the Keyboard ___________________________ 216
Table 4-18 Logic Gates Constraints and Dynamic Operation Status___________________________ 220
Table 4-19 Digital Input Option Action on Contact Closure _________________________________ 222
Table 4-20 Digital Input Combinations “DIG IN1” or “DIG IN2” ____________________________ 225
Table 4-21 Digital Inputs 1 and 2 Combination___________________________________________ 226
Table 4-22 Auto/Manual Station Mode Configuration Procedure_____________________________ 228
Table 4-23 Procedure for selecting Two Loop Algorithm___________________________________ 234
Table 4-24 Digital Display Indication—Two Loops _______________________________________ 235
Table 4-25 Procedure for Displaying Alarm Setpoints _____________________________________ 237
Table 4-26 Procedure for Displaying TPSC Motor Position _________________________________ 239
Table 4-27 Procedure for Setting a Failsafe Value_________________________________________ 240
Table 4-28 Procedure for Setting a Failsafe Mode_________________________________________ 241
Table 4-29 Running A Setpoint Ramp__________________________________________________ 246
Table 4-30 Program Contents_________________________________________________________ 248
Table 4-31 Ramp/Soak Profile Example (Using 12 Segments) _______________________________ 251
Table 4-32 Program #1 Record Sheets __________________________________________________ 252
Table 4-33 Program #2 Record Sheets __________________________________________________ 254
Table 4-34 Program #3 Record Sheets __________________________________________________ 256
Table 4-35 Program #4 Record Sheets __________________________________________________ 258
Table 4-36 Run/Monitor Functions ____________________________________________________ 260
Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input Range Values _______________ 280
Table 5-2 Equipment Needed_________________________________________________________ 282
Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath ________________ 284
Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using a Thermocouple Source _______ 285
Table 5-5 Set Up Wiring Procedure for RTD Inputs _______________________________________ 286
Table 5-6 Set Up Wiring Procedure for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple
Differential Inputs (Except 0-10 Volts and –1 to 1 Volts)________________________________ 287
Table 5-7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the
Factory Setting _________________________________________________________________ 288
Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts or –1 to 1 Volts _________________________ 289
Table 5-9 Set Up Wiring Procedure for Milliampere Inputs _________________________________ 290
Table 5-10 Set Up Wiring Procedure for Dual High Level Voltage Inputs______________________ 291
Table 5-11 Set Up Wiring Procedure for Dual High Level Milliampere Inputs __________________ 292
Table 5-12 Input Calibration Procedure _________________________________________________ 293
Table 5-13 Restore Factory Calibration _________________________________________________ 295
Table 6-1 Set Up Wiring Procedure for the First Current Output _____________________________ 298
Table 6-2 First Current Output Calibration Procedure______________________________________ 299
Table 6-3 Set Up Wiring Procedure for the Second Current Output ___________________________ 300
Table 6-4 Second Current Output Calibration Procedure ___________________________________ 301
Table 6-5 Set Up Wiring Procedure for the Third Current Output ____________________________ 302
Table 6-6 Third Current Output Calibration Procedure _____________________________________ 303
Table 6-7 Position Proportional and Three Position Step Output Calibration Procedure ___________ 305
xii UDC3500 Universal Digital Controller Product Manual March 2012
Table 6-8 Restore Factory Calibration __________________________________________________ 307
Table 7-1 Procedure for Identifying the Software Version __________________________________ 311
Table 7-2 Procedure for Displaying the Status Test Results _________________________________ 312
Table 7-3 Background Tests__________________________________________________________ 313
Table 7-4 Controller Failure Symptoms_________________________________________________ 318
Table 7-5 Troubleshooting Power Failure Symptoms ______________________________________ 320
Table 7-6 Troubleshooting Current Output Failure ________________________________________ 320
Table 7-7 Troubleshooting Position Proportional Output Failure _____________________________ 322
Table 7-8 Troubleshooting Time Proportional Output Failure _______________________________ 325
Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure ___________ 326
Table 7-10 Troubleshooting Alarm Relay Output Failure ___________________________________ 327
Table 7-11 Troubleshooting a Keyboard Failure __________________________________________ 328
Table 7-12 Troubleshooting an Analog Input Failure ______________________________________ 329
Table 7-13 Troubleshooting a RS-485 Communications Failure______________________________ 330
Table 7-14 Troubleshooting an Ethernet Communications Failure ____________________________ 332
Table 7-15 Troubleshooting an Email Failure ____________________________________________ 333
Table 7-16 Restoring Factory Configuration _____________________________________________ 334
Table 7-17 Software Upgrades________________________________________________________ 335
Table 8-1 Parts Identification_________________________________________________________ 338
Table 8-2 Parts Not Shown___________________________________________________________ 338
Table 8-3 Software Upgrades (see Section 7.9)___________________________________________ 339
Table 9-1 Integer Parameter Type _____________________________________________________ 341
Table 9-2 Floating Point Parameter Type________________________________________________ 341
Table 9-3 Register Parameter ID Address Format for Function Code 20 _______________________ 343
Table 9-4 Register Parameter ID Address Format for Function Code 21 _______________________ 347
Table 10-1 Control Data Parameters ___________________________________________________ 352
Table 10-2 Option Status ____________________________________________________________ 353
Table 10-3 Miscellaneous Read Onlys__________________________________________________ 354
Table 10-4 SetPoint Program Read Only Information______________________________________ 354
Table 10-5 Setpoint Code Selections ___________________________________________________ 355
Table 10-6 Setpoint Associated Parameters______________________________________________ 356
Table 10-7 Computer Setpoint Selection ________________________________________________ 357
Table 10-8 Computer Setpoint Associated Parameters for Loop 1 ____________________________ 358
Table 10-9 Computer Setpoint Associated Parameters for Loop2_____________________________ 359
Table 10-10 Set-up Group – Tuning Loop 1 _____________________________________________ 360
Table 10-11 Set-up Group – Tuning Loop 2______________________________________________ 362
Table 10-12 Set-up Group – Setpoint Ramp/Rate/Program #1 _______________________________ 363
Table 10-13 Set-up Group – Setpoint Program #2_________________________________________ 369
Table 10-14 Set-up Group – Setpoint Program #3_________________________________________ 375
Table 10-15 Set-up Group – Setpoint Program #4_________________________________________ 381
Table 10-16 Set-up Group – Adaptive Tune _____________________________________________ 387
Table 10-17 Set-up Group – Algorithm _________________________________________________ 389
Table 10-18 Set-up Group – Math _____________________________________________________ 394
Table 10-19 Set-up Group – Logic_____________________________________________________ 397
Table 10-20 Set-up Group – Output Algorithms __________________________________________ 401
Table 10-21 Set-up Group – Input 1____________________________________________________ 403
Table 10-22 Set-up Group – Input 2____________________________________________________ 405
Table 10-23 Set-up Group – Input 3____________________________________________________ 407
Table 10-24 Set-up Group – Input 4____________________________________________________ 409
Table 10-25 Set-up Group – Input 5____________________________________________________ 411
March 2012 UDC3500 Universal Digital Controller Product Manual xiii
Table 10-26 Set-up Group – Control ___________________________________________________ 413
Table 10-27 Set-up Group – Control2 __________________________________________________ 416
Table 10-28 Set-up Group – Options ___________________________________________________ 419
Table 10-29 Set-up Group – Communications____________________________________________ 423
Table 10-30 Set-up Group – Alarms ___________________________________________________ 425
Table 10-31 Set-up Group – Maintenance _______________________________________________ 429
Table 10-32 Set-up Group – Time Event________________________________________________ 432
Table 10-33 Set-up Group – Display ___________________________________________________ 434
Table 10-34 Set-up Group – Clock ____________________________________________________ 435
Table 10-35 Modbus RTU Data Layer Status Exception Codes ______________________________ 437
xiv UDC3500 Universal Digital Controller Product Manual March 2012
Figures
Figure 1-1 UDC3500 Operator Interface __________________________________________________ 6
Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket PC_________________ 8
Figure 1-3 Depiction of infrared communications ___________________________________________ 9
Figure 2-1 Model Number Interpretation_________________________________________________ 17
Figure 2-2 Mounting Dimensions (not to scale)____________________________________________ 21
Figure 2-3 Mounting Methods _________________________________________________________ 22
Figure 2-4 Composite Wiring Diagram___________________________________________________ 28
Figure 2-5 Mains Power Supply ________________________________________________________ 29
Figure 2-6 Input 1 Connections_________________________________________________________ 30
Figure 2-7 Input 2 Connections_________________________________________________________ 31
Figure 2-8 Input 3 Connections_________________________________________________________ 32
Figure 2-9 HLAI Inputs 2 and 4 Connections______________________________________________ 33
Figure 2-10 HLAI Inputs 3 and 5 Connections_____________________________________________ 34
Figure 2-11 Optional Analog Input Jumper Positions________________________________________ 34
Figure 2-12 First Current Output________________________________________________________ 35
Figure 2-13 Second Current Output _____________________________________________________ 35
Figure 2-14 Output #2 – Electromechanical Relay Output____________________________________ 36
Figure 2-15 Output #2 – Solid State Relay Output __________________________________________ 36
Figure 2-16 Output #2 – Open Collector Output- Third ______________________________________ 37
Figure 2-17 Output #2 – Third Current Output_____________________________________________ 37
Figure 2-18 Output #2 – Dual Relay Output for Time Duplex_________________________________ 38
Figure 2-19 Output #2 – Dual Relay Output for Position Proportional or Three Position Step Control _38
Figure 2-20 RS-422/485 Communications Option Connections________________________________ 39
Figure 2-21 Ethernet Communications Option with Adaptor Board_____________________________ 39
Figure 2-22 Ethernet Communications Option without Adaptor Board __________________________ 40
Figure 2-23 Digital Inputs_____________________________________________________________ 42
Figure 2-24 Optional Electromechanical Relay Outputs______________________________________ 43
Figure 2-25 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open Collector Output_____ 43
Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Second Current Output ____ 44
Figure 3-1 Mass Flow Example ________________________________________________________ 92
Figure 3-2 Example of Eight Segment Characterizer________________________________________ 99
Figure 3-3 Ethernet Configuration Screen _______________________________________________ 183
Figure 3-4 Email Configuration Screen _________________________________________________ 184
Figure 4-1 Operator Interface_________________________________________________________ 195
Figure 4-2 Auto/Manual Station for Loop 1 (Loop 2 similar) ________________________________ 227
Figure 4-3 Functional Overview Block Diagram of a Single Loop (Loop #1) or
Dual Loop Controller (Loop #1 and Loop #2)_________________________________________ 232
Figure 4-4 Functional Overview Block Diagram of Internal Cascade Controller _________________ 233
Figure 4-5 Hi/Lo Override Selector ____________________________________________________ 234
Figure 4-6 Carbon Potential Control ___________________________________________________ 243
Figure 4-7 Ramp/Soak Profile Example_________________________________________________ 251
Figure 4-8 SP Program #1 Record Sheets _______________________________________________ 252
Figure 4-9 SP Program #2 Record Sheets _______________________________________________ 254
Figure 4-10 SP Program #3 Record Sheets ______________________________________________ 256
Figure 4-11 SP Program #4 Record Sheets ______________________________________________ 258
Figure 4-12 Loop Data Maintenance Screen _____________________________________________ 262
Figure 4-13 Alarm Details Maintenance Screen __________________________________________ 263
Figure 4-14 Digital Inputs Details Maintenance Screen_____________________________________ 264
March 2012 UDC3500 Universal Digital Controller Product Manual xv
Figure 4-15 Status Data Maintenance Screen_____________________________________________ 265
Figure 4-16 Diagnostic History Maintenance Screen_______________________________________ 266
Figure 4-17 Ethernet Status Maintenance Screen__________________________________________ 267
Figure 4-18 Healthwatch Data Maintenance Screen _______________________________________ 268
Figure 4-19 Healthwatch Data Reset Screen _____________________________________________ 269
Figure 4-20 Totalizer Maintenance Screen ______________________________________________ 270
Figure 4-21 Real Time Clock Maintenance Screen ________________________________________ 271
Figure 4-22 IR Communications Address _______________________________________________ 272
Figure 4-23 Configuration Upload in Progress ___________________________________________ 273
Figure 4-24 Ethernet Communications Address __________________________________________ 275
Figure 4-25 Configuration Upload in Progress ___________________________________________ 276
Figure 5-1 Input Wiring Terminals ____________________________________________________ 282
Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath ____________________ 284
Figure 5-3 Wiring Connections for Thermocouple Inputs Using a Thermocouple Source __________ 285
Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device) ____________________ 286
Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts, Carbon, Oxygen or
Thermocouple Differential Inputs (Except 0-10 Volts and –1 to 1 Volts)____________________ 287
Figure 5-6 Wiring Connections for 0 to 10 Volts or –1 to 1 Volts_____________________________ 289
Figure 5-7 Wiring Connections for Milliampere Inputs_____________________________________ 290
Figure 5-8 Wiring Connections for Dual High Level Voltage Inputs __________________________ 291
Figure 5-9 Wiring Connections for Dual High Level Milliampere Inputs_______________________ 292
Figure 6-1 Wiring Connections for Calibrating the First Current Output _______________________ 298
Figure 6-2 Wiring Connections for Calibrating the Second Current Output _____________________ 300
Figure 6-3 Wiring Connections for Calibrating Third Current Output _________________________ 302
Figure 8-1 UDC3500 Exploded View __________________________________________________ 337
Figure 10-1 Software Option Status Information__________________________________________ 353
xvi UDC3500 Universal Digital Controller Product Manual March 2012
1.1 Overview
Function
The UDC3500 is a microprocessor-based stand-alone controller. It combines a high
degree of functionality and operating simplicity in a 1/4 DIN size controller. This
instrument is an ideal controller for regulating temperature and other process variables in
numerous heating and cooling applications, as well as in metal working, food,
pharmaceuticals, semiconductor, testing and environmental work.
The UDC3500 monitors and controls temperatures and other variables in applications
such as environmental chambers, plastic processing machines, furnaces and ovens, and
packaging machinery.
Features
Introduction
1 Introduction
3 Universal Analog Inputs (can be configured to act as one Universal and four High
Level)
± 0.10% Analog Input Accuracy (can be Field Calibrated to ± 0.05%)
16-bit Analog Input resolution typical
Fast scanning rate (166ms)
Up to 7 Analog and Digital Outputs
4 Digital Inputs
Two Math Functions, two Characterizers, one Polynomial equation and one
Totalizer available
Two Independent Loops or Cascade Loop
Up to four 20-segment Setpoint Programs (can be concatenated to form two 40-
segment Setpoint Programs)
Ethernet TCP/IP with Email or RS-485 Modbus communication
Infrared PC & Pocket PC configuration
NEMA4X and IP66 front face protection
Multilanguage prompts
¼ DIN Size
Easily Field Upgradeable
Easy to read displays
Bright, dual displays with multi-language prompts (in English, French, German, Spanish,
or Italian) make the operator interface easy to read, understand, and operate. Simple
keystrokes let you set operating parameters that meet your process control needs.
March 2012 UDC3500 Universal Digital Controller Product Manual 1
Introduction
Analog Inputs
The UDC3500 has three universal analog inputs with a typical accuracy of ±0.10% of
full-scale input and a typical resolution of 16 bits. These can be configured to act as one
Universal and four High Level Inputs for a total of five analog inputs. All analog inputs
are sampled six times per second (every 166 ms).
The Process Variable input can be one of the various Thermocouple, RTD, Radiamatic or
linear actuations. Linear actuations have Thermocouple, RTD, and Radiamatic
transmitter characterization capability as a standard feature. Linear actuations also have
square root capability.
The optional second and third inputs are isolated from each other and all other inputs and
outputs and accept the same actuations as input one. Input 3 provides the Slidewire input
for Position Proportional control. These optional inputs can each be split into two high
level inputs. The fourth input is enabled by first configuring Input 2 as a 20 mA or 5 Vdc
input type (high level) and moving a jumper on the Second Optional Input Board. Input 4
will then be available as a high level input. The fifth input is enabled by first configuring
Input 3 as a 20 mA or 5 Vdc input type (high level) and moving a jumper on the Third
Optional Input Board. Input 5 will then be available as a high level input.
All actuations and characterizations are keyboard configurable. Cold junction
compensation is provided for thermocouple type inputs. Upscale, downscale or failsafe
sensor break protection is keyboard configurable. A configurable digital filter of 0 to 120
seconds provides input signal damping.
Thermocouple Health—In addition to the standard configurable upscale, downscale or
failsafe output burnout selections, the condition of the thermocouple can be monitored to
determine if it is good, failing or in danger of imminent failure.
Math Functions
Algorithm—Two pre-configured algorithms are available for easy implementation. This
includes the capability of using a Ratio and Bias with any input. You can select from the
following menu:
Feedforward Summer—Uses any input, followed by a Ratio/Bias calculation, summed
directly with the computed PID output value to provide a resultant output to the final
control element (standard feature).
Weighted Average —Computes the weighted average of a PV or SP for the control
algorithm from two inputs (standard feature).
Feedforward Multiplier—Uses any input, multiplied by the calculated PID output to
provide a resultant output, which is sent to the final control element (standard feature).
Summer/Subtractor—Will add or subtract inputs with the result used as the derived PV.
Multiplier/Divider—Uses the analog inputs to calculate a derived PV. It is available
with or without Square Root.
Input High/Low Select—Specifies the PV input as the higher or lower of two inputs.
2 UDC3500 Universal Digital Controller Product Manual March 2012
Introduction
8 Segment Characterizers—Two characterizers are available that can be applied to any
Analog Input, to Loop 1 Output or to Loop 2 Output. The Characterizers can be
combined to produce a single 16-segment characterizer. †
Totalizer—Calculates and displays the total flow volume as measured by any of the
analog inputs or as derived by either Math algorithm. Displayed value is eight digits with
a configurable scaling factor. The totalizer value may be reset.
Combinational Inputs—Inputs can be combined for use with Relative Humidity, %
Oxygen, Carbon Potential, Dewpoint or Math Algorithms. This controller can accept
carbon probes from Cambridge, Marathon Monitors, Corning, A.A.A.C, Barber
Coleman, MacDhui, Bricesco or Furnace Controls.
Polynomial Curve Characterizer—A fifth order polynomial equation can be used on
any one of the analog inputs.
Logic Gates—Five Logic Gates configurable as OR, NOR, AND, NAND, XOR, XNOR,
or COMPARATOR. Each Gate has two inputs and one output. The Gates may be linked
together to perform more complex functions.
†
Characterizers are mutually exclusive with Setpoint Program #4.
Digital Inputs
Four isolated digital inputs are provided for remote dry contact closure to select one of 25
actions. Also, two of these digital inputs can allow one of six additional selections to be
combined with one of the above selections.
Outputs
Output Types - The UDC3500 may have up to seven of the following outputs:
Current Outputs (4-20 or 0-20 mA)
Electromechanical Relays (5 amps)
Solid State Relay (1 amp)
Dual Electromechanical Relays (2 amps)
Open Collector Output (+30 VDC @ 20 mA)
Alarms
Up to four electromechanical alarm relays are available to activate external equipment
when preset alarm setpoints are reached. Each of the four alarms can be set to monitor
two independent setpoints. Each alarm setpoint can be either high or low alarm. The
alarm type can be selected to be either of the inputs, the Process Variable, Deviation,
Output, Shed from communications, PV rate of change, or to alarm on manual mode
activation or a Current Output Open failure. It can also be used as an On or Off event at
the beginning or end of a Ramp/Soak segment. An individual alarm hysteresis setting is
provided for each relay and these are configurable from 0 to 100% of range.
Alarms can be configured as latching or non-latching. continued
March 2012 UDC3500 Universal Digital Controller Product Manual 3
Introduction
Alarm blocking is also available which allows start-up without alarm energized
until after it first reaches the operating region.
PV rate of change alarm.
Loop break alarm.
Timer output reset.
Diagnostic Alarm
Communications
A communications link is provided between the UDC3500 and a host computer or PLC
via the RS422/485 Modbus® RTU or Ethernet TCP/IP * communications option. An
infrared communication link is also available allowing a non-intrusive configuration of
the instrument.
Miscellaneous Features
Auxiliary Output * (optional)—All of the three current outputs can function as Auxiliary
Outputs which can be scaled from 4-20 ma for 0 to 100% for any range. These can be
configured to represent any analog input, PV, active Setpoint, Local SP1, Deviation, or
the Control Output for either control loop.
Transmitter Power—This feature provides up to 30 volts dc to power a 2-wire transmitter (requires the use of open collector output selection or one of the current outputs).
Four Local and one Remote Setpoints—Can be configured to provide four Local and
one Remote Setpoints, which are selectable either via the keyboard or by Digital Input.
Universal Switching Power—Operates on any line voltage from 90 to 250 Vac 50/60 Hz
without jumpers. 24 Vac/dc instrument power is available as an option.
Timer—This standard feature provides a configurable time period of 0 to 99 hours, 59
minutes or units of minutes and seconds. It can be started via the keyboard, alarm 2, or by
a digital input. The timer output is Alarm 1, which energizes at the end of the Timer
Period. Alarm 1 can be automatically reset. The Timer Period can be changed between
each batch. Status is shown on the lower display.
Healthwatch—Consists of three timers and three counters, which can each be assigned to
track UDC3500 controller functions. Selected Maintenance & Diagnostic data can be
accessed from the front panel or via communications. Alarms can be configured to
activate when a desired threshold is reached. A security code is required to perform
resetting of any of the above listed counter or timer functions.
Real Time Clock—An optional battery-backed clock feature that allows the user to
perform such things as starting an SP Program on a specific date and time.
Auto/Manual Station Plus Back-up Control—A UDC3500 can act as both an
Auto/Manual Station PLUS as a back-up PID Controller, should the primary loop
controller fail. Since the PID control is sometimes implemented via a PLC, this feature
provides a very cost-effective way to insure the process does not have to shutdown or
4 UDC3500 Universal Digital Controller Product Manual March 2012
Introduction
remain in manual mode if the PLC should fail. Switching from the Auto/Manual Station
to the back-up control mode is accomplished using the Digital Input option.
Moisture Protection—The NEMA4X and IP66 rated front face permits use in
applications where it may be subjected to moisture, dust, or hose-down conditions. UL
and CSA approved as Type 4 protection.
Setpoint Ramp/Soak Programming (Optional)—Enables you to program and store ten
Ramp and ten Soak segments (total of twenty segments) for setpoint programming. Run
or Hold of program is keyboard or remote digital switch selectable.
Enhanced Setpoint Programming (Optional) )—Four Setpoint Programs each of ten
Ramp and ten Soak Segments. Each pair can be concatenated so as to form a single
Setpoint Program of twenty Ramps and twenty Soaks. †
Setpoint Rate—Lets you define a ramp rate to be applied to any local setpoint change. A
separate upscale or downscale rate is configurable. A single setpoint ramp is also
available as an alternative.
Output Rate Limiter—A maximum output rate may be configured for both the upscale
and the downscale output directions.
CE Mark—Conformity with 73/23/EEC, Low Voltage Directive and 89/336/EEC, the
EMC Directive as a standard feature.
Approval Body Options—CSA certification and UL listing are available as an option.
Four Sets of Tuning Constants—Four sets of PID parameters can be configured for each
loop and automatically or keyboard selected.
Data Security—Five levels of keyboard security protect tuning, configuration, and
calibration data, accessed by a configurable 4-digit code. Nonvolatile EEPROM memory
assures data integrity during loss of power.
Diagnostic/Failsafe Outputs—Continuous diagnostic routines detect failure modes,
trigger a failsafe output value and identify the failure to minimize troubleshooting time.
High Noise Immunity—The controller is designed to provide reliable, error-free
performance in industrial environments that often affect highly noise-sensitive digital
equipment.
Accutune III™ —This standard feature provides a truly plug and play tuning algorithm,
which will, at the touch of a button or through a digital input, accurately identify and tune
any process including those with deadtime and integrating processes. This speeds up and
simplifies start-up plus allows retuning at any setpoint. The algorithm used is an
TM
improved version of the Accutune II
algorithm found on earlier controllers. Two
possibilities are now offered when tuning your process: Fast Tune and Slow Tune.
Fast Tune will tune the process in such a way that the temp is reached faster, a
slight overshoot will be allowed.
Slowtune will minimize overshoot, but it will take more time for the process
temperature to reach the target setpoint.
March 2012 UDC3500 Universal Digital Controller Product Manual 5
Introduction
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 temporarily modifies the internal controller response to suppress
overshoot. This allows more aggressive tuning to co-exist with smooth PV
response. It can be enabled or disabled depending on the application or the control
criteria.
* The Second Current Output option is mutually exclusive with the Ethernet
Communications option.
†
Characterizers are mutually exclusive with Setpoint Program #4.
1.2 Operator Interface
Figure 1-1 UDC3500 Operator Interface
6 UDC3500 Universal Digital Controller Product Manual March 2012
1.2.1 Function of Displays and Keys
Table 1-1 Function of Displays and Keys
Display Indicators
Introduction
3200
3500
SP 3500
SP
ALMALM
DIDI
Upper display with 4 larger digits shows
Process Variable value (normal operation)
and special annunciator features. During
Configuration, the upper display provides
guidance for the operator through prompts (7
– characters)
During normal operation, the lower display
shows key-selected operating parameters
such as Output, Setpoints, Inputs, Deviation,
active Tuning Parameter Set, Timer Status, or
minutes remaining in a setpoint ramp (4
digits). During configuration, the lower display
provides guidance for the operator through
prompts (8-characters).
Indicates Alarm 1 and/or Alarm 2 conditions
exist.
Indicates Digital Input 1 and/or 2 on.
Keys and Functions
Indicates Control Relay 1 and/or 2 on.
OUT
FF
Or
Indicates either degrees Fahrenheit or
Centigrade.
CC
MAN
Or
Indicates either Manual or Auto mode.
AA
Indicates Local Setpoint #1. Also, a bar is
SPSP
lighted when the setpoint being used is shown
on the lower display.
Func
Loop 1/2
Selects functions within each
configuration group. Switches between
Loop Displays for Two Loop and
Man
Man
Man
Auto
Auto
Auto
Selects Manual or Auto mode.
Cascade units.
SetupSetup
Lower
Lower
Lower
Display
Display
Display
Scrolls through the configuration
groups.
Returns Controller to normal display
from Set Up mode. Toggles various
operating parameters for display.
Increases setpoint or output value.
Increases the configuration values or
changes functions in Configuration
mode groups.
Infrared transceiver
SP
SP
SP
Select
Select
Select
Run
Run
Run
Hold
Hold
Hold
Hold key down to cycle through configured
setpoints.
Enables Run/Hold of the SP Ramp or Program
plus Timer start.
Decreases setpoint or output value. Decreases
the configuration values or changes functions in
Configuration mode groups.
NEMA4X and IP66 screw attachment (each
corner)
March 2012 UDC3500 Universal Digital Controller Product Manual 7
Introduction
1.3 Process Instrument Explorer Software
Overview
Process Instrument Explorer (P.I.E.) lets you configure your instrument on a
desktop/laptop or Pocket PC. For details see Process Instrument Explorer Manual #5152-25-131.
Features
Create configurations with intuitive software program running on a Pocket PC, a
Desktop or a laptop computer.
Create/edit configurations live, just connect software to the controller via a
communications port.
Create/edit configurations offline and download to controller later via a
communications port.
Communication types available on every UDC3500:
Infrared (standard)
RS 485 (optional)
Ethernet (optional)
Same port types on UDC2500 and UDC3200 allow interconnectivity.
This software is available in English, Spanish, Italian, German and French.
Figure 1-2 Screen capture of Process Instrument Explorer
running on a Pocket PC
8 UDC3500 Universal Digital Controller Product Manual March 2012
Infrared communications
The infrared connection provides a non-intrusive wireless connection with the instrument
and maintains NEMA4X AND IP66 integrity.
No need to get access to the back of the controller to communicate with the instrument,
no need to take your screw driver to wire the communication cable, no wiring mistake
possible. You can now duplicate an instrument’s configuration, upload or download a
new configuration in a matter of seconds, just by pointing your Pocket PC in the direction
of the instrument.
It takes just a few seconds to upload a configuration from an instrument. You can then
save the configuration file onto your PC or pocket PC for review, modification or
archiving. Furthermore, this software also gives you important maintenance information
on the controller: instantly, get information on the current operating parameters, digital
inputs and alarm status, identify internal or analog input problems.
Question: What if I have several controllers on the same panel? How can I be sure I am
communicating with the correct one?
Answer: The infrared port of the controller is normally “off”. You activate the infrared
port by pressing any controller’s key. You can now communicate. After 4 minutes, the
port will be shut down again. Each controller may also be assigned a different
communications address.
Introduction
Figure 1-3 Depiction of infrared communications
March 2012 UDC3500 Universal Digital Controller Product Manual 9
Introduction
1.4 CE Conformity (Europe)
This product is in conformity with the protection requirements of the following European
Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC
Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be
assumed.
Product Classification: Class I: Permanently connected, panel-mounted Industrial
Control Equipment with protective earthing (grounding) (EN61010-1).
Enclosure Rating: This controller must be panel-mounted with the rear terminals
enclosed within the panel. The front panel of the controller is rated at NEMA4X and IP66
when properly installed.
Installation Category (Overvoltage Category): Category II (EN61010-1)
Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with
occasional conductivity caused by condensation. (Ref. IEC 664-1)
EMC Classification: Group 1, Class A, ISM Equipment (EN61326, emissions), Industrial
Equipment (EN61326, immunity)
Method of EMC Assessment: Technical File (TF)
Declaration of Conformity: 51453681
Deviation from the installation conditions specified in this manual, and the special
conditions for CE conformity in Subsection 2.1, may invalidate this product’s conformity
with the Low Voltage and EMC Directives.
ATTENTION
The emission limits of EN61326 are designed to provide reasonable protection
against harmful interference when this equipment is operated in an industrial
environment. Operation of this equipment in a residential area may cause harmful
interference. This equipment generates, uses, and can radiate radio frequency
energy and may cause interference to radio and television reception when the
equipment is used closer than 30 meters (98 feet) to the antenna(e). In special
cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the
electromagnetic emissions of this equipment.
WARNING
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
10 UDC3500 Universal Digital Controller Product Manual March 2012
2.1 Overview
Introduction
Installation of the UDC3500 consists of mounting and wiring the controller according to
the instructions given in this section. Read the pre-installation information, check the
model number interpretation (Subsection 2.3) and become familiar with your model
selections, then proceed with installation.
What’s in this section?
The following topics are covered in this section.
2.1 Overview 11
Installation
2 Installation
TOPIC See Page
2.2 Condensed Specifications 13
2.3 Model Number Interpretation 17
2.4 Control and Alarm Relay Contact Information 20
2.5 Mounting 21
2.6 Wiring 23
2.7 Wiring Diagrams
Figure 2-4 Composite Wiring Diagram
Figure 2-5 Mains Power Supply
Figure 2-6 Input 1 Connections
Figure 2-7 Input 2 Connections
Figure 2-8 Input 3 Connections
Figure 2-9 HLAI Inputs 2 and 4
Figure 2-10 HLAI Inputs 3 and 5
Figure 2-11 Optional Analog Input Jumper Positions
Figure 2-12 First Current Output
Figure 2-13 Second Current Output
Figure 2-14 Output #2 – Electromechanical Relay Output
Figure 2-15 Output #2 – Solid State Relay Output
Figure 2-16 Output #2 – Open Collector Output
Figure 2-17 Output #2 – Third Current Output
Figure 2-18 Output #2 – Dual Relay Output for Time
Figure 2-19 Output #2 – Dual Relay Output for Position
Proportional or Three Position Step Control
Figure 2-20 RS-422/485 Communications Option
Duplex
28
29
30
31
32
33
34
34
35
35
36
36
37
37
38
38
39
40
March 2012 UDC3500 Universal Digital Controller Product Manual 11
Installation
Figure 2-22 Ethernet Communications Option
Figure 2-23 Digital Inputs
Figure 2-24 Optional Electromechanical Relay Outputs
Figure 2-25 Transmitter Power for 4-20 mA — 2 wire
Transmitter Using Open Collector Output
Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire
Transmitter Using Second Current Output
42
43
43
44
44
12 UDC3500 Universal Digital Controller Product Manual March 2012
Pre-installation Information
If the controller has not been removed from its shipping carton, inspect the carton for
damage then remove the controller.
Inspect the unit for any obvious shipping damage and report any damage due to
transit to the carrier.
Make sure a bag containing mounting hardware is included in the carton with the
controller.
Check that the model number shown on the inside of the case agrees with what you
have ordered.
2.2 Condensed Specifications
Honeywell recommends that you review and adhere to the operating limits listed in Table
2-1 when you install your controller.
Table 2-1 Condensed Specifications
Analog Inputs
Analog Input Signal
Failure Operation
Stray Rejection Common Mode
Digital Inputs (Four)
(Optional)
Up to three Universal analog inputs. These can easily be configured to operate as 2
Universal and 2 High Level or as 1 Universal and 4 High Level inputs.
Accuracy:
± 0.10% of full scale typical (± 1 digit for display)
Can be field calibrated to ± 0.05% of full scale typical
16-bit resolution typical
Sampling Rate: All inputs are sampled six times per second
Temperature Stability: ± 0.0075% of Full Scale span / ˚C change—typical
Input Impedance:
0-20 and 4-20 Milliampere Inputs: 250 ohms
0-10 Volt and –1 to +1 Volt Input: 200K ohms
All Others: 10 megohms
Maximum Lead Wire Resistance:
Thermocouples: 50 ohms/leg
100 ohm, 200 ohm, 500 ohm and 1000 ohm RTD: 100 ohms/leg
100 ohm Low RTD: 10 ohms/leg
Slidewire Input for Position Proportional Control (Input 3 only):
100 ohm to 1000 ohm resistive slidewire types
Herculine
Burnout Selections: Upscale, Downscale, Failsafe or None
Thermocouple Health: Good, Failing, Failure Imminent or Failed
Failsafe Output Level: Configurable 0-100% of Output range
AC (50 or 60 Hz): 120 dB (with maximum source impedance of 100 ohms) or ± 1 LSB (least
significant bit) whichever is greater with line voltage applied.
DC: 120 dB (with maximum source impedance of 100 ohms) or a ±1 LSB whichever is
greater with 120 Vdc applied.
DC (to 1 KHz): 80 dB (with maximum source of impedance of 100 ohms) or ±1 LSB
whichever is greater with 50 Vac applied.
Normal Mode
AC (50 or 60 Hz): 60 dB (with 100 % span peak-to-peak maximum)
+30 Vdc source for external dry contacts or isolated solid-state contacts. Digital Inputs are
isolated from line power, earth ground, analog inputs and all outputs.
Models 10260 and 11280 Slidewire Emulation
Installation
Specifications
March 2012 UDC3500 Universal Digital Controller Product Manual 13
Installation
Current and Auxiliary
Outputs
Output 2 Options
Three Relay Board
(Optional)
Specifications
Up to three Milliamp Outputs. These outputs provide a 0 to 21 mA current output into a
negative or positive grounded load or into a non-grounded load. Current outputs are isolated
from each other, line power, earth ground and all inputs. Outputs can easily be configured
via the keyboard to be 0 to 20 mA or 4 to 20 mA without field calibration and for either direct
or reverse action when used as a control output.
Any current output not being used as a control output can be used in an Auxiliary Output
mode. Auxiliary Outputs can be configured to represent any Analog Input, PV, Setpoint,
Deviation, or Control Output. The range of an Auxiliary Output can be scaled per the range
of the selected variable and can be set anywhere between 0 to 21 mA.
Resolution: 14 bits over 0 to 21 mA
Accuracy: 0.05% of full scale
Temperature Stability: 0.01% F.S./°C typical
Load Resistance: 0 to 1000 ohms
The First Current Output is a standard feature and is present on all instruments. The Second
Current Output is an option and is mutually exclusive with Ethernet Communications. The
Third Current Output is an option and is mutually exclusive with the other Output 2 Options
listed directly below.
Output 2 is a socket which may be populated with any one of the following output types:
Electromechanical Relay
SPDT contacts. Both Normally Open and Normally Closed contacts are brought out to the
rear terminals.
Resistive Load: 5 amps @ 120 Vac or 240 Vac or 30 Vdc
Inductive Load (cos
Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
Motor: 1/6 H.P.
Dual Electromechanical Relays
Two SPST relays. One Normally Open contact for each relay is brought out to the rear
terminals. This option must be used as the Loop 1 output for On-Off Duplex, Time Duplex,
Three Position Step Control and Position Proportional Control applications. Instruments with
this option can have a total of five relays plus one or two current outputs.
Resistive Load: 2 amps @ 120 Vac, 240 Vac or 30 Vdc
Inductive Load (cos
Inductive Load (L/R = 7 milliseconds): 1 amp @ 30 Vdc
Solid State Relay
SPST solid-state contact consisting of a triac N.O. output with zero-crossing detection.
Resistive Load: 1.0 amp @ 25°C ambient temperature and 120 or 240 Vac
0.5 amp @ 55°C ambient temperature and 120 or 240 Vac
Inductive Load: 50 VA @ 55°C ambient temperature and 120 or 240 Vac
Minimum Load: 20 milliamps
Open Collector Output
Transistor drive for powering an external relay. Isolated from earth ground and all other
circuits except the First Current Output. Internally powered @ 30 Vdc.
Note: Applying an external power supply to this output will damage the instrument.
Maximum Sink Current: 20 mA
Overload Protection: 100 mA
Third Current Output
See above.
Three SPDT contacts. Both Normally Open and Normally Closed contacts are brought out to
the rear terminals for each relay. These relays are used for Alarm outputs or for the output of
the second control loop. They may also be used as outputs for Logic Gate functions.
Resistive Load: 5 amps @ 120 Vac or 240 Vac or 30 Vdc
Inductive Load (cos
Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
Motor: 1/6 H.P.
= 0.4): 3 amps @ 130 Vac or 250 Vac
= 0.4): 1 amp @ 130 Vac or 250 Vac
= 0.4): 3 amps @ 130 Vac or 250 Vac
14 UDC3500 Universal Digital Controller Product Manual March 2012
Specifications
Alarm Outputs
(Optional)
Isolation (Functional)
RS422/485 Modbus
RTU
Communications
Interface (Optional)
Ethernet TCP/IP
Communications
Interface (Optional)
RS-485 and Ethernet
Transaction rates
Infrared
Communications
(Standard)
Power Consumption 24 VA maximum (90 to 250 Vac)
Power Inrush Current
Weight
A maximum of four alarm relays are available, depending upon the type and quantity of
outputs used for control purposes. Each alarm may have one or two setpoints, each of which
can be independently set as high or low alarm. Setpoints can be on any Input, Process
Variable, Deviation, Manual Mode, Failsafe, PV Rate, RSP Mode, Communication Shed, or
Output. A single adjustable hysteresis of 0.0 to 100.0% is provided. The alarm can also be
set as an ON or OFF event at the beginning of a Setpoint Program Ramp or Soak segment.
Alarm status is accessible via any communications port and is shown on the display
annunciators.
AC Power: Electrically isolated from all other inputs and outputs and earth ground to
withstand a HIPOT potential of 1900 Vdc for 2 seconds per Annex K of EN61010-1.
Analog Inputs and Outputs: Are isolated from each other and all other circuits to withstand a
HIPOT potential of 850 Vdc for 2 seconds per Annex K of EN61010-1.
Digital Inputs and Digital Outputs: Electrically isolated from all other circuits to withstand a
HIPOT potential of 850 Vdc for 2 seconds per Annex K of EN61010-1.
Relay Contacts: With a working voltage of 115/230 Vac, these are electrically isolated from
all other circuits to withstand a HIPOT potential of 345 Vdc for 2 seconds per Annex K of
EN61010-1
Baud Rate: 4800, 9600,19,200 or 38,400 baud selectable
Data Format: Floating point or integer
Length of Link:
2000 ft (600 m) max. with Belden 9271 Twinax Cable and 120 ohm termination resistors
4000 ft. (1200 m) max. with Belden 8227 Twinax Cable and 100 ohm termination resistors
Link Characteristics: Two-wire (half-duplex), multi-drop Modbus RTU protocol, 15 drops
maximum or up to 31 drops for shorter link length.
Type: 10Base-T
Length of Link: 330 ft. (100 m) maximum. Use Shielded twisted-pair, Category 5 (STP
CAT5) Ethernet cable.
Link Characteristics: Four-wire plus shield, single drop, five hops maximum
IP Address: IP Address is 10.0.0.2 as shipped from the Factory
Recommended network configuration: Use Switch rather than Hub in order to maximize
UDC Ethernet performance.
Configuration: Ethernet parameters are configured via the Process Instrument Explorer.
Email: The capability to send two different Emails is provided. These must be configured via
the Process Instrument Explorer. It is recommended that the Real Time Clock Option be
purchased for any instrument that needs to send Email.
Ethernet Communications is mutually exclusive with the Second Current Output.
Host computer must allow a minimum of 20 milliseconds between Read transactions and a
minimum of 200 milliseconds between Write transactions.
Type: Serial Infrared (SIR)
Length of Link: 3 ft. (1 m) maximum for IrDA 1.0 compliant devices
Baud Rate: 19,200 or 38,400 baud selectable
18 VA maximum (24 Vac/dc)
10A maximum for 4 ms (under operating conditions), reducing to a maximum of 265 mA (90
to 250 Vac operation) or 900 mA (24 Vac/dc operation) after one second.
CAUTION
power is supplied. Otherwise, the instruments may not start up normally due to voltage drop
from the inrush current.
3 lbs. (1.3 kg)
When applying power to more than one instrument, make sure that sufficient
Installation
March 2012 UDC3500 Universal Digital Controller Product Manual 15
Installation
Environmental and Operating Conditions
Parameter Reference Rated Operative
Ambient Temperature
Relative Humidity
Vibration
Frequency (Hz)
Acceleration (g)
Mechanical Shock
Acceleration (g)
Duration (ms))
Line Voltage (Vdc)
24 Vdc
Line Voltage (Vac)
90 to 240 Vac
24 Vac
Frequency (Hz)
(For Vac)
* The maximum moisture rating only applies up to 40 °C (104 °F). For higher temperatures, the RH specification is derated to
maintain constant moisture content.
25 ± 3 °C
77 ± 5 °F
10 to 55* 10 to 90* 5 to 90* 5 to 95*
0
0
0
0
+24 ± 1
120 ± 1
240 ± 2
24 ± 1
50 ± 0.2
60 ± 0.2
15 to 55 °C
58 to 131 °F
0 to 70
0.4
1
30
22 to 27
90 to 240
20 to 27
49 to 51
59 to 61
Limits
0 to 55 °C
32 to 131 °F
0 to 200
0.6
5
30
20 to 30
90 to 250
20 to 27
48 to 52
58 to 62
Transportation and Storage
–40 to 66 °C
–40 to 151 °F
0 to 200
0.5
20
30
- -
- -
- -
- -
- -
- -
16 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
_
_ _
_ _
_
_
_
2.3 Model Number Interpretation
Introduction
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.
Figure 2-1 Model Number Interpretation
UDC3500 Universal Digital Controller
Model Selection Guide
New! Easy To Use UDC3500 1/4 DIN Single & Dual Loop Controller
The UDC3500 Controller packs new powerful features while retaining all the simplicity and flexibility of
the industry standard UDC3300 Controller. Many new features include:
- NEMA 4X, IP66 Front Face Protection
- Built-in infrared communications port for configuring with a Pocket PC or Laptop
- PC Based Configuration Tools
- Ethernet Communications
- 20 Segment Set Point Programming
- One or Two Loops of Control
- Real Time Clock
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 - UDC3500 Single & Dual Loop Controller
Digital Controller for use with 90 to 250Vac Power + Current Output #1 DC3500
Digital Controller for use with 24Vac/dc Power + Current Output #1 DC3501
TABLE I - Specify optional Output and/or Alarms
Output #2
Relay Outputs #3, #4
and #5
TABLE II - Communications and Software Selections
Communications
Software Selections
Enhanced
Loops of Control
Real-Time Clock
None
Current Output (4 to 20mA, 0 to 20 mA) (Current Output #3)
Electro Mechanical Relay (5 Amp Form C)
Solid State 1 Amp (Zero-Crossing Type)
Open Collector transistor output
Dual 2 Amp Relays (Form A) (Heat/Cool, Pos Prop, TPSC, Relays 1 & 2)
None
Three (3) E-M Relay (5 Amp Form C)
None
Current Output #2 + (4) Digital Inputs
Current Output #2 + (4) Digital Inputs + Modbus RS-485
10 Base-T Ethernet (Modbus RTU) + (4) Digital Inputs
Standard Functions, Includes Accutune
Math Option
Set Point Programming (1 Program, 20 Segments)
Set Point Programming Plus Math (1 Pr ogram, 20 Segments)
HealthWatch
SPP + HealthWatch (1 Program, 20 Segments)
Math + HealthWatch
SPP + Math + HealthWatch (1 Program, 20 Segments)
Enhanced SPP (4 Programs, 20 Segments each)
Enhanced SPP + Math (4 Programs, 20 Segments each)
Enhanced SPP + HealthWatch (4 Programs, 20 Segments each)
Enhanced SPP + Math + HealthWatch (4 Programs, 20 Segments each)
Single Loop
2 Loops + Internal Cascade
None
Real-Time Clock (RTC)
IIIII
_ _
Description
VI
VIIV
Selection
Availability
0 _
C _
E _
A _
T _
R _
_ 0
_ E
0 _ _ _
1 _ _ _
2 _ _ _
3 _ _ _
_ 0 _ _
_ A _ _
_ B _ _
_ C _ _
_ D _ _
_ E _ _
_ F _ _
_ G _ _
_ H _ _
_ J _ _
_ K _ _
_ L _ _
_ _ 0 _
_ _2 _
_ _ _ 0
_ _ _ C
March 2012 UDC3500 Universal Digital Controller Product Manual 17
Installation
TABLE III - Input types can be changed in the field
Input 1
Input 2
Input 3
TABLE IV - Options
Approvals
Tags
Special Options
Future Options
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, -1-1V, 0-10V
None
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, -1-1V, 0-10V
Two HLAI instead of 1 LLAI
Relative Humidity (Requires Input 2)
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, -1-1V, 0-10V
Two HLAI instead of 1 LLAI _ _3
Slidewire Input for Position Prop. (Requires Dual Relay Output)
CE (Standard)
CE, UL and CSA
None
Stainless Steel Customer ID Tag - 3 lines w/22 characters/line
None
Custom Calibration (0.05%) For one Range Type Only (
None
None
Note 1)
Selection
1 _ _
2 _ _
3 _ _
_ 0 _
_ 1 _
_ 2 _
_ 3 _
_ 5 _
_ 6 _
_ _0
_ _1
_ _2
_ _4
0 _ _ _ _
1 _ _ _ _
_ 0 _ _ _
_ T _ _ _
_ _ 0 _ _
_ _ 1 _ _
_ _ _ 0 _
_ _ _ _ 0
Availability
DC 3500 3501
bb
bb
aa
TABLE V - Product Manuals
Manuals
Certificate
TABLE VI
Note 1:
The specific range and input actuation to be calibrated to 0.05% must be specified for each input.
Form F3399 Supplemental Data must be completed. This form can be downloaded from the Honeywell SalesNet site
or Global Technical Services site: >http://content.honeywell.com/ipc/faq/<
Only one range type can be calibrated for each input. All other universal ranges will remain at 0.10%.
ORDERING INSTRUCTIONS: These are provided as guidance for ordering such as those listed
1. Part numbers are provided to facilitate Distributor Stock.
2. Orders may be placed either by model selection or by part number.
3. Part numbers are shown within the model selection tables to assist with compatibility information.
4. Orders placed by model selection are systematically protected against incompatibility.
5. Compatibility assessment is the responsibility of the purchaser for orders placed by part number.
6. Items labeled as N/A are not available via the stocking program and must be ordered by model selection.
RESTRICTIONS
Restriction Letters
a
b
Product Information on CD - (English) 0 _
English Manual (Hard Copy) E _
French Manual (Hard Copy) F _
German Manual (Hard Copy) G _
Italian Manual (Hard Copy) I _
Spanish Manual (Hard Copy)
None
Certificate of Conformance (F3391)
None 0
Available Only With Not Available With
Table
Selection Table
I
III
R _
1 _ _
Selection
S _
_ 0
_ C
18 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
UDC3500
Universal Digital Controller
Description Part Number
Bezel Assembly and Bezel Gasket 51453143-503
Display/Keyboard (with IR) 51452845-501
Power/Output PWA with Current Out #1 and E-M Relay (90-264 Vac) 51452831-501
Power/Output PWA with Current Out #1 and E-M Relay (24 Vac/dc) 50006376-501
Optional Analog Input PWA 51452825-501
2nd Current Output/Digital Inputs/RS-422/485 Communications PWA 51452837-502
Digital Inputs/Ethernet Communications PWA 51452840-501
MCU/Inputs PWA 51452828-502
Electro-Mechanical Relay 30755306-501
Open Collector Output PWA 30756679-501
Solid State Relay 30756725-501
3rd Current Output PWA 51452834-501
Dual Electromechanical Relay PWA 51452807-501
Optional Relay PWA (Relays 3, 4 & 5) 51452843-501
Ethernet Cable Jack Assembly (DONGLE) 50002382-501
Ethernet Adaptor Kit 50010425-501
Case Assembly (including Mounting Kit with four brackets) 51452846-501
Varistor (MOV) 120 Vac 30732481-501
Varistor (MOV) 240 Vac 30732481-502
Thermocouple Input Cold Junction Resistor Assembly 51453364-501
4-20 mA Input Resistor Assembly (250 ohm) 30731996-506
0-10 Volt Input Resistor Assembly (100K pair) 30754465-501
Mounting Kits (12 Brackets) 51452763-501
DIN Adaptor Kit 30755223-003
Process Instrument Explorer Software 50001619-001
Math Software Upgrade 50004636-501
SPP Software Upgrade 50004636-502
Healthwatch 50004636-503
Two Loops/Cascade 50004636-504
Battery Replacement Kit 51453140-501
Panel Bracket Kit 50004821-501
Product Information on CD All Languages
Quick Start Manual (2 page) Standard English
Product Manual English 51-52-25-120
Supplemental
Accessories & Kits
51453375-501
51-52-25-130
March 2012 UDC3500 Universal Digital Controller Product Manual 19
Installation
2.4 Control and Alarm Relay Contact Information
Control Relays
ATTENTION
Control relays operate in the standard control mode (that is, energized when output state is on).
Table 2-2 Control Relay Contact Information
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
On
Control Relay
Wiring
N.O. Open
N.C. Closed
N.O.
N.C.
Contact
Open
Closed
Closed
Open
Table 2-3 Alarm Relay Contact Information
Alarm Relay
Wiring
Variable NOT in Alarm State Variable in Alarm State Unit
Relay
Contact
Indicators Relay
Output #1 or #2
Indicator Status
Off
Off
On
Off
On
Indicators
Contact
Off
On
20 UDC3500 Universal Digital Controller Product Manual March 2012
N.O. Open Open
N.C. Closed
N.O. Closed Open
N.C. Open
Off
Closed
Off
Closed
Off
On
2.5 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. See Figure 2-3 and Table 2-4 Mounting Procedure.
Overall Dimensions
mm
inches
Max. panel thickness
19,1
0.75
9,0
0.35
Installation
92,0 + 0,8
- 0,00
3.62 + 0.03
- 0.00
Mounting Notes
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.
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
148,0
5.81
90,6
3.57
108,6
4.28
March 2012 UDC3500 Universal Digital Controller Product Manual 21
Installation
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
1
information in Figure 2-2.
Orient the case properly and slide it through the panel hole from the front.
2
Remove the mounting kit from the shipping container and install the kit as follows:
3
For normal installation (NEMA 3/IP55) 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 (NEMA 4/IP66) 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 Ncm) to secure the case against the panel.
CAUTION: Over tightening will cause distortion and the unit may not seal properly.
For water-protected installation (NEMA 4/IP66), install four screws with washers into
4
the four recessed areas in the corners of the front bezel (Figure 2-3). Push the point of
the screw through the center piercing the elastomeric material and then tighten screws
to 5 lb-in (56 Ncm).
Figure 2-3 Mounting Methods
Table 2-4 Mounting Procedure
22 UDC3500 Universal Digital Controller Product Manual March 2012
2.6 Wiring
2.6.1 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 250 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 90-250 Vac applications; or 2 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.
Installation
Applying 90-250 Vac to an instrument rated for 24 Vac/dc will severely
damage the instrument and is a fire and smoke hazard.
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.
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 mm2) 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, Table 2-5.
Electrical Noise Precautions
Electrical noise is composed of unabated electrical signals, which produce undesirable
effects in measurements and control circuits.
March 2012 UDC3500 Universal Digital Controller Product Manual 23
Installation
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:
Separate External Wiring—Separate connecting wires into bundles
(See Permissible Wiring Bundling - Table 2-5) 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 2-5 Permissible Wiring Bundling
Bundle No. Wire Functions
1
2 Analog signal wire, such as:
3
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
24 UDC3500 Universal Digital Controller Product Manual March 2012
2.7 Wiring Diagrams
Identify Your Wiring Requirements
To determine the appropriate diagrams for wiring your controller, refer to the model
number interpretation in this section. The model number of the controller is on the
outside of the case.
Output Functionality and Restrictions
Table 2-6 and Table 2-7 show the control functionality and number of alarms that are
available based upon the installed outputs quantity and type. First, use the left-most
column to find the Control Output Algorithm desired for your instrument. Then use the
second column to find the Output 2 Option selection installed in your instrument. The
rest of the columns will then show how the instrument delivers your desired Output
functionality and the quantity of alarms available.
In Table 2-6, “HEAT” is used as meaning Loop 1 Control Output #1 and “COOL” is
used as meaning Loop 1 Control Output #2. When Position Proportional or Three
Position Step Control (TPSC) is configured, then “HEAT” means OPEN while “COOL”
means CLOSE.
In Table 2-7, “Loop 2 HEAT” is used as meaning Loop 2 Control Output #1 and “Loop 2
COOL” is used as meaning Loop 2 Control Output #2.
See Figure 2-4 Composite Wiring Diagram, for information on where the customer
terminals are for all of these outputs and alarms.
Installation
ATTENTION
The selection for Loop 1 Output takes precedence over the selection for Loop 2 Output.
For example, if you select the Loop 1 Output Algorithm as Current Duplex 50%, then
you cannot have Current Duplex 50% as the Output Algorithm for Loop 2.
The Output 2 option shown in these tables as “Single Relay” can be any of the
following selections: Electro-Mechanical Relay, Solid-State Relay or Open Collector
Output.
If the controller is configured to use the same relay for more than one function, then the
following priority is used to determine how the relay functions: Control Outputs take
precedence over Alarms, which in turn take precedence over Time/Events, which in turn
take precedence over Logic Gate Outputs.
For example, if you select the Loop 2 Output Algorithm as Time Simplex (which uses
Relay 3), enable Alarm 3 (which also uses Relay 3) and configure a Logic Gate to use
Relay 3, then the instrument will use Relay #3 to perform the Time Simplex output and
ignore the Alarm and Logic Gate functions.
March 2012 UDC3500 Universal Digital Controller Product Manual 25
Installation
Output Alg.
Selection
Time Simplex
or ON-OFF
Simplex
Time Duplex or
ON-OFF
Duplex or
TPSC or
Position
Proportional **
Current
Simplex
Current Duplex
100 %
1st Current
Output =
COOL and
HEAT
Current Duplex
50 % ***
Cur #1 = HEAT
Cur #2 or #3 =
COOL
Current/Time
First Current
Out = COOL
Time = HEAT
Time/Current
Time = COOL
First Current
Out = HEAT
Table 2-6 Single or Cascade Loop Controller – Loop 1 Output Functionality
and Restrictions
Output #2
Option
Single Relay HEAT NUL1 NUL1 Alarm 3 Alarm 2 Alarm 1
Third Current Output N/A N/A N/A N/A N/A N/A
Dual Relay HEAT NUL1 NUL1 Alarm 3 Alarm 2 Alarm 1
None N/A N/A N/A N/A N/A N/A
Single Relay N/A N/A N/A N/A N/A N/A
Third Current Output N/A N/A N/A N/A N/A N/A
Dual Relay HEAT and
None N/A N/A N/A N/A N/A N/A
Single Relay Alarm 4 HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
Third Current Output NUL1 HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
Dual Relay Alarm 4 HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
None N/A HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
Single Relay Alarm 4 HEAT and
Third Current Output NUL1 HEAT and
Dual Relay Alarm 4 HEAT and
None N/A HEAT and
Single Relay Alarm 4 HEAT COOL Alarm 3 Alarm 2 Alarm 1
Third Current Output NUL1 *** HEAT COOL *** Alarm 3 Alarm 2 Alarm 1
Dual Relay Alarm 4 HEAT COOL Alarm 3 Alarm 2 Alarm 1
None N/A HEAT COOL Alarm 3 Alarm 2 Alarm 1
Single Relay HEAT COOL NUL1 Alarm 3 Alarm 2 Alarm 1
Third Current Output N/A N/A N/A N/A N/A N/A
Dual Relay HEAT COOL NUL1 Alarm 3 Alarm 2 Alarm 1
None N/A N/A N/A N/A N/A N/A
Single Relay COOL HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
Third Current Output N/A N/A N/A N/A N/A N/A
Dual Relay COOL HEAT NUL1 Alarm 3 Alarm 2 Alarm 1
None N/A N/A N/A N/A N/A N/A
Function of
Output #2
COOL
1st Current
Output
NUL1 NUL1 Alarm 3 Alarm 2 Alarm 1
COOL
COOL
COOL
COOL
2nd Current
Output *
NUL1 Alarm 3 Alarm 2 Alarm 1
NUL1 Alarm 3 Alarm 2 Alarm 1
NUL1 Alarm 3 Alarm 2 Alarm 1
NUL1 Alarm 3 Alarm 2 Alarm 1
Relay #3 Relay #4 Relay #5
TPSC = Three Position Step Control
N/A = The output form or the individual output is N
Output #2 Option selection.
NUL1 = N
26 UDC3500 Universal Digital Controller Product Manual March 2012
ot Used on Loop 1 – This particular output is not used for the selected Loop 1 Output
Type, But it may be used for the Second Loop Output Type. Refer to the selection made in
Table 2-7. Any current output not used as a Control Output for either loop may be used as
an Auxiliary Output.
ot Available, not operable or is not used for this
Loop 2 Output
Algorithm
Selection
ON-OFF Simplex
Table 2-7 Dual Loop Controller – Loop 2 Output Functionality and
Restrictions
Output #2
Option
Third Current
Output
Function of
Output #2
NUL2 NUL2 NUL2 Loop 2
1st Current
Output
2nd Current
Output *
Relay #3 Relay #4 Relay #5
HEAT
Alarm 2 Alarm 1 Time Simplex or
Installation
ON-OFF Duplex
100 %
Second or Third
Current Out =
COOL and HEAT
50 % ***
Second Current =
HEAT
Third Current =
COOL
Second or Third
Current = COOL
Time = HEAT
All Other
Options
Third Current
Output
All Other
Options
Third Current
Output
All Other
Options
Third Current
Output
All Other
Options
Third Current
Output
All Other
Options
Third Current
Output
All Other
Options
NUL2 NUL2 NUL2 Loop 2
HEAT
NUL2 NUL2 NUL2 Loop 2
HEAT
NUL2 NUL2 NUL2 Loop 2
HEAT
Loop 2 HEAT NUL2 NUL2 Alarm 3 Alarm 2 Alarm 1 Current Simplex
NUL2 NUL2 Loop 2
HEAT
Loop 2 HEAT
and COOL
NUL2 NUL2 Loop 2
Loop 2 HEAT NUL2 Loop 2
N/A2 N/A2 N/A2 N/A2 N/A2 N/A2
Loop 2 COOL NUL2 NUL2 Loop 2
NUL2 NUL2 Loop 2
NUL2 NUL2 Alarm 3 Alarm 2 Alarm 1 Current Duplex
HEAT and
COOL
COOL
COOL
Alarm 3 Alarm 2 Alarm 1
Alarm 3 Alarm 2 Alarm 1
Alarm 3 Alarm 2 Alarm 1 Current Duplex
HEAT
Loop 2
HEAT
Alarm 2 Alarm 1
Loop 2
COOL
Loop 2
COOL
Alarm 2 Alarm 1 Current/Time
Alarm 2 Alarm 1
Alarm 1 Time Duplex or
Alarm 1
Time = COOL
Second or Third
Current = HEAT
NUL2 = N ot Used on Loop 2 – This particular output is not used for the selected Second Loop
N/A2 =
* The Second Current Output and Ethernet Communications are mutually exclusive.
** TPSC and Position Proportional are available only on Loop 1.
*** Current Duplex 50% is available only on Loop 1 or Loop 2, it cannot be used on both loops. If the
Second Current Output is not present, then the Third Current Output is used as Loop 1 COOL output.
March 2012 UDC3500 Universal Digital Controller Product Manual 27
Third Current
Output
All Other
Options
Output type, but it may be used for the First Loop Output type. Refer to the selection made
in Table 2-6. Any Current Output not used as a Control Output on either loop may be
configured as an Auxiliary Output.
Current Duplex 50% is N
installed.
Loop 2 HEAT NUL2 NUL2 Loop 2
COOL
NUL2 NUL2 Loop 2
HEAT
ot Available on Loop 2 unless the Third Current Output is
Loop 2
COOL
Alarm 2 Alarm 1 Time/Current
Alarm 2 Alarm 1
Installation
Wiring the Controller
Using the information contained in the model number, select the appropriate wiring
diagrams from the composite wiring diagram below. Refer to the individual diagrams
listed to wire the controller according to your requirements.
8
10
1
9
2
3
L1
11
L2/N
12
4
13
5
14
6
15
7
16
8
17
18
9
See table for callout details
19
20
21
22
23
24
25
26
27
7
28
29
30
31
32
33
34
35
36
9
Figure 2-4 Composite Wiring Diagram
Callout Details
1 AC/DC Line Voltage Terminals. See Figure 2-5.
2 First Current Output Terminals. See Figure 2-12.
6
5
4
3 Output 2 Option Terminals. See Figure 2-14 through Figure 2-19.
4 Input #1 Terminals. See Figure 2-6.
5 Input #2 Terminals. See Figure 2-7.
Dual HLAI Inputs #2 and #4 Terminals. See Figure 2-9 and Figure 2-11.
6 Input #3 Terminals. See Figure 2-8.
Dual HLAI Inputs #3 and #5 Terminals. See Figure 2-10 and Figure 2-11.
7 Digital Inputs Terminals. See Figure 2-23.
8 Optional Relays Terminals (Relays 3, 4 and 5). See Figure 2-24.
9 Optional Interface
Second Current Output Terminals. See Figure 2-13.
RS-485 Communications T
erminals. See Figure 2-20.
Ethernet Communications Terminals. See Figure 2-22.
28 UDC3500 Universal Digital Controller Product Manual March 2012
Earth
Earth
1
1
Ground
3
3
AC/DC
AC/DC
Line
Line
Voltage
Voltage
1
1
PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is
PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is
installed, shall b e in accordance with National and local electrical code s. To min imize
installed, shall b e in accordance with National and local electrical code s. To min imize
electrical noise and transients that may adversely affect the system, supplementary
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
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
conductor is recommended. Before powering the controller, see “Prelimnary Checks” in
this section of the Product Manual.
this section of the Product Manual.
2
2
Ground
Hot
Hot
Neutral
Neutral
L1
L1
L2/N
L2/N
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
2
2
28
28
29
29
30
30
31
31
32
32
33
33
34
34
35
35
36
36
) copper
) copper
Installation
2
2
It is the user’s responsibility to provide a swit ch and non-time delay (North America),
It is the user’s responsibility to provide a swit ch and non-time delay (North America),
quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuit-
quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuitbreaker for 90-264 Vac applications; or 2 A, 125 V fuse or circuit breaker for 24 Vac/dc
breaker for 90-264 Vac applications; or 2 A, 125 V fuse or circuit breaker for 24 Vac/dc
applications, as part of the installation.
applications, as part of the installation.
3
3
Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely
Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely
damage the instrument a nd i s a fire and smoke hazard.
damage the instrument a nd i s a fire and smoke hazard.
Figure 2-5 Mains Power Supply
March 2012 UDC3500 Universal Digital Controller Product Manual 29
Installation
Input #2
Input #1
Thermocouple
Thermocouple
0-10 Volts or –1 to 1 Volts
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
3
1
3 2
+
+
1
1
100K
100K
2
Volt
Volt
source
source
2
1
3
100K
100K
3
3
–
–
RTD
22
R
34
R
23
+
35
+
–
–
24
36
Milliamps
Milliamps
22
R
34
R
–
–
Xmitter
23
35
24
36
Xmitter
+
+
+
+
–
–
Power
Power
Supply
Supply
250
250
1
3
–+
–+
except 0 to 10 Volts or –1 to 1 Volts
22
R
34
2324+
3536+
R
mV or
mV or
+
+
Volt
Volt
source
–
–
22
R
34
R
23
35
+
+
24
–
36
–
source
–
–
Thermocouple Differential
Thermocouple Differential
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
+
+
–
–
2
4
–
–
5
+
+
22
34
23
35
24
36
R
R
+
+
–
–
22
R
34
R
23
+
35
+
–
–
24
36
RTD
Carbon, Oxygen, Millivolt or Volts
1
Remove the “R” terminal screw and install the C/J Sensor in its place. Connect the tang to the ““ termin al.
This controller does not produce a steady current for burnout detection. For that reason, when a
2
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 Failsafe Output must be set to ensure proper operation when the thermocouple fails.
The 250 ohm resistor for milliamp inputs or the voltage divider for 0 to10 Volt or –1 to 1Volt inputs are
3
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, -1 to 1 Volt and 0-10 Volt 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
4
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 the highest accuracy, the
thermocouples should be matched or, preferably, made from the same batch of wire.
The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient
5
temperature mean of 450°F / 232°C. Cold Junction Compensation is not required for this input type.
Figure 2-6 Input 1 Connections
30 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
Input #2
Input #2
Millivolt or Volts except
Thermocouple
Thermocouple
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
3 2
22
R
31
23
32
24
33
R
+
+
–
–
3
1
0-10 Volts or –1 to 1 Volts
22
R
31
23
32
24
33
R
+
+
–
–
+
+
1
1
100K
100K
0 – 10
Volt
Volt
source
source
1
Remove the “R” terminal screw and install the C/J Sensor in its place. Connect the tang to the ““ termin al.
This controller does not produce a steady current for burnout detection. For that reason, when a
2
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 Failsafe Output must be set to ensure proper operation when the thermocouple fails.
2
2
1
3
100K
100K
3
3
–
–
RTD
RTD
Milliamps
Milliamps
–
–
Xmitter
Xmitter
+
+
250
250
Power
Power
–+
–+
Supply
Supply
0 to 10 Volts or –1 to 1 Volts
source
22
R
31
R
2324+
3233+
–
–
22
R
31
R
1
3
23
32
24
33
+
+
–
–
source
mV or
mV or
+
+
Volt
Volt
source
source
–
–
Thermocouple Differential
Thermocouple Differential
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
+
+
–
–
2
4
–
–
5
+
+
22
31
23
32
24
33
R
R
+
+
–
–
22
R
31
R
23
+
32
+
–
–
24
33
The 250 ohm resistor for milliamp inputs or the voltage divider for 0 to10 Volt or –1 to 1Volt inputs are
3
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, -1 to 1 Volt and 0-10 Volt 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
4
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 the highest accuracy, the
thermocouples should be matched or, preferably, made from the same batch of wire.
The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient
5
temperature mean of 450°F / 232°C. Cold Junction Compensation is not required for this input type.
Figure 2-7 Input 2 Connections
March 2012 UDC3500 Universal Digital Controller Product Manual 31
Installation
Input #2
Input #3
Thermocouple RTD
Thermocouple RTD
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
0-10 Volts or –1 to 1 Volts
Volt
Volt
source
source
22
R
28
22
28
23
29
24
30
23
29
24
30
R
+
+
–
–
R
R
+
+
–
–
Milliamps
Milliamps
–
–
Xmitter
Xmitter
+
+
250
250
Power
Power
–+
–+
Supply
Supply
Slidewire Input
Slidewire Input
3
1
3 2
+
+
1
1
100K
100K
2
2
1
3
100K
100K
3
3
–
–
(for Position Proportional Control or Three Position Step Contro
(for Position Proportional Control or Three Position Step Control)
Millivolt or Volts except
0 to 10 Volts or –1 to 1 Volts
source
22
R
28
R
2324+
2930+
–
–
R
R
22
28
1
3
23
29
24
30
+
+
–
–
source
mV or
mV or
+
+
Volt
Volt
source
source
–
–
Thermocouple Differential
Thermocouple Differential
Use Thermocouple
Use Thermocouple
extension wire only
extension wire only
+
+
–
–
2
4
–
–
5
+
+
22
28
23
29
24
30
R
R
+
+
–
–
22
R
28
R
23
+
29
+
–
–
24
30
4
46
Open
Open
Wiper
Wiper
Close
Close
1
Remove the “R” terminal screw and install the C/J Sensor in its place. Connect the tang to the “
1
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
This controller does not produce a steady current for burnout detection. For that reas on, when a
2
up when the controller is wire d. For 0-20 mA applications, the resistor should be located at the
thermocouple is used in parallel with another instrument, it may be desirable to configure the burnout
transmitter terminals if Burnout detec tion is desired.
selection for this controller to “NOFS” and use the burnout current from the other instrument to also drive
this controller. The Failsafe Output must be set to ensure proper operation when the thermocouple fails.
2
Splice and tape this junction between the two thermocouples. Thi s junction may be located
anywhere between the thermocouples and the instrument terminals, it does not need to be close
The 250 ohm resistor for milliamp inputs or the voltage divider for 0 to10 Volt or –1 to 1Volt inputs are
3
to the other thermocou ple junctions. Both thermocouples must be of the same type. For bes t
supplied with the controller when those inputs are specified. These items must be i nstalled prior to start up
accuracy, the two thermocouples should be matched or, preferably , made from the same batch
when the controller is wired. For 0-20 mA, -1 to 1 Volt and 0-10 Volt applications, the resistor should be
of wire.
located at the transmitter terminals if Burnout detection is desired.
This controller does not produce a steady c urrent for burnout detection. For that rea son, when a
3
Splice and tape this junction between the two thermocouples. This junction may be located anywhere
4
thermocouple is used in parallel with another instrument, it m ay be desirable to configure the
between the thermocouples and the instrument terminals, it does not need to be close to the other
burnout selection for this controller to “NOFS” and use the burnout current from the other
thermocouple junctions. Both thermocouples m ust be of the same type. For the highest accurac y, the
instrument to also drive this controller.
thermocouples should be matched or, preferably, made from the same batch of wire.
The millivolt values for the Thermocouple Differential I nput are for a pair of J thermocouples at an ambient
5
temperature mean of 450°F / 232°C. Cold Junction Compensation is not required f or this input type.
Input 3 is used to measure the Slidewire Input for Position Proportional Control.
6
22
28
2324+
2930+
R
R
–
–
“ terminal.
xxxx
Figure 2-8 Input 3 Connections
32 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
A
TTENTION:
Check Input 2 jumper when
replacing single input with two
HLAI.
0-5V or 1-5V Connections
Input 4 Source
Input 2 Source
1
The 250 ohm resistors for milliamp 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 sho uld be located at the transmitter ter min als if Burnout detection is desired .
+
–
+
–
L1
11
L2/N
12
4
13
5
14
6
15
7
16
8
17
18
9
29
20
30
21
31
22
32
23
33
24
34
25
26
35
36
27
+
+
–
0-20 or 4-20mA Connections
High Level
Analog Input
Connections
See Below
28
19
10
Transmitter 4
31
31
32
33
+
+
–
Transmitter 2
+
–
+
–
+
1
250
250
1
–
32
33
+
+
–
Power
Supply
Figure 2-9 HLAI Inputs 2 and 4 Connections
See Figure 2-11 for Jumper Positions.
March 2012 UDC3500 Universal Digital Controller Product Manual 33
Installation
A
2
TTENTION:
Check Input 3 jumper when
replacing single input with two
HLAI.
0-5V or 1-5V Connections
Input 5 Source
Input 3 Source
L1
11
12
L2/N
4
5
6
7
8
9
13
14
15
16
17
18
29
20
30
21
31
22
32
23
33
24
34
25
35
26
36
27
0-20 or 4-20mA Connections
28
19
10
+
+
–
High Level
Analog Input
Connections
See Below
Transmitter 5
28
29
30
+
+
–
+
28
29
30
+
+
–
Transmitter 3
+
–
+
–
–
+
–
+
Power
Supply
1
250
250
1
–
See Figure 2-11 for Jumper Positions.
Jumper
Location
Jumper
Position
Input Types
Available
1
The 250 ohm resistors for milliamp 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.
Figure 2-10 HLAI Inputs 3 and 5 Connections
Top of unit
W1
W2
nd
2
Input becomes HLAI Inputs 2 & 4
rd
3
Input becomes HLAI Inputs 3 & 5
W1
W2
W1
W2
Two HLAI
3rd Input PWA
nd Input PWA
MCU/Input PWA
Single Input
Thermocouple, RTD, Volt, Millivolt,
Milliamp, Radiamatic and
(Input 3 only) Slidewire
Figure 2-11 Optional Analog Input Jumper Positions
34 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
_
28
29
30
31
32
33
34
35
36
+
Output Load
0 - 1000 ohms
1
The First Current Output is standard on all instruments.
Current Output
0-20 or 4-20 mA
–
1
L1
L2/N
4
5
6
7
8
9
Figure 2-12 First Current Output
See Table 2-6 and Table 2-7 for other information about output types.
19
20
21
22
1
23
24
+
Output Load
0 – 1000 ohms
25
26
27
Connect shield
to ground at one
end only.
1
The Second Current Output is mutually exclusive with Ethernet
Communications.
Figure 2-13 Second Current Output
See Table 2-6 and Table 2-7 for other information about output types.
March 2012 UDC3500 Universal Digital Controller Product Manual 35
Installation
28
L1
L2/N
4
5
6
7
Load
Supply
Power
Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc.
1
Customer should size fuses accordingly. Use Fast Blo fuses only.
Relay Load
7 (N.C.) or 9 (N.O.)
1
To terminal
8
9
N.C.
N.O.
29
30
31
32
33
34
35
36
Figure 2-14 Output #2 – Electromechanical Relay Output
See Table 2-6 and Table 2-7 for other information about output types.
28
L1
L2/N
4
5
1
Dummy Resistor
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
1
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
2
fuse accordingly. Use Fast Blo fuses only.
Relay Load
2
6
7
8
N.O.
9
29
30
31
32
33
34
35
36
Figure 2-15 Output #2 – Solid State Relay Output
See Table 2-6 and Table 2-7 for other information about output types.
36 UDC3500 Universal Digital Controller Product Manual March 2012
28
28
29
29
30
30
31
31
32
32
33
33
34
34
35
35
36
36
Maximum Sink Current: 20mA
Maximum Sink Current: 20mA
Overload Protection: 100mA
Overload Protection: 100mA
Customer Supplied
Customer Supplied
Electromechanical relay
Electromechanical relay
+
+
–
–
Customer Supplied
Customer Supplied
Solid-State relay
Solid-State relay
Open collector outputs are internally powered at +30 Vdc. Connecting an external
CAUTION
1
CAUTION
11
Open collector outputs are internally powered at +30 Vdc. Connecting an external
power supply will damage the controller.
power supply will damage the controller.
L1
L1
L2/N
L2/N
4
4
5
5
6
6
7
7
+
+
+
–
–
8
8
9
9
+
OC Output
OC Output
–
–
1
1
Figure 2-16 Output #2 – Open Collector Output- Third
Installation
See Table 2-6 and Table 2-7 for other information about output types.
28
29
30
31
32
33
34
35
Output Load
+
Current Output
0-20 or 4-20 mA
L1
L2/N
4
5
6
7
8
0 - 1000 ohm s
–
9
36
Figure 2-17 Output #2 – Third Current Output
See Table 2-6 and Table 2-7 for other information about output types.
March 2012 UDC3500 Universal Digital Controller Product Manual 37
Installation
28
L1
L2/N
4
5
6
Cool Relay Load
Load
1
Power
Supply
1
Dual Electromechanical relays are rated at 2 Amps @120 Vac or 240 Vac or
Heat Relay Load
7
8
9
Out Relay #2
N.O.
Out Relay #1
N.O.
30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.
29
30
31
32
33
34
35
36
Figure 2-18 Output #2 – Dual Relay Output for Time Duplex
See Table 2-6 and Table 2-7 for other information about output types.
28
Motor
Power
Supply
Motor
L2/N
L1/Hot
Close (CCW)
1
Open (CW)
L1
L2/N
4
5
6
7
8
9
Out Relay #2
N.O.
Out Relay #1
N.O.
29
30
31
32
33
34
35
36
2
1
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.
See Input 3 Wiring Diagram for Slidewire Connections.
2
Figure 2-19 Output #2 – Dual Relay Output for Position Proportional or
Three Position Step Control
See Table 2-6 and Table 2-7 for other information about output types. See Figure 2-8 for
Slidewire connections.
38 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
COMMUNICATION MASTER
COMMUNICATION MASTER
SHLD D–(A)
SHLD D–(A)
D+ (B)
UDC3500
UDC3500
UDC3500
UDC3500
1
2
2
1
4 SHLD
4 SHLD
4 SHLD
4 SHLD4 SHLD
26 D+ (B)
26 D+ (B)
26 D+ (B)
26 D+ (B)
27 D– (A)
27 D– (A)
27 D– (A)
27 D– (A)
Do not run the communications lines in the same conduit as AC power.
Do not run the communications lines in the same conduit as AC power.
1
1
Maximum Distance 4000 feet.
Maximum Distance 4000 feet.
Use shielded twisted pair cables (Belden 9271 Twinax or equivalent).
Use shielded twisted pair cables (Belden 9271 Twinax or equivalent).
2
2
SHLD
SHLD
1
D+
D+
D–
D–
TO OTHER
TO OTHER
COMMUNICATION
COMMUNICATION
CONTROLLERS
CONTROLLERS
D+D–
D+D–
120 OHMS ON LAST LEG
120 OHMS ON LAST LEG
D+ (B)
120 OHMS
120 OHMS
Connect shield
Connect shield
to ground at one
to ground at one
end only.
end only.
Figure 2-20 RS-422/485 Communications Option Connections
RS-422/485 connections must be “daisy-chained,” T-drop connections are not allowed.
10
11
L1
12
L2/N
13
4
14
5
15
6
16
7
17
8
9
18
Tie Wraps (2)
19
20
21
22
23
24
25
26
27
28
Ethernet
29
30
31
32
33
Ethernet
Cable To
34
Hub or
35
36
24
27
Figure 2-21 Ethernet Communications Option with Adaptor Board
Instruments equipped with the Ethernet Communications Option come with an Ethernet
Adaptor Kit. To use this kit, first remove the four screws on your instrument from
Terminal Block positions 24 through 27. Place the Ethernet Adaptor Board on to the
terminal block as shown and then secure it in place with the four long screws provided in
the kit. Route the long wire on the Ethernet Adaptor Board over to Terminal #4 on your
instrument. The RJ-45 connector on the Ethernet Adaptor Board will allow you to use a
March 2012 UDC3500 Universal Digital Controller Product Manual 39
Installation
straight-through cable to connect the controller to a MDI Compliant Hub or Switch.
Alternatively, you may use a crossover cable to connect your controller directly to a PC,
which is useful for commissioning purposes. Use only Category 5 (STP CAT5) shielded
twisted-pair Ethernet cables. For strain relief, secure your Ethernet cable to the controller
with the tie wraps included in the kit using the holes in the bottom controller flange.
COMMUNICATION MASTER
COMMUNICATION MASTER
TXD +TXD -SHLD
TXD +TXD -SHLD
4 SHLD
4 SHLD
24 RXD +
24 RXD +
25 RXD -
25 RXD -
26 TXD +
26 TXD +
27 TXD -
27 TXD -
Do not run the communications lines in the same conduit as AC
Do not run the communications lines in the same conduit as AC
1
1
power. Direct connection to a PC may require the use of an
power. Direct connection to a PC may require the use of an
Ethernet cross-over cable.
Ethernet cross-over cable.
2
2
Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.
Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.
Maximum Distance 330 Ft.
Maximum Distance 330 Ft.
Use Switch rather than Hub to maximize performance.
Use Switch rather than Hub to maximize performance.
3
3
Ethernet Communications is mutually exclusive with the Sec o nd Current
Ethernet Communications is mutually exclusive with the Sec o nd Current
Ethernet Communications is mutually exclusive with the Sec o nd Current
4
4
4
Output.
Output.
Output.
RXD -
RXD -
RXD +
RXD +
3
3
1
1
2
2
Figure 2-22 Ethernet Communications Option without Adaptor Board
If you would rather wire your UDC to your Ethernet connection without using the
Ethernet Adaptor Board, then Figure 2-22 and Table 2-8 show the connections for 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.
40 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
Table 2-9 shows the connections for a UDC to a PC utilizing a straight-through cable
(wiring the UDC cable this way makes the necessary cross-over connections).
Table 2-8 Terminals for connecting a UDC to a MDI Compliant Hub or
Switch utilizing a cross-over cable
UDC Terminal UDC Signal Name RJ45 Socket Pin # Switch Signal Name
Position 4 Shield Shield Shield
Position 24 RXD- 6 TXDPosition 25 RXD+ 3 TXD+
Position 26 TXD- 2 RXDPosition 27 TXD+ 1 RXD+
March 2012 UDC3500 Universal Digital Controller Product Manual 41
Installation
_
Table 2-9 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 4 Shield Shield Shield
Position 24 RXD- 2 TXDPosition 25 RXD+ 1 TXD+
Position 26 TXD- 6 RXDPosition 27 TXD+ 3 RXD+
Use only Category 5 (STP CAT5) shielded twisted-pair Ethernet cables.
19
20
21
22
23
+
+
+
+
Digital Input #1
Digital Input #2
Digital Input #3
Digital Input #4
24
25
26
27
Connect shield
to ground at one
end only.
Figure 2-23 Digital Inputs
42 UDC3500 Universal Digital Controller Product Manual March 2012
Installation
A
A
_
A
Relay #3
Load
Supply
Power
Load
Supply
Power
Load
Supply
Power
1
Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc. Size fuses
accordingly. Use only Fast-Blo fuze types.
Relay #3 Load
To terminal
10 (N.C.) or 12 (N.O.)
1
Relay #4 Load
To terminal
13 (N.C.) or 15 (N.O.)
1
Relay #5 Load
To terminal
16 (N.C.) or 18 (N.O.)
1
10
11
13
14
15
16
17
18
12
N.C.
N.O.
Relay #4
N.C.
N.O.
Relay #5
N.C.
N.O.
28
29
30
31
32
33
34
35
36
Figure 2-24 Optional Electromechanical Relay Outputs
See Table 2-6 and Table 2-7 for other information about output types.
2 Wire Transmitter
1
+
8 +
250
9 -
larm 4
If necessary, install a zener diode here to reduce voltage at the
1
transmitter. A 1N4733 will reduce the voltage at the transmitter to
approximately 25 Vdc.
Configure:
A4S1TY = DEV
Configure:
A4S1VAL = 9999
4S1TY = NONE
A4S1HL = HIGH
4S2TY = NONE
A4S2TY = NONE
OUTALG = CURRENT
35 +
36 -
Input 1
Figure 2-25 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open
Collector Output
March 2012 UDC3500 Universal Digital Controller Product Manual 43
Installation
_
2 Wire Transmitter
Configure:
1
CUROUT2 = OUT
Current Output #2 Calibration
+
24 +
250
25 -
Second Current Output
If necessary, install a zener diode here to reduce voltage at the
1
transmitter. A 1N4733 will reduce the voltage at the transmitter to
approximately 25 Vdc.
ZEROVAL = 16383
SPANVAL = 16383
35 +
36 -
Input #1
Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Second
Current Output
44 UDC3500 Universal Digital Controller Product Manual March 2012
3.1 Overview
Introduction
Configuration is a dedicated operation where you use straightforward keystroke
sequences to select and establish (configure) pertinent control data best suited for your
application.
To assist you in the configuration process, there are prompts that appear in the upper and
lower displays. These prompts let you know what group of configuration data (Set Up
prompts) you are working with and also, the specific parameters (Function prompts)
associated with each group.
Table 3-1 shows an overview of the prompt hierarchy as it appears in the controller.
What’s in this section?
Configuration
3 Configuration
The following topics are covered in this section.
Table 3-1 Configuration Topics
TOPIC See Page
3.1 Overview 45
3.2 Configuration Prompt Hierarchy 47
3.3 Configuration Procedure 51
3.4 Loop 1 Tuning Set Up Group 52
3.5 Loop 2 Tuning Set Up Group 56
3.6 SP Ramp Set Up Group 59
3.7 SP Program 2 Set Up Group 65
3.8 SP Program 3 Set Up Group 68
3.9 SP Program 4 Set Up Group 71
3.10 Accutune Set Up Group 74
3.11 Algorithm Set Up Group 79
3.12 Math Set Up Group 94
3.13 Logic Gates Set Up Group 100
3.14 Output Set Up Group 107
3.15 Input 1 Set Up Group 118
3.16 Input 2 Set Up Group 122
3.17 Input 3 Set Up Group 125
3.18 Input 4 Set Up Group 128
March 2012 UDC3500 Universal Digital Controller Product Manual 45
Configuration
3.19 Input 5 Set Up Group 131
3.20 Control Set Up Group 134
3.21 Control 2 Set Up Group 143
3.22 Options Set Up Group 150
3.23 Communications Set Up Group 162
3.24 Alarms Set Up Group 166
3.25 Real Time Clock Set Up Group 174
3.26 Maintenance Set Up Group 175
3.27 Display Set Up Group 178
3.28 Read Maintenance Set Up Group 180
3.29 Time Events Set Up Group 181
3.30 P.I.E. Tool Ethernet and Email Configuration Screens 183
3.31 Configuration Record Sheet 186
TOPIC See Page
46 UDC3500 Universal Digital Controller Product Manual March 2012
3.2 Configuration Prompt Hierarchy
Table 3-2 Configuration Prompt Hierarchy
Set Up Group Function Prompts
Configuration
TUNING
TUNING 2
SPRAMP
PROP BD
or
GAIN
RATE3MIN RSET3MIN
LOCKOUT AUTO MAN RUN HOLD SP SEL
PROP BD5
or
GAIN5
RATE7MIN RSET7MIN
SP RAMP TIME MIN FINAL SP HOTSTART SP RATE EU/HR UP EU/HR DN SP PROG
STRT SEG END SEG RAMPUNIT RECYCLES PROG END STATE POWER UP KEYRESET
HOTSTART
RATE MIN RSET MIN
or
RSET3RPM
RATE5MIN RSET5MIN
or
RSET7RPM
SEGxRAMP
or
SEGxRATE*
or
RSET RPM
PROPBD4
or
GAIN 4
or
RSET5RPM
PROPBD8
or
GAIN 8
SEG x PID* SEGx SP* SEGxTIME* SOAKxDEV
MAN RSET PROPBD2
or
GAIN 2
RATE4MIN RSET4MIN
or
RSET4RPM
MAN RSET PROPBD6
or
GAIN 6
RATE8MIN RSET8MIN
or
RSET8RPM
RATE2MIN RSET2MIN
CYC SEC
or
CYC SX3
RATE6MIN RSET6MIN
CYC5 SEC
or
CYC5 SX3
or
RSET2RPM
CYC2 SEC
or
CYC2 SX3
or
RSET6RPM
CYC6 SEC
or
CYC6 SX3
* x = 1 to 20. Program
concludes after
Segment 20
PROPBD3
or
GAIN 3
SECURITY
PROPBD7
or
GAIN 7
SP PROG2
SP PROG3
SP PROG4
PROGRAM2
SEGx SP* SEGxTIME* SOAKxDEV
PROGRAM3
SEGx SP* SEGxTIME* SOAKxDEV
PROGRAM4
SEGx SP* SEGxTIME* SOAKxDEV
STRT SEG END SEG RAMPUNIT RECYCLES HOTSTART
STRT SEG END SEG RAMPUNIT RECYCLES HOTSTART
STRT SEG END SEG RAMPUNIT RECYCLES HOTSTART
SEGxRAMP
SEGxRATE*
* x = 1 to 20. Program
concludes after
Segment 20
SEGxRAMP
SEGxRATE*
* x = 1 to 20. Program
concludes after
Segment 20
SEGxRAMP
SEGxRATE*
* x = 1 to 20. Program
concludes after
Segment 20
or
SEG x PID*
SEG x PID*
or
SEG x PID*
or
March 2012 UDC3500 Universal Digital Controller Product Manual 47
Configuration
Set Up Group Function Prompts
ACCUTUNE
ALGORTHM
MATH
LOGIC
FUZZY
SP CHANG2
CONT ALG PIDLOOPS CONT2ALG OUT OVRD TIMER PERIOD START LWR DISP
RESET INCRMENT INALG 1 MATH K CALC HI CALC LO ALG1 INA ALG1 INB
ALG1 INC PCO SEL PCT CO PCT H2 ATM PRES ALG1 BIAS INALG 2 MATH K2
CALC HI CALC LO ALG2 INA ALG2 INB ALG2 INC ALG2 BIAS
8 SEG CH1 Xn VALUE Yn VALUE 8 SEG CH2 Xn VALUE Yn VALUE
TOT SCAL TOT SCR Σ RESET? TOT RATE POLYNOM C0 VALUE C1 VALUE
C2 X 10 -3 C2 X 10 -4 C2 X 10 -5
LOG GATE GATE1TYP GATE1INA GATE1 K GATE1INB GATE1OUT GATE2TYP GATE2 K
GATE2INB GATE2OUT GATE3TYP GATE3INA GATE3 K GATE3INB GATE3OUT GATE4TYP
GATE4INA GATE4 K GATE4INB GATE4OUT GATE5TYP GATE5INA GATE5 K GATE5INB
ACCUTUNE
KPG2 CRITERIA2 AT ERROR AT ERR 2
DUPLEX
SP CHANGE
KPG CRITERIA
ACCUTUN2
TOTALIZE
DUPLEX
ΣXXXXXXX
C2 X 10 -1
OUTPUT
INPUT1
INPUT2
INPUT3
INPUT4
INPUT5
GATE5OUT
OUT ALG OUT RNG C1 RANGE RLYSTATE RLY TYPE MOTOR TI OUT2 ALG OUT2 RNG
C3 RANGE RLYSTAT2 CUR OUT1 LOW VAL HIGH VAL
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
IN3 TYPE XMITTER3 IN3 HIGH IN3 LOW RATIO 3 BIAS IN3 FILTER 3 BURNOUT3
EMISSIV3
IN4 TYPE XMITTER4 IN4 HIGH IN4 LOW RATIO 4 BIAS IN4 FILTER 4 BURNOUT4
IN5 TYPE XMITTER5 IN5 HIGH IN5 LOW RATIO 5 BIAS IN5 FILTER 5 BURNOUT5
48 UDC3500 Universal Digital Controller Product Manual March 2012
Set Up Group Function Prompts
Configuration
CONTROL
CONTROL2
OPTIONS
COM
PV SOURC PID SETS SW VAL12 SW VAL23 SW VAL34 LSP’S RSP SRC AUTOBIAS
SP TRACK
PCT/M DN OUTHiLIM OUTLoLIM I Hi LIM I Lo LIM DROPOFF
FAILMODE
PV 2SRC LINK LPS PID SETS SW VAL 12 SW VAL23 SW VAL34 LSP’S RSP SRC
AUTOBIAS SP TRACK PWRMODE SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP
PCT/M DN OUTHiLIM OUTLoLIM I Hi LIM I Lo LIM DROPOFF
FAILSAFE
CUR OUT2 C2RANGE HIGH VAL LOW VAL CUR OUT3 C3RANGE LOW VAL HIGH VAL
DIG1 INP
Com ADDR ComSTATE IR ENABLE BAUD TX DELAY WSFLOAT SHEDENAB SHEDTIME
SHEDMODE
PWR MODE
FAILSAFE SW FAIL MAN OUT AUTO OUT PBorGAIN MINorRPM
DIG1 COMB
SHEDSP UNITS CSP RATO CSP BIAS CSP2RATO CSP2BIAS
PWR OUT SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP
DEADBAND
DEADBAND
DIG INP2
DIG2 COMB
DIG INP3 DIG INP4 Dion LP2
OUT HYST
FAILMODE
LOOPBACK
ALARMS
CLOCK
MAINTNCE
DISPLAY
READ
MAINTNCE
TIME
EVENT
A1S1TYPE A1S1 VAL A1S1 H L A1S1 EV A1S2 TYPE A1S2 VAL A1S2 H L A1S2 EV
A2S1TYPE A2S1 VAL ALHYST1 A2S1 H L A2S1 EV A2S2TYPE A2S2 VAL A2S2 H L
A2S2 EV ALHYST2 A3S1TYPE A3S1 VAL A3S1 H L A3S1 EV A3S2TYPE A3S2 VAL
A3S2 H L A3S2 EV ALHYST3 A4S1TYPE A4S1 VAL A4S1 H L A4S1 EV A4S2TYPE
A4S2 VAL A4S2 H L A4S2 EV ALHYST4 ALM OUT1 BLOCK DIAGNOST ALRM MSG
HOURS MINUTES SECONDS YEAR MONTH DAY SET CLK? ADJUST
TIME 1 TIME 2 TIME 3 COUNT 1 COUNT 2 COUNT 3
DECIMAL DECIMAL2 TEMPUNIT PWR FREQ RATIO 2
DAYS 1 HRS:MIN1 DAYS 2 HRS:MIN2 DAYS 3
COUNTS 3
EVENT 1 TIME 1 HOUR 1 MINUTE 1 MONTH 1
HOUR 2 MINUTE2 MONTH 2 DAY 2
LANGUAGE TC DIAGN IDNUMBER
HRS:MIN3 COUNTS 1 COUNTS 2
DAY 1 EVENT 2
PASSWORD
RES TYPE
TIME 2
March 2012 UDC3500 Universal Digital Controller Product Manual 49
Configuration
Set Up Group Function Prompts
CALIB
STATUS
USED FOR FIELD CALIBRATION
VERSION FAILSAFE TESTS
50 UDC3500 Universal Digital Controller Product Manual March 2012
3.3 Configuration Procedure
Introduction
Each of the Set Up groups and their functions are pre-configured at the factory.
The factory settings are shown in Table 3-4 through Table 3-24. If you want to change
any of these selections or values, follow the procedure in Table 3-3. This procedure tells
you the keys to press to get to any Set Up group and any associated Function prompt.
Procedure
ATTENTION
The prompting scrolls at a rate of one group every 2/3 seconds when the SET UP or FUNC/LOOP 1/2 key
is held in. Also, or keys will move group prompts forward or backward twice as fast.
Table 3-3 Configuration Procedure
Step Operation Press Result
1
2
3
4
5
6
Enter Set Up Mode
Select any
Select a F
Change the Value
or Selection
Enter the Value or
Exit Configuration
Set Up
Group
unction
Parameter
Selection
Set Up Upper Display = SETUP
Lower Display = TUNING (This is the first Set Up Group title)
display
Set Up
Func
or
Func
Lower
Display
Sequentially
prompt hierarchy in Table 3-2 Configuration Prompt Hierarchy.
You can also use the
in both 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 Man/Auto key once. This will recall the original
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.
s the other Set Up group titles shown in the
prompt of the selected Set Up group.
or keys to scan the Set Up groups
Configuration
March 2012 UDC3500 Universal Digital Controller Product Manual 51
Configuration
3.4 Loop 1 Tuning Set Up Group
Introduction
Tuning consists of establishing the appropriate values for the tuning constants you are
using so that your controller responds correctly to changes in process variable and
setpoint. You can start with predetermined values but you will have to watch the system
to see how to modify them. The Accutune feature automatically selects Gain, Rate, and
Reset on demand.
There can be as many as four PID sets available for Loop 1.
ATTENTION
Because this group contains functions that have to do with security and lockout, we recommend
that you configure this group last, after all other configuration data has been loaded.
Function Prompts
Table 3-4 TUNING Group Function Prompts
Function Prompt
Lower Display
PROP BD
or
GAIN
Selections or
Range of Setting
Upper Display
0.1 to 9999 %
or
0.001 to 1000
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.
100%
G =
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.
PB%
RATE MIN
52 UDC3500 Universal Digital Controller Product Manual March 2012
0.00 to 10.00 minutes
RATE action, in minutes, affects the controller’s
output whenever the deviation is changing; and
affects it more when the deviation is changing faster.
Also defined as “HEAT” Rate on Duplex models for
variations of Heat/Cool applications.
Configuration
Function Prompt
Lower Display
RSET MIN
or
RSET RPM
MAN RSET
Selections or
Range of Setting
Upper Display
0.02 to 50.00
–100 to +100
(in % output)
Parameter
Definition
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.
PROPBD2
or
GAIN 2
RATE2MIN
RSET2MIN
RSET2RPM
PROPBD3
or
GAIN 3
RATE3MIN
ATTENTION Bias is shown on the lower display.
0.1 to 9999 %
or
0.001 to 1000
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.
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.
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.
0.1 to 9999 %
or
0.001 to 1000
0.00 to 10.00 minutes
PROPORTIONAL BAND 3 or GAIN 3 parameters
are the same as previously described. This prompt
appears only when four PID sets are enabled.
RATE 3 MINUTES parameter is the same as
previously described. This prompt appears only
when four PID sets are enabled.
March 2012 UDC3500 Universal Digital Controller Product Manual 53
Configuration
Function Prompt
Lower Display
RSET3MIN
RSET3RPM
PROPBD4
or
GAIN 4
RATE4MIN
RSET4MIN
RSET4RPM
CYC SEC
or
CYC SX3
Selections or
Range of Setting
Upper Display
0.02 to 50.00
0.1 to 9999 %
or
0.001 to 1000
0.00 to 10.00 minutes
0.02 to 50.00
1 to 120
Parameter
Definition
RESET 3 MINUTES or RSET 3 REPEATS PER
MINUTE parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
PROPORTIONAL BAND 4 or GAIN 4, RATE 4, and
RESET 4 parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
RATE 4 MINUTES parameter is the same as
previously described. This prompt appears only
when four PID sets are enabled.
RESET 4 MINUTES or RSET 3 REPEATS PER
MINUTE parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
CYCLE TIME (HEAT) determines the length of one
time proportional output relay cycle. Defined as
“HEAT” cycle time for Heat/Cool applications.
CYC2 SEC
or
CYC2 SX3
SECURITY
1 to 120
0 to 9999
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.
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 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.
54 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
LOCKOUT
AUTO MAN
Selections or
Range of Setting
Upper Display
NONE
CALIB
+ CONF
+ VIEW
MAX
Parameter
Definition
LOCKOUT applies to one of the functional groups:
Configuration, Calibration, Tuning, or Accutune.
DO NOT CONFIGURE UNTIL ALL OTHER
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.
MANUAL/AUTO KEY LOCKOUT—Allows you to
disable the Manual/Auto key
RUN HOLD
SP SEL
DISABLE
ENABLE
DISABLE
ENABLE
DISABLE
ENABLE
DISABLE
ENABLE
ATTENTION Can only be viewed if LOCKOUT is
configured for NONE.
RUN/HOLD KEY LOCKOUT—Allows you to disable
Run/Hold key, for either SP Ramp or SP
the
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.
March 2012 UDC3500 Universal Digital Controller Product Manual 55
Configuration
3.5 Loop 2 Tuning Set Up Group
Introduction
Tuning consists of establishing the appropriate values for the tuning constants you are
using so that your controller responds correctly to changes in process variable and
setpoint. You can start with predetermined values but you will have to watch the system
to see how to modify them. The Accutune feature automatically selects Gain, Rate, and
Reset on demand.
There can be as many as four PID sets available for Loop 2.
Function Prompts
Table 3-5 TUNING 2 Group Function Prompts
Function Prompt
Lower Display
PROP BD5
or
GAIN 5
Selections or
Range of Setting
Upper Display
0.1 to 9999 %
or
0.001 to 1000
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.
100%
G =
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.
PB%
RATE5MIN
56 UDC3500 Universal Digital Controller Product Manual March 2012
0.00 to 10.00 minutes
RATE action, in minutes, affects the controller’s
output whenever the deviation is changing; and
affects it more when the deviation is changing faster.
Also defined as “HEAT” Rate on Duplex models for
variations of Heat/Cool applications.
Configuration
Function Prompt
Lower Display
RSET5MIN
or
RSET5RPM
MAN5RSET
Selections or
Range of Setting
Upper Display
0.02 to 50.00
–100 to +100
(in % output)
Parameter
Definition
RSET5MIN = Reset in Minutes per Repeat
RSET5RPM = 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
CONTROL2 parameters group under the prompt
MINorRPM.
MANUAL5RESET is only applicable if you use
control algorithm PD WITH MANUAL RESET for
Loop 2 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.
PROPBD6
or
GAIN 6
RATE6MIN
RSET6MIN
RSET6RPM
PROPBD7
or
GAIN 7
RATE7MIN
ATTENTION Bias is shown on the lower display.
0.1 to 9999 %
or
0.001 to 1000
PROPORTIONAL BAND 6 or GAIN 6, RATE 6 and
RESET 6 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.
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.
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.
0.1 to 9999 %
or
0.001 to 1000
0.00 to 10.00 minutes
PROPORTIONAL BAND 7 or GAIN 7 parameters
are the same as previously described. This prompt
appears only when four PID sets are enabled.
RATE 7 MINUTES parameter is the same as
previously described. This prompt appears only
when four PID sets are enabled.
March 2012 UDC3500 Universal Digital Controller Product Manual 57
Configuration
Function Prompt
Lower Display
RSET7MIN
RSET7RPM
PROPBD8
or
GAIN 4
RATE8MIN
RSET8MIN
RSET8RPM
CYC5 SEC
or
CYC5 SX3
Selections or
Range of Setting
Upper Display
0.02 to 50.00
0.1 to 9999 %
or
0.001 to 1000
0.00 to 10.00 minutes
0.02 to 50.00
1 to 120
Parameter
Definition
RESET 7 MINUTES or RSET 7 REPEATS PER
MINUTE parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
PROPORTIONAL BAND 8 or GAIN 8, RATE 8, and
RESET 8 parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
RATE 8 MINUTES parameter is the same as
previously described. This prompt appears only
when four PID sets are enabled.
RESET 8 MINUTES or RSET 8 REPEATS PER
MINUTE parameters are the same as previously
described. This prompt appears only when four PID
sets are enabled.
CYCLE TIME (HEAT) determines the length of one
time proportional output relay cycle. Defined as
“HEAT” cycle time for Heat/Cool applications.
CYC6 SEC
or
CYC6 SX3
1 to 120
CYC5 SEC—Electromechanical relays
CYC5 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.
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.
CYC6 SEC—Electromechanical relays
CYC6 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.
58 UDC3500 Universal Digital Controller Product Manual March 2012
3.6 SP Ramp Set Up Group
Introduction
Set Point Ramp, Set Point Programs and Set Point Rates can be configured in this group.
A single Setpoint Ramp [SP RAMP] can be configured to occur between the current local
setpoint and a final local setpoint over a time interval of from 1 to 255 minutes.
A Set Point Rate [SPRATE] lets you configure a specific rate of change for any local
setpoint change.
A single Set Point Program [SP PROG] with up to 20 segments can be configured.
For more information on Set Point Rate, Ramp and Programming, see Sections 4.27
through 4.30.
Configuration
You can start and stop the ramp
PV Hot Start is a configurable feature and means that, at initialization, the setpoint is set
to the current PV value and the Ramp or Rate or Program then starts from this value.
Added Features not found in other UDC products:
Up to Four SP Programs rather than one
20 segments instead of 12 in each program
SP Programs 1 and 2 can be linked to give a SP Program of up to 40 segments
SP Programs 3 and 4 can be linked to give a SP Program of up to 40 segments
Guaranteed Soak Settings for each Soak Segment
PID Set selection for each Segment
Function Prompts
ATTENTION
Please note that the configurations used in SP Program #1 for Program End,
Program State, Power Up and Key Reset affect all other SP Programs. For this
reason, Program #1 must always be enabled in order to enable Programs #2, 3
and/or 4.
/program using the
RUN/HOLD key.
March 2012 UDC3500 Universal Digital Controller Product Manual 59
Configuration
Table 3-6 SPRAMP Group Function Prompts
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.
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).
HOTSTART
DISABLE
ENABLE
DISABLE—LSP1 is used as the initial ramp setpoint.
ENABLE—Current PV value is used as the initial
ramp setpoint.
SP RATE
SP Rate operates on
any LSP when both
SP Ramp and SP
DISABLE
SETPOINT RATE—Lets you configure a specific rate
of change for any local setpoint change.
DISABLE SETPOINT RATE—Disables the setpoint
rate option.
Programming are not
active.
ENABLE
ENABLE SETPOINT RATE—Allows the SP rate
feature.
60 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
EU/HR UP
EU/HR DN
SP PROG
(optional feature)
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.
Selections or
Range of Setting
Upper Display
0 to 9999 in engineering
units per hour
0 to 9999 in engineering
units per hour
DISABLE
ENABLE
ENABLE2
ENABL12
Parameter
Definition
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).
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).
SETPOINT RAMP/SOAK PROGRAM #1—Available
only with controllers that contain this option.
SP RAMP must be disabled.
DISABLE—Disables all Setpoint Programs.
ENABLE—Setpoint Program runs on Loop 1.
ENABLE2—Setpoint Program runs on Loop 2.
ENABL12—Setpoint Program runs on both Loop1
and Loop 2.
ATTENTION SP Program #1 must be enabled in
order to use SP Programs 2, 3 and 4.
STRT SEG
END SEG
1 to 20
2 to 20 even numbers
Always end in a soak
segment
(2, 4, ... 20)
START SEGMENT NUMBER
END SEGMENT NUMBER
ATTENTION When SP Programs 1 and 2 are
linked, this parameter does not appear. The value is
automatically set to 20 and the End Segment Number
is controlled by the selection for End Segment in SP
Program #2.
RAMPUNIT
TIME
EU/MIN
EU/HR
RECYCLES
March 2012 UDC3500 Universal Digital Controller Product Manual 61
0 to 100 recycles Number of Program Recycles
RAMPUNIT—Engineering Units for Ramp Segments
TIME in hours: minutes
RATE in Engineering units per minute
RATE in Engineering units per hour
Configuration
Function Prompt
Lower Display
PROG END
STATE
POWER UP
Selections or
Range of Setting
Upper Display
LASTSP
F SAFE
DISABLE
HOLD
ABORT
RESUME
RESTART
Parameter
Definition
PROGRAM TERMINATION STATE
LAST SETPOINT—Hold at last setpoint in the
program
FAIL SAFE—Manual mode/Failsafe output
ATTENTION Selection affects all enabled SP
Programs.
PROGRAM STATE AT PROGRAM END
ATTENTION Selection affects all enabled SP
Programs.
POWER UP—This configuration determines what the
Program will do in the case of a power outage during
the Program. This prompt only appears on those
instruments that have the Real Time Clock option.
ATTENTION Selection affects all enabled SP
Programs.
ABORT—Program terminated on power up
RESUME—Continue at the same point in program
RESTART—Restart program at beginning of the
same cycle
KEYRESET
DISABLE
ToBEGIN
KEY RESET—Reset/Rerun SP Program
DISABLE
RESET TO BEGINNING OF SETPOINT
PROGRAM—When enabled, this selection allows you
to reset via the keyboard to the beginning of the
program and resets the Recycle value to 0. The
program mode is placed in HOLD.
If the current Local Setpoint 1 value is at any value
other than that Setpoint value used in the first Soak
segment in the program, then the program will restart
at the current Local Setpoint 1 value and at the
beginning of the first Ramp segment in the program.
If the current Local Setpoint 1 value is at the same
Setpoint value as that used for the first Soak segment
in the program, then the first Ramp segment is
skipped and the program will restart at the beginning
of the first Soak segment in the program.
ATTENTION Selection affects all enabled SP
Programs.
62 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
HOTSTART
SEG1RAMP or
SEG1RATE
SEG1PID
Selections or
Range of Setting
Upper Display
RERUN
DISABLE
ENABLE
0-99 hours.0-59 minutes
Engineering units/minute
or
Engineering units/hour
1-4
Parameter
Definition
RERUN CURRENT CYCLE—When enabled, this
selection allows you to reset the program via the
keyboard to the beginning of the current cycle. The
Recycle value is not affected. The program mode
(RUN or HOLD) is not affected.
HOT START—This feature allows the SP Program to
start at the current PV value rather than the current
Setpoint value.
Segment #1 Ramp Time or
Segment #1 Ramp Rate
ATTENTION This parameter is affected by the
RAMPUNIT configuration (see above). All ramps will
use the same selection.
PID Set Selection
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD. See
Section 3.20 (Control 1) and Section 3.21 (Control 2).
SEG2 SP
SEG2TIME
SOAK2DEV
SEG2 PID
SEG3RAMP or
SEG3RATE
SEG3 PID
SEG4 SP
SEG4TIME
SOAK4DEV
SEG4 PID
SEG5RAMP or
SEG5RATE
SEG5 PID
SEG6 SP
SEG6TIME
Within the Setpoint limits
0-99 hours.0-59 minutes
0.000 to 99.99
1-4
Selections are same as
above.
Segment #2 Soak Setpoint Value
Segment #2 Soak Duration
Guaranteed Soak Deviation Value For Soak
Segment #2—The number selected will be the PV
value (in engineering units) above and below the
setpoint outside of which the Soak Segment timer
halts. A value of 0.000 is equivalent to no Guaranteed
Soak.
PID Set Selection—This selection is Loop
dependent.
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD. See
Section 3.20 (Control 1) and Section 3.21 (Control 2).
Same as above
March 2012 UDC3500 Universal Digital Controller Product Manual 63
Configuration
Function Prompt
Lower Display
SOAK6DEV
SEG6 PID
SEG7RAMP or
SEG7RATE
SEG7 PID
SEG8 SP
SEG8TIME
SOAK8DEV
SEG8 PID
SEG9RAMP or
SEG9RATE
SEG9 PID
SG10 SP
SG10TIME
SOAK10DEV
SG10 PID
SG11RAMP or
SG11RATE
SG11 PID
SG12 SP
SG12TIME
SOAK12DEV
SG12 PID
SG13RAMP or
SG13RATE
SG13 PID
SG14 SP
SG14TIME
SOAK14DEV
SG14 PID
SG15RAMP or
SG15RATE
SG15 PID
SG16 SP
SG16TIME
SOAK16DEV
SG16 PID
SG17RAMP or
SG17RATE
SG17 PID
SG18 SP
SG18TIME
SOAK18DEV
SG18 PID
SG19RAMP or
SG19RATE
SG19 PID
SG20 SP
SG20TIME
SOAK20DEV
SG20 PID
Selections or
Range of Setting
Upper Display
Parameter
Definition
64 UDC3500 Universal Digital Controller Product Manual March 2012
3.7 SP Program 2 Set Up Group
Introduction
An optional second SetPoint Program. SP Programs #1 and #2 can be linked together to
form a single, longer SP Program.
ATTENTION
Please note that the configurations used in SP Program #1 for Program End,
Program State, Power Up and Key Reset affect all other SP Programs. For this
reason, Program #1 must always be enabled in order to enable Programs #2, 3
and/or 4.
Function Prompts
Table 3-7 SP PROG2 Group Function Prompts
Configuration
Function Prompt
Lower Display
SP PROG2
(optional feature)
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.
STRT SEG
END SEG
RAMPUNIT
Selections or
Range of Setting
Upper Display
DISABLE
ENABLE
ENABLE2
ENABL12
LINK
1 to 20
2 to 20 even numbers
Always end in a soak
segment
(2, 4, ... 20)
TIME
EU/MIN
EU/HR
Parameter
Definition
SETPOINT RAMP/SOAK PROGRAM #2—Available
only with controllers that contain this option.
SP RAMP must be disabled.
DISABLE—Disables setpoint programming.
ENABLE—Enables setpoint programming–Loop 1.
ENABLE2—Enables setpoint programming–Loop 2.
ENABL12—Enables setpoint programming–Both
Loop1 and Loop 2.
LINK—Programs 1 and 2 are linked
START SEGMENT NUMBER
ATTENTION When SP Programs 1 and 2 are
linked, this prompt does not appear and this value is
automatically set to 1
END SEGMENT NUMBER
ATTENTION When linking Setpoint Programs 1
and 2, this End Segment Number determines the
end of the entire linked program.
RAMPUNIT—Engineering Units for Ramp Segments
TIME in hours: minutes
RATE in Engineering units per minute
RATE in Engineering units per hour
ATTENTION Normally the same as Program #1
when linking programs.
RECYCLES
March 2012 UDC3500 Universal Digital Controller Product Manual 65
0 to 100 recycles
Number of Program Recycles
Configuration
Function Prompt
Lower Display
HOTSTART
SEG1RAMP or
SEG1RATE
SEG1PID
SEG2 SP
SEG2TIME
SOAK2DEV
Selections or
Range of Setting
Upper Display
DISABLE
ENABLE
0-99 hours.0-59 minutes
Engineering units/minute
or
Engineering units/hour
1-4
Within the Setpoint limits
0-99 hours.0-59 minutes
0.000 to 99.99
Parameter
Definition
HOT START—This feature allows the SP Program
to start at the current PV value rather than the
current Setpoint value.
ATTENTION Not used when linking programs
Segment #1 Ramp Time or
Segment #1 Ramp Rate
ATTENTION This parameter is affected by the
RAMPUNIT configuration (see above). All ramps will
use the same selection.
PID Set Selection
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Segment #2 Soak Setpoint Value
Segment #2 Soak Duration
Guaranteed Soak Deviation Value For Soak
Segment #2—The number selected will be the PV
value (in engineering units) above and below the
setpoint outside of which the Soak Segment timer
halts. A value of 0.000 is equivalent to no
Guaranteed Soak.
SEG2 PID
SEG3RAMP or
SEG3RATE
SEG3 PID
SEG4 SP
SEG4TIME
SOAK4DEV
SEG4 PID
SEG5RAMP or
SEG5RATE
SEG5 PID
SEG6 SP
SEG6TIME
SOAK6DEV
SEG6 PID
SEG7RAMP or
SEG7RATE
1-4
Selections are same as
above.
PID Set Selection—This selection is Loop
dependent.
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Same as above
66 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
SEG7 PID
SEG8 SP
SEG8TIME
SOAK8DEV
SEG8 PID
SEG9RAMP or
SEG9RATE
SEG9 PID
SG10 SP
SG10TIME
SOAK10DEV
SG10 PID
SG11RAMP or
SG11RATE
SG11 PID
SG12 SP
SG12TIME
SOAK12DEV
SG12 PID
SG13RAMP or
SG13RATE
SG13 PID
SG14 SP
SG14TIME
SOAK14DEV
SG14 PID
SG15RAMP or
SG15RATE
SG15 PID
SG16 SP
SG16TIME
SOAK16DEV
SG16 PID
SG17RAMP or
SG17RATE
SG17 PID
SG18 SP
SG18TIME
SOAK18DEV
SG18 PID
SG19RAMP or
SG19RATE
SG19 PID
SG20 SP
SG20TIME
SOAK20DEV
SG20 PID
Selections or
Range of Setting
Upper Display
Parameter
Definition
March 2012 UDC3500 Universal Digital Controller Product Manual 67
Configuration
3.8 SP Program 3 Set Up Group
Introduction
An optional third SetPoint Program. SP Programs #3 and #4 can be linked together to
form a single, longer SP Program.
ATTENTION
Please note that the configurations used in SP Program #1 for Program End,
Program State, Power Up and Key Reset affect all other SP Programs. For this
reason, Program #1 must always be enabled in order to enable Programs #2, 3
and/or 4.
Function Prompts
Table 3-8 SP PROG3 Group Function Prompts
Function Prompt
Lower Display
SP PROG3
(optional feature)
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.
STRT SEG
END SEG
RAMPUNIT
Selections or
Range of Setting
Upper Display
DISABLE
ENABLE
ENABLE2
ENABL12
1 to 20
2 to 20 even numbers
Always end in a soak
segment
(2, 4, ... 20)
TIME
EU/MIN
EU/HR
Parameter
Definition
SETPOINT RAMP/SOAK PROGRAM #3—Available
only with controllers that contain this option.
SP RAMP must be disabled.
DISABLE—Disables setpoint programming.
ENABLE—Enables setpoint programming–Loop 1.
ENABLE2—Enables setpoint programming–Loop 2.
ENABL12—Enables setpoint programming–Both
Loop1 and Loop 2.
START SEGMENT NUMBER
END SEGMENT NUMBER
ATTENTION When SP Programs 3 and 4 are
linked, this parameter does not appear. The value is
automatically set to 20 and the End Segment
Number is controlled by the selection for End
Segment in SP Program #4.
RAMPUNIT—Engineering Units for Ramp Segments
TIME in hours: minutes
RATE in Engineering units per minute
RATE in Engineering units per hour
RECYCLES
HOTSTART
68 UDC3500 Universal Digital Controller Product Manual March 2012
0 to 100 recycles
DISABLE
ENABLE
Number of Program Recycles
ATTENTION Not used when linking programs
HOT START—This feature allows the SP Program
to start at the current PV value rather than the
current Setpoint value.
Configuration
Function Prompt
Lower Display
SEG1RAMP or
SEG1RATE
SEG1PID
SEG2 SP
SEG2TIME
SOAK2DEV
Selections or
Range of Setting
Upper Display
0-99 hours.0-59 minutes
Engineering units/minute
or
Engineering units/hour
1-4
Within the Setpoint limits
0-99 hours.0-59 minutes
0.000 to 99.99
Parameter
Definition
Segment #1 Ramp Time or
Segment #1 Ramp Rate
ATTENTION This parameter is affected by the
RAMPUNIT configuration (see above). All ramps will
use the same selection.
PID Set Selection
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Segment #2 Soak Setpoint Value
Segment #2 Soak Duration
Guaranteed Soak Deviation Value For Soak
Segment #2—The number selected will be the PV
value (in engineering units) above and below the
setpoint outside of which the Soak Segment timer
halts. A value of 0.000 is equivalent to no
Guaranteed Soak.
SEG2 PID
SEG3RAMP or
SEG3RATE
SEG3 PID
SEG4 SP
SEG4TIME
SOAK4DEV
SEG4 PID
SEG5RAMP or
SEG5RATE
SEG5 PID
SEG6 SP
SEG6TIME
SOAK6DEV
SEG6 PID
SEG7RAMP or
SEG7RATE
SEG7 PID
SEG8 SP
SEG8TIME
SOAK8DEV
SEG8 PID
1-4
Selections are same as
above.
PID Set Selection—This selection is Loop
dependent.
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Same as above
ATTENTION When linking programs, all 20
segments in Program 3 MUST be used.
March 2012 UDC3500 Universal Digital Controller Product Manual 69
Configuration
Function Prompt
Lower Display
SEG9RAMP or
SEG9RATE
SEG9 PID
SG10 SP
SG10TIME
SOAK10DEV
SG10 PID
SG11RAMP or
SG11RATE
SG11 PID
SG12 SP
SG12TIME
SOAK12DEV
SG12 PID
SG13RAMP or
SG13RATE
SG13 PID
SG14 SP
SG14TIME
SOAK14DEV
SG14 PID
SG15RAMP or
SG15RATE
SG15 PID
SG16 SP
SG16TIME
SOAK16DEV
SG16 PID
SG17RAMP or
SG17RATE
SG17 PID
SG18 SP
SG18TIME
SOAK18DEV
SG18 PID
SG19RAMP or
SG19RATE
SG19 PID
SG20 SP
SG20TIME
SOAK20DEV
SG20 PID
Selections or
Range of Setting
Upper Display
Parameter
Definition
70 UDC3500 Universal Digital Controller Product Manual March 2012
3.9 SP Program 4 Set Up Group
Introduction
An optional fourth SetPoint Program. SP Programs #3 and #4 can be linked together to
form a single, longer SP Program.
ATTENTION
Please note that the configurations used in SP Program #1 for Program End, Program
State, Power Up and Key Reset affect all other SP Programs. For this reason, Program
#1 must always be enabled in order to enable Programs #2, 3 and/or 4.
Enabling SP Program 4 automatically disables the characterizers in the Math Setup
Group.
Function Prompts
Table 3-9 SP PROG4 Group Function Prompts
Configuration
Function Prompt
Lower Display
SP PROG4
(optional feature)
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.
STRT SEG
END SEG
RAMPUNIT
Selections or
Range of Setting
Upper Display
DISABLE
ENABLE
ENABLE2
ENABL12
LINK
1 to 20
2 to 20 even numbers
Always end in a soak
segment
(2, 4, ... 20)
TIME
EU/MIN
EU/HR
Parameter
Definition
SETPOINT RAMP/SOAK PROGRAM #2—Available
only with controllers that contain this option.
SP RAMP must be disabled.
DISABLE—Disables setpoint programming.
ENABLE—Enables setpoint programming–Loop 1.
ENABLE2—Enables setpoint programming–Loop 2.
ENABL12—Enables setpoint programming–Both
Loop1 and Loop 2.
LINK—Programs 3 and 4 are linked
START SEGMENT NUMBER
ATTENTION When SP Programs 3 and 4 are
linked, this prompt does not appear and this value is
automatically set to 1.
END SEGMENT NUMBER
ATTENTION When linking Setpoint Programs 3
and 4, this End Segment Number determines the
end of the entire linked program.
RAMPUNIT—Engineering Units for Ramp Segments
TIME in hours: minutes
RATE in Engineering units per minute
RATE in Engineering units per hour
ATTENTION Normally the same as Program #3
when linking programs.
March 2012 UDC3500 Universal Digital Controller Product Manual 71
Configuration
Function Prompt
Lower Display
RECYCLES
HOTSTART
SEG1RAMP or
SEG1RATE
SEG1PID
SEG2 SP
Selections or
Range of Setting
Upper Display
0 to 100 recycles
DISABLE
ENABLE
0-99 hours.0-59 minutes
Engineering units/minute
or
Engineering units/hour
1-4
Within the Setpoint limits
Parameter
Definition
Number of Program Recycles
HOT START—This feature allows the SP Program
to start at the current PV value rather than the
current Setpoint value.
ATTENTION Not used when linking programs.
Segment #1 Ramp Time or
Segment #1 Ramp Rate
ATTENTION This parameter is affected by the
RAMPUNIT configuration (see above). All ramps will
use the same selection.
PID Set Selection
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Segment #2 Soak Setpoint Value
SEG2TIME
SOAK2DEV
SEG2 PID
SEG3RAMP or
SEG3RATE
SEG3 PID
SEG4 SP
SEG4TIME
SOAK4DEV
SEG4 PID
SEG5RAMP or
SEG5RATE
SEG5 PID
SEG6 SP
SEG6TIME
SOAK6DEV
SEG6 PID
SEG7RAMP or
0-99 hours.0-59 minutes
0.000 to 99.99
1-4
Selections are same as
above.
Segment #2 Soak Duration
Guaranteed Soak Deviation Value For Soak
Segment #2—The number selected will be the PV
value (in engineering units) above and below the
setpoint outside of which the Soak Segment timer
halts. A value of 0.000 is equivalent to no
Guaranteed Soak.
PID Set Selection—This selection is Loop
dependent.
ATTENTION The PID Set Selection prompts will
only show up when PID SETS in the Control 1 or
Control 2 Setup Group is set to 4 KEYBD.
Same as above
72 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
SEG7RATE
SEG7 PID
SEG8 SP
SEG8TIME
SOAK8DEV
SEG8 PID
SEG9RAMP or
SEG9RATE
SEG9 PID
SG10 SP
SG10TIME
SOAK10DEV
SG10 PID
SG11RAMP or
SG11RATE
SG11 PID
SG12 SP
SG12TIME
SOAK12DEV
SG12 PID
SG13RAMP or
SG13RATE
SG13 PID
SG14 SP
SG14TIME
SOAK14DEV
SG14 PID
SG15RAMP or
SG15RATE
SG15 PID
SG16 SP
SG16TIME
SOAK16DEV
SG16 PID
SG17RAMP or
SG17RATE
SG17 PID
SG18 SP
SG18TIME
SOAK18DEV
SG18 PID
SG19RAMP or
SG19RATE
SG19 PID
SG20 SP
SG20TIME
SOAK20DEV
SG20 PID
Selections or
Range of Setting
Upper Display
Parameter
Definition
March 2012 UDC3500 Universal Digital Controller Product Manual 73
Configuration
3.10 Accutune Set Up Group
Introduction
Accutune III automatically calculates GAIN, RATE, and RESET TIME (PID) tuning
constants for your control loop. When initiated on demand, the Accutune algorithm
measures a process step response and automatically generates the PID tuning constants
needed for no overshoot on your process.
The Accutune III set up group offers these selections:
Fuzzy, Fuzzy Overshoot Suppression: When enabled, this configuration will suppress
or eliminate any overshoot that may occur as a result of the existing tuning
parameters, as the PV approaches the setpoint.
Tune, Demand Tuning: This tuning cycles the output to the output limits causing the
PV to oscillate around the SP value. This tuning does not require the process to be at
lineout (stabilized) and may be moving. The tuning process is initiated through the
operator interface keys or via a digital input (if configured). The algorithm then
calculates new tuning parameters and enters them in the tuning group. Tune will
operate with PIDA, PIDB, PD+MR and Three Position Step Control algorithms.
SP, SP Tuning: When activated in automatic control, the output makes an output step
in the direction of the SP and starts measurement activities to calculate the tuning
parameters based on the PV response. In order to work properly, this tuning requires
that the process be at lineout (stabilized) for a period before SP Tune is initiated.
SP tuning continuously adjusts the PID parameters in response to setpoint changes.
You can select tuning on minimum setpoint changes of 5 % up to 15 % span.
Perform SP tuning after you have configured the controller. SP Tuning does not
operate with the Three Position Step Control algorithm.
Tune + PV or SP + PV, PV Tuning: The (TUNE) Demand Tuning or the (SP) Setpoint
Tuning portions of these selections work as stated above. PV Adapt will occur during
Process Variable (PV) disturbances (0.3% span or larger) which result from nonlinearities, process dynamics, load changes, or other operating conditions. When this
condition exists, the controller monitors the process response for 1 and 1/2 process
cycles around the setpoint to determine whether there has been a true process change
or a momentary upset.
Process retuning occurs as the process dynamics are learned. When the process is
being learned with possible retune, a “t” is shown in the upper left display digit.
Simplex Tuning is used when a Simplex Control Algorithm is configured and uses the
current SP value and alters the output over the Output Limit Range.
Duplex Tuning is used when a Duplex Control Algorithm is configured. To perform a
Duplex Tune, Two Local Setpoints must be configured per the Control Group in
Section 3.20.
See Section 4.10 for additional information.
74 UDC3500 Universal Digital Controller Product Manual March 2012
Function Prompts
Table 3-10 ACCUTUNE Group Function Prompts
Configuration
Function Prompt
Lower Display
FUZZY
ACCUTUNE
Selections or
Range of Setting
Upper Display
DISABLE
ENABLE
ENABLE2
ENABL12
DISABLE
TUNE
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.
ENABLE ON LOOP2 ONLY—Fuzzy Tune used only
on Loop 2.
ENABLE ON BOTH LOOPS—Fuzzy Tune used on
both loops.
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.
TUNE is the recommended start-up mode—to be
used when no knowledge of the process tuning
values is available. In the Start-up mode, after
enabling ACCUTUNE, the operator simply
configures the desired SP value and enables the
ACCUTUNE process via the keyboard.
March 2012 UDC3500 Universal Digital Controller Product Manual 75
SP
SETPOINT TUNING—This selection tunes on
setpoint changes only. It employs time domain
analysis to accelerate line out at any desired setpoint
without prior initialization or process knowledge. This
method should only be used after the process has
lined out (stabilized).
ATTENTION When SP Tune is active (T displayed)
the Tuning Group parameters cannot be changed.
Configuration
Function Prompt
Lower Display
DUPLEX
Selections or
Range of Setting
Upper Display
TUNE+PV
SP+PV
Parameter
Definition
DEMAND TUNING PLUS PV ADAPTIVE
TUNING—This selection provides “TUNE” on
demand tuning plus PV Adaptive tuning whenever a
PV process disturbance equal to or greater than
0.3% of span occurs. After a disturbance of 1.5
process cycles around the Setpoint occurs, this
selection will initiate a recalculation of the Tuning
parameters.
SETPOINT TUNING PLUS PV ADAPTIVE
TUNING—This selection tunes whenever the SP is
changed plus performs a PV Adaptive Tune
whenever a PV process disturbance equal to or
greater than 0.3% of span occurs. After a
disturbance of 1.5 process cycles around the
Setpoint occurs, this selection will initiate a
recalculation of the Tuning parameters.
ATTENTION When SP Tune is active (T displayed)
the Tuning Group parameters cannot be changed.
DUPLEX ACCUTUNING III—These prompts only
appear when a duplex output type has been
configured and TUNE or TUNE+PV has been
selected.
SP CHANG
MANUAL
AUTO
DISABLE
5 to 15%
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.
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).
SETPOINT CHANGE—This prompt appears only
when SP or SP+PV has been selected. This is the
minimum Setpoint change on Loop 1 that will result
in a re-tuning process.
For example, if the SP range is 0 to 2400 and
Setpoint change is set to 5%, then a re-tuning
process will take place whenever the SP is changed
by 120 or more.
76 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
KPG
CRITERIA
Selections or
Range of Setting
Upper Display
0.10 to 10.00
NORMAL
FAST
Parameter
Definition
PROCESS GAIN—This prompt appears only when
SP or SP+PV has been selected. This is the Gain of
the Loop 1 process being tuned. It is automatically
recalculated during the tuning process. This is
normally a READ ONLY value, but can be changed
manually if the controller fails to identify the process.
In that case, set the KPG value to the algebraic
value of PV in percent divided by the output in
percent while in manual mode.
For example, if the PV range is 0 to 2400, the PV is
currently at 1200 and the output is currently at
50.0%, then KPG should be set to
1200/2400100/50 or 1.0.
TUNING CRITERIA (SETPOINT ADAPTIVE)—This
prompt appears only when SP or SP+PV has been
selected. Select criteria best suited for your process.
NORMAL—Original critical damping (no overshoot).
FAST—A more aggressive tuning with overshoot
equal to or less than 0.5%.
ACCUTUNE2
DUPLEX 2
SP CHAN2
KPG 2
CRITERA2
Same selections as for
Loop 1.
Same selections as for
Loop 1.
5 to 15%
0.10 to 10.00
ACCUTUNE III FOR LOOP 2—Available only when
the instrument is configured for Cascade or Two
Loop operation.
Same selections as for Loop 1.
DUPLEX ACCUTUNING III FOR LOOP 2—These
prompts only appear when a duplex output type has
been configured for Loop 2 and TUNE or TUNE+PV
has been selected.
Same selections as for Loop 1.
SETPOINT CHANGE—This prompt appears only
when SP or SP+PV has been selected for Loop 2.
This is the minimum Setpoint change on Loop 2 that
will result in a re-tuning process.
PROCESS GAIN FOR LOOP 2—This prompt
appears only when SP or SP+PV has been selected.
This is the Gain of the Loop 2 process being tuned.
TUNING CRITERIA (SETPOINT ADAPTIVE) FOR
LOOP 2—This prompt appears only when SP or
SP+PV has been selected for Loop 2.
Same selections as for
Same selections as for Loop 1.
Loop 1.
March 2012 UDC3500 Universal Digital Controller Product Manual 77
Configuration
Function Prompt
Lower Display
AT ERROR
(Read Only)
Selections or
Range of Setting
Upper Display
NONE
RUNNING
ABORT
SP2
Parameter
Definition
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
input detected
heat region of output but a cool output was
calculated, or vice versa
SP was changed while PV (error) tune was in
process
SP2—LSP2 not configured or a Setpoint other than
LSP1 or LSP2 is in use.
AT ERR 2
(Read Only)
OUTLIM
IDFAIL
LOW PV
Same as Loop 1.
OUTPUT LIMIT REACHED (HIGH OR LOW)—
Applies only to SP or SP+PV tuning. Output
insufficient to get to SP value.
ATTENTION This error will cause the controller to
switch from Automatic to Manual Mode. The output
is then set to the value present at the beginning of
the ACCUTUNE process.
PROCESS IDENTIFICATION PROCESS FAILED—
Applies only to SP or SP+PV tuning. An illegal value
for Gain, Rate or Reset was calculated.
LOW PV—Applies only to SP or SP+PV tuning. PV
did not change sufficiently or the PV has increased
by more than 4% but Deadtime was not determined.
ACCUTUNE ERROR STATUS FOR LOOP 2
78 UDC3500 Universal Digital Controller Product Manual March 2012
3.11 Algorithm Set Up Group
Introduction
This data deals with various control algorithms and Timer functions.
The Timer section allows you to configure a time-out period and to select the timer start
by either the keyboard (RUN/HOLD key) or Alarm 2. An optional digital input can also be
configured to the start the timer. The timer display is selectable as either “time
remaining” (see TI REM) or “elapsed time” (see E TIME).
Alarm 1 is activated at the end of the time-out period. When the timer is enabled, it has
exclusive control of the alarm 1 relay—any previous alarm 1 configuration is ignored. At
time-out, the timer is ready to be activated again by whatever action has been configured.
Function Prompts
Table 3-11 ALGORTHM Group Function Prompts
Configuration
Function Prompt
Lower Display
CONT ALG
Selections or
Range of Setting
Upper Display
ON-OFF
Parameter
Definition
CONTROL ALGORITHM FOR LOOP 1—The
Control Algorithm lets you select the type of control
that is best for your process.
ON/OFF—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—This is an extension of the ON-
OFF 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
March 2012 UDC3500 Universal Digital Controller Product Manual 79
Configuration
Function Prompt
Lower Display
Selections or
Range of Setting
Upper Display
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
Parameter
Definition
PID A—This normally used for three-mode control.
Three mode control means that the output can be
adjusted to be at any point between 0 % and 100 %.
It applies all three control actions—Proportional (P),
Integral (I), and Derivative (D)—to the error signal.
Proportional (Gain)
—Regulates the controller’s
output in proportion to the error signal (the difference
between Process Variable and Setpoint).
Integral (Reset
)—Regulates the controller’s output
to the size of the error and the time the error has
existed. (The amount of corrective action depends
on the value of proportional Gain.)
Derivative (Rate)
—Regulates the controller’s output
in proportion 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.
PD+MR
PD WITH MANUAL RESET—This is used whenever
integral action is not wanted for automatic control
action. The equation is computed with no integral
contribution. The MANUAL RESET value, which is
operator adjustable, is then added to the present
output to form the controller output.
Switching between manual and automatic mode is
bumpless (output does not change value).
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
80 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
Selections or
Range of Setting
Upper Display
3PSTEP
Parameter
Definition
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.
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 “POSPROP”. See Subsection 3.14.
Refer to the Operation section for motor position
displays.
PID LOOPS
1 LOOP
2 LOOPS
CASCADE
As a customer configurable option, when a third
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.
lue is used for display only. It is NOT
a
This v
used in the Three Position Step algorithm. To
configure this option, set Input 3 actuation to
SLIDEW and then calibrate Input 3 per Subsection
6.5.
ATTENTION Other prom
pts affected: DEADBAND
PID LOOPS—Number of PID Loops to be used.
1 LOOP—Select one loop of control.
2 LOOPS—Select two independent loops of control,
each with its own PID tuning sets and control
parameters.
CASCADE—Select Cascade Control. In a Cascade
control system, the output of the primary loop (loop
2) is used to adjust the remote setpoint of the
secondary loop (loop 1). The output of the
secondary loop is used to control the final control
element.
March 2012 UDC3500 Universal Digital Controller Product Manual 81
Configuration
Function Prompt
Lower Display
CONT2ALG
OUT OVRD
Selections or
Range of Setting
Upper Display
PID A
PID B
PD+MR
DISABLE
HI SEL
Parameter
Definition
CONTROL ALGORITHM FOR LOOP 2—This
prompt only appears if Two Loop or Cascade control
has been selected.
3PSTEP and ON-OFF control are not available on
the Second Control Loop.
PID A—Same as Loop 1.
PID B—Same as Loop 1.
PD WITH MANUAL RESET—Same as Loop 1.
OUTPUT OVERRIDE SELECT—This selection lets
you select high or low output override. Only available
if the controller is configured for Two Loop operation.
Not applicable for Three Position Step applications.
ATTENTION Loop 1 must be in Automatic for this
selection to work. While the output is being
overridden, a blinking “O” appears on the left of the
upper display.
DISABLE—Disables the override function.
HIGH SELECT—The controller will select the higher
of output 1 or output 2 and direct it to the rear
terminals for output 1.
TIMER
PERIOD
START
LO SEL
DISABLE
ENABLE
0:00 to 99:59
KEY
ALARM 2
LOW SELECT—The controller will select the lower
of output 1 or output 2 and direct it to the rear
terminals for output 1.
TIMER—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 (via the
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 reactivated by whatever action has been configured.
Alarm 1 is activated at the end of the timeout period.
PERIOD—The length of timeout period (either from
0 to 99 hours: 59 minutes or from 59 minutes: 59
seconds depending upon Period configuration).
START—Select whether the timer starts with the
keyboard (via the
Run/Hold key) or via Alarm 2.
82 UDC3500 Universal Digital Controller Product Manual March 2012
Configuration
Function Prompt
Lower Display
LWR DISP
RESET
INCRMENT
Selections or
Range of Setting
Upper Display
TI REM
EL TIME
KEY
ALARM 1
MINUTE
SECOND
Parameter
Definition
LOWER DISPLAY—Select whether time remaining
(TI REM) or elapsed time (EL 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.
TIMER RESET CONTROL—Select how the timer is
reset.
KEY - Timer reset with the
Run/Hold key.
ALARM 1 - Timer reset with either Alarm 1 or by the
Run/Hold key
INCREMENT—Select the increments of the Period
configuration.
INPUT MATH ALGORITHMS—Controllers with at least two analog inputs are provided with two input
algorithms. Each algorithm can be configured to provide a derived (calculated) PV or a derived Remote
Setpoint. Up to three inputs may be used in each algorithm. In addition, the two algorithms may be
“linked” so as to combine the calculations by configuring one algorithm to be an input to the other
algorithm.
All algorithms operate in Engineering Units except Feedforward, which operates in percent of range 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—Represents one of the
following selections:
NONE
W AVG
(See Note 2)
(Standard feature on
controllers with two or
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:
more analog inputs)
Alg1 = [(Input A x Ratio A + Bias A) + (K x Input B x Ratio B + Bias B)] / (1 + K)] +
Alg1Bias
March 2012 UDC3500 Universal Digital Controller Product Manual 83
Configuration
Function Prompt
Lower Display
Selections or
Range of Setting
Parameter
Definition
Upper Display
F FWRD
(Standard feature on
controllers with two or
more 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. Algorithm 1 Feedforward works only on
Loop 1 while Algorithm 2 Feedforward works only on
Loop 2.
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 or
more 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. Algorithm 1 Feedforward works only on
Loop 1 while Algorithm 2 Feedforward works only on
Loop 2.
The following formula applies:
Controller Output = PID Output x (Input A x Ratio A + Bias A) / Input A Range
RELHUM
(Standard feature on
controllers with two or
more analog inputs)
RELATIVE HUMIDITY—Input 1 reads the wet bulb
temperature. Input 2 reads the dry bulb temperature.
The controller will indicate measured Relative
Humidity as a Process Variable (PV) with a Setpoint
range of 0 % to 100 % RH.
ATTENTION The Relative Humidity selection will
automatically force both Input 1 and Input 2
actuations to the RTD 100 ohm low setting.
See Note 6.
SUMMER
(See Note 2)
SUMMER WITH RATIO AND BIAS—The following
formula applies:
Alg1 = (Input A x Ratio A + Bias A) + (Input B x Ratio B + Bias B) + (Input C x
Ratio C + Bias C) + 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 A or Input B. The following formula applies:
Alg1 = higher of (Input A x Ratio A + Bias A) or (Input B x Ratio B + Bias B)
84 UDC3500 Universal Digital Controller Product Manual March 2012
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