Honeywell UDC3500 Operating Manual
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
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