Honeywell UDC3500 User Manual

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UDC3500

Universal Digital Controller

Product Manual

51-52-25-120 September 2006

Industrial Measurement and Control

Notices and Trademarks

Revision 2

September 2006

WARRANTY/REMEDY

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application.

Industrial Measurement and Control

Honeywell

1100 Virginia Drive

Fort Washington, PA 19034

UDC3500 is a U.S. registered trademark of Honeywell

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

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UDC3500 Universal Digital Controller Product Manual

About This Document

Abstract

This document provides descriptions and procedures for the Installation, Configuration, Operation, and Troubleshooting of your UDC3500 Controller.

Contacts

World Wide Web

The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.

Honeywell Organization	WWW Address (URL)

Corporate	http://www.honeywell.com
Industrial Measurement and Control	http://www.honeywell.com/imc

Telephone

	Organization	Phone Number

United States and Canada	Honeywell	1-800-423-9883	Tech. Support
		1-800-525-7439	Service

Web

http://content.honeywell.com/ipc/faq/

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UDC3500 Universal Digital Controller Product Manual

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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.

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		Contents
1	INTRODUCTION ...................................................................................................		1
1.1		Overview.........................................................................................................................................	1
1.2		Operator Interface ...........................................................................................................................	6
	1.2.1 Function of Displays and Keys ............................................................................................		7
1.3		Process Instrument Explorer Software............................................................................................	8
1.4		CE Conformity (Europe)...............................................................................................................	10
2	INSTALLATION...................................................................................................		11
2.1		Overview.......................................................................................................................................	11
2.2		Condensed Specifications .............................................................................................................	13
2.3		Model Number Interpretation .......................................................................................................	17
2.4		Control and Alarm Relay Contact Information.............................................................................	19
2.5		Mounting.......................................................................................................................................	20
2.6		Wiring ...........................................................................................................................................	22
	2.6.1 Electrical Considerations ...................................................................................................		22
2.7		Wiring Diagrams...........................................................................................................................	24
3	CONFIGURATION...............................................................................................		43
3.1		Overview.......................................................................................................................................	43
3.2		Configuration Prompt Hierarchy ..................................................................................................	45
3.3		Configuration Procedure...............................................................................................................	48
3.4		Loop 1 Tuning Set Up Group .......................................................................................................	49
3.5		Loop 2 Tuning Set Up Group .......................................................................................................	53
3.6		SP Ramp Set Up Group ................................................................................................................	56
3.7		Accutune Set Up Group ................................................................................................................	62
3.8		Algorithm Set Up Group...............................................................................................................	67
3.9		Math Set Up Group.......................................................................................................................	82
3.10		Logic Gates Set Up Group ........................................................................................................	89
3.11		Output Set Up Group.................................................................................................................	96
3.12		Input 1 Set Up Group ..............................................................................................................	107
3.13		Input 2 Set Up Group ..............................................................................................................	111
3.14		Input 3 Set Up Group ..............................................................................................................	114
3.15		Input 4 Set Up Group ..............................................................................................................	117
3.16		Input 5 Set Up Group ..............................................................................................................	120
3.17		Control Set Up Group .............................................................................................................	123
3.18		Control 2 Set Up Group ..........................................................................................................	132

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3.19		Options Set Up Group .............................................................................................................		139
3.20		Communications Set Up Group...............................................................................................		150
3.21		Alarms Set Up Group ..............................................................................................................		154
3.22		Real Time Clock Set Up Group...............................................................................................		162
3.23		Maintenance Set Up Group .....................................................................................................		163
3.24		Display Set Up Group .............................................................................................................		166
3.25		Read Maintenance Set Up Group............................................................................................		168
3.26		Time Events Set Up Group .....................................................................................................		169
3.27		P.I.E. Tool Ethernet and Email Configuration Screens...........................................................		171
3.28		Configuration Record Sheet ....................................................................................................		174
4	MONITORING AND OPERATING THE CONTROLLER...................................			181
4.1		Overview.....................................................................................................................................		181
4.2		Operator Interface .......................................................................................................................		182
4.3	Entering a Security Code ............................................................................................................			182
4.4		Lockout Feature ..........................................................................................................................		183
4.5		Monitoring Your Controller........................................................................................................		185
	4.5.1		Annunciators ....................................................................................................................	185
	4.5.2 Viewing the operating parameters....................................................................................			186
	4.5.3		Diagnostic Messages ........................................................................................................	187
4.6	Start Up Procedure for Operation ...............................................................................................			188
4.7		Control Modes ............................................................................................................................		189
	4.7.1		Mode Definitions .............................................................................................................	189
	4.7.2 What happens when you change modes...........................................................................			190
4.8		Setpoints......................................................................................................................................		190
4.9		Timer	...........................................................................................................................................	192
4.10		Accutune .............................................................................................................................III		193
	4.10.1 ............................................................................................		Tune for Simplex Outputs	195
	4.10.2 .......................................................................................		Tune for Duplex (Heat/Cool)	196
	4.10.3 .................................		Using AUTOMATIC TUNE at start - up for Duplex (Heat/Cool)	197
	4.10.4 ......................................		Using BLENDED TUNE at start - up for Duplex (Heat/Cool)	198
	4.10.5 .......................................		Using MANUAL TUNE at start - up for Duplex (Heat/Cool)	199
	4.10.6 ............................................................................................		ACCUTUNE Error Codes	200
4.11		Fuzzy .................................................................................................Overshoot Suppression		201
4.12		Using ......................................................................................Two Sets of Tuning Constants		202
4.13		Input ............................................................................................................Math Algorithms		204
4.14		Logic ..............................................................................................................Gate Operation		206
4.15		Digital ...............................................................................Input Option (Remote Switching)		208
4.16		Auto/Manual ...............................................................................................................Station		213
4.17		Two .............................................................................................................Loops of Control		217
4.18		Configuring .........................................................................................Two Loops of Control		220

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4.19		Monitoring Two Loops of Control..........................................................................................		221
4.20		Operating Two Loops of Control ............................................................................................		222
4.21		Alarm Setpoints.......................................................................................................................		222
4.22		Three Position Step Control Algorithm...................................................................................		225
4.23		Setting a Failsafe Output Value for Restart After a Power Loss.............................................		226
4.24		Setting Failsafe Mode..............................................................................................................		227
4.25		Carbon Potential, Oxygen and Dewpoint Algorithms.............................................................		227
4.26		Healthwatch.............................................................................................................................		230
4.27		Setpoint Rate/Ramp/Program Overview .................................................................................		230
4.28		Setpoint Rate ...........................................................................................................................		231
4.29		Setpoint Ramp .........................................................................................................................		231
4.30		Setpoint Ramp/Soak Programming .........................................................................................		233
4.31		P.I.E. Tool Maintenance Screens ............................................................................................		242
4.32		Configuring your Ethernet Connection ...................................................................................		252
5	INPUT CALIBRATION.......................................................................................			257
5.1		Overview.....................................................................................................................................		257
5.2	Minimum and Maximum Range Values .....................................................................................			258
5.3		Preliminary Information..............................................................................................................		260
5.4	Input Set Up Wiring....................................................................................................................			262
	5.4.1 Thermocouple Inputs Using an Ice Bath..........................................................................			262
	5.4.2 Thermocouple Inputs Using a Thermocouple Source......................................................			263
	5.4.3		RTD Inputs.......................................................................................................................	264
	5.4.4 Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple Differential Inputs....			265
	5.4.5 0 to 10 Volts or –1 to 1 Volts...........................................................................................			267
	5.4.6		Milliamperes ....................................................................................................................	268
	5.4.7 Dual High Level Voltage Inputs ......................................................................................			269
	5.4.8 Dual High Level Milliamperes Inputs..............................................................................			270
5.5		Input Calibration Procedure........................................................................................................		271
5.6	Restore Input Factory Calibration...............................................................................................			273
6	OUTPUT CALIBRATION...................................................................................			275
6.1		Overview.....................................................................................................................................		275
6.2	First Current Output Calibration.................................................................................................			276
6.3	Second Current Output Calibration.............................................................................................			278
6.4	Third Current Output Calibration ...............................................................................................			280
6.5	Position Proportional and Three Position Step Output Calibration ............................................			282
6.6	Restore Factory Output Calibration ............................................................................................			285
7	TROUBLESHOOTING/SERVICE......................................................................			287
7.1		Overview.....................................................................................................................................		287

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	7.2	Troubleshooting Aids..................................................................................................................		288
	7.3	Power-up Tests............................................................................................................................		290
	7.4	Status Tests .................................................................................................................................		290
	7.5	Background Tests and Diagnostic Messages ..............................................................................		291
	7.6	Controller Failure Symptoms......................................................................................................		296
	7.7	Troubleshooting Procedures .......................................................................................................		297
	7.7.1 Procedure #1 – Power ......................................................................................................			298
	7.7.2 Procedure #2 – Current Outputs.......................................................................................			298
	7.7.3 Procedure #3 – Position Proportional ..............................................................................			300
	7.7.4 Procedure #4 – Time Proportional ...................................................................................			303
	7.7.5 Procedure #5 – Current/Time or Time Current/Proportional...........................................			304
	7.7.6 Procedure #6 – Alarm Relays ..........................................................................................			305
	7.7.7 Procedure #7 – Keyboard.................................................................................................			306
	7.7.8 Procedure #8 – Analog Input ...........................................................................................			307
	7.7.9 Procedure #9 – RS-485 ....................................................................................................			308
	7.7.10		Procedure #10 – Ethernet .............................................................................................	310
	7.7.11		Procedure #11 – Email .................................................................................................	311
	7.8	Restoring Factory Configuration ................................................................................................		312
	7.9	Software Upgrades......................................................................................................................		313
8	PARTS LIST ......................................................................................................			315
	8.1	Exploded View............................................................................................................................		315
	8.2	Removing the chassis..................................................................................................................		317
9	MODBUS RTU FUNCTION CODES..................................................................			318
	9.1	Overview.....................................................................................................................................		318
	9.2	General Information....................................................................................................................		318
	9.3	Function Code 20 (14h) - Read Configuration Reference Data..................................................		320
	9.3.1		Read Configuration Examples .........................................................................................	322
	9.4	Function Code 21 (15h) - Write Configuration Reference Data.................................................		324
	9.4.1		Write Configuration Examples ........................................................................................	326
10	MODBUS READ, WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION
CODES........................................................................................................................				327
	10.1	Overview .................................................................................................................................		327
	10.2	Reading Control Data..............................................................................................................		330
	10.3 Read Software Options Status.................................................................................................			331
	10.4	Miscellaneous Read Onlys ......................................................................................................		332
	10.4.1		Register Addresses for Read Onlys ..............................................................................	332
	10.4.2		SetPoint Program Read Only Information....................................................................	332
	10.5	Setpoints ..................................................................................................................................		333
	10.6 Using a Computer Setpoint (Overriding Controller Setpoint) ................................................			335

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10.7	Configuration Parameters........................................................................................................		338
10.7.1		Tuning Loop 1 ..............................................................................................................	338
10.7.2		Tuning Loop2 ...............................................................................................................	340
10.7.3		SP Ramp/Rate/Program................................................................................................	341
10.7.4		Accutune.......................................................................................................................	348
10.7.5		Algorithm .....................................................................................................................	350
10.7.6		Math..............................................................................................................................	355
10.7.7		Logic.............................................................................................................................	358
10.7.8		Output Algorithms........................................................................................................	362
10.7.9		Input 1...........................................................................................................................	364
10.7.10		Input 2...........................................................................................................................	366
10.7.11		Input 3...........................................................................................................................	368
10.7.12		Input 4...........................................................................................................................	370
10.7.13		Input 5...........................................................................................................................	372
10.7.14		Control..........................................................................................................................	374
10.7.15		Control Loop 2 .............................................................................................................	377
10.7.16		Options .........................................................................................................................	380
10.7.17		Communications...........................................................................................................	384
10.7.18		Alarms ..........................................................................................................................	386
10.7.19		Maintenance .................................................................................................................	391
10.7.20		Time Event ...................................................................................................................	394
10.7.21		Display..........................................................................................................................	396
10.7.22		Clock ............................................................................................................................	397
10.8	Modbus RTU Exception Codes...............................................................................................		398

11	FURTHER INFORMATION................................................................................		400
	11.1	Modbus RTU Serial Communications ....................................................................................	400
	11.2	Modbus Messaging on Ethernet TCP/IP .................................................................................	400
	11.3	How to Apply Digital Instrumentation in Severe Electrical Noise Environments..................	400
12	INDEX................................................................................................................		401
13	SALES AND SERVICE......................................................................................		406

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Tables

Table 2-1 Condensed Specifications ____________________________________________________ 13 Table 2-2 Control Relay Contact Information _____________________________________________ 19 Table 2-3 Alarm Relay Contact Information ______________________________________________ 19 Table 2-4 Mounting Procedure _________________________________________________________ 21 Table 2-5 Permissible Wiring Bundling__________________________________________________ 23 Table 2-6 Single or Cascade Loop Controller – Loop 1 Output Functionality and Restrictions _______ 25 Table 2-7 Dual Loop Controller – Loop 2 Output Functionality and Restrictions __________________ 26 Table 2-8 Terminals for connecting a UDC to a MDI Compliant Hub or Switch utilizing a cross-over cable

______________________________________________________________________________ 39 Table 2-9 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable ________ 40 Table 3-1 Configuration Topics ________________________________________________________ 43 Table 3-2 Configuration Prompt Hierarchy _______________________________________________ 45 Table 3-3 Configuration Procedure _____________________________________________________ 48 Table 3-4 TUNING Group Function Prompts _____________________________________________ 49 Table 3-5 TUNING 2 Group Function Prompts____________________________________________ 53 Table 3-6 SPRAMP Group Function Prompts _____________________________________________ 56 Table 3-7 ACCUTUNE Group Function Prompts __________________________________________ 63 Table 3-8 ALGORTHM Group Function Prompts _________________________________________ 67 Table 3-9 MATH Group Function Prompts _______________________________________________ 82 Table 3-10 LOGIC Group Function Prompts ______________________________________________ 89 Table 3-11 OUTPUT Group Function Prompts ____________________________________________ 96 Table 3-12 INPUT 1 Group Function Prompts ___________________________________________ 107 Table 3-13 INPUT 2 Group Function Prompts ___________________________________________ 111 Table 3-14 INPUT 3 Group Function Prompts ___________________________________________ 114 Table 3-15 INPUT 4 Group Function Prompts ___________________________________________ 117 Table 3-16 INPUT 5 Group Function Prompts ___________________________________________ 120 Table 3-17 CONTROL Group Function Prompts __________________________________________ 123 Table 3-18 CONTROL2 Group Function Prompts _________________________________________ 132 Table 3-19 OPTION Group Function Prompts ___________________________________________ 139 Table 3-20 Communications Group Function Prompts _____________________________________ 150 Table 3-21 ALARMS Group Function Prompts __________________________________________ 155 Table 3-22 CLOCK Group Function Prompts ____________________________________________ 162 Table 3-23 MAINTENANCE Group Function Prompts ____________________________________ 163 Table 3-24 DISPLAY Group Function Prompts __________________________________________ 166 Table 3-25 READ MAINTENANCE Group Function Prompts ______________________________ 168 Table 3-26 TIME EVT Group Function Prompts _________________________________________ 169 Table 3-27 Configuration Record Sheet _________________________________________________ 174 Table 4-1 Procedure to Enter a Security Code ____________________________________________ 183 Table 4-2 Annunciators _____________________________________________________________ 185 Table 4-3 Lower Display Key Parameter Prompts_________________________________________ 186 Table 4-4 Procedure for Starting Up the Controller ________________________________________ 188 Table 4-5 Control Mode Definitions ___________________________________________________ 189 Table 4-6 Changing Control Modes ____________________________________________________ 190 Table 4-7 Procedure for Changing the Local Setpoints _____________________________________ 191 Table 4-8 Procedure for Switching Between Setpoints _____________________________________ 191 Table 4-9 Procedure for Starting “TUNE” _______________________________________________ 195 Table 4-10 Procedure for Using AUTOMATIC TUNE at Start-up for Duplex Control ____________ 197 Table 4-11 Procedure for Using BLENDED TUNE at Start-up for Duplex Control_______________ 198

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Table 4-12 Procedure for Using MANUAL TUNE for Heat side of Duplex Control ______________ 199 Table 4-13 Procedure for Using MANUAL TUNE for Cool side of Duplex Control ______________ 199 Table 4-14 Procedure for Accessing Accutune Error Codes _________________________________ 200 Table 4-15 Accutune Error Codes _____________________________________________________ 200 Table 4-16 Set Up Procedure _________________________________________________________ 202 Table 4-17 Procedure for Switching PID SETS from the Keyboard ___________________________ 203 Table 4-18 Logic Gates Constraints and Dynamic Operation Status ___________________________ 206 Table 4-19 Digital Input Option Action on Contact Closure _________________________________ 208 Table 4-20 Digital Input Combinations “DIG IN1” or “DIG IN2” ____________________________ 211 Table 4-21 Digital Inputs 1 and 2 Combination___________________________________________ 212 Table 4-22 Auto/Manual Station Mode Configuration Procedure _____________________________ 214 Table 4-23 Procedure for selecting Two Loop Algorithm ___________________________________ 220 Table 4-24 Digital Display Indication—Two Loops _______________________________________ 221 Table 4-25 Procedure for Displaying Alarm Setpoints _____________________________________ 223 Table 4-26 Procedure for Displaying TPSC Motor Position _________________________________ 225 Table 4-27 Procedure for Setting a Failsafe Value_________________________________________ 226 Table 4-28 Procedure for Setting a Failsafe Mode_________________________________________ 227 Table 4-29 Running A Setpoint Ramp __________________________________________________ 232 Table 4-30 Program Contents_________________________________________________________ 234 Table 4-31 Run/Monitor Functions ____________________________________________________ 240 Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input Range Values _______________ 258 Table 5-2 Equipment Needed_________________________________________________________ 260 Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath ________________ 262 Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using a Thermocouple Source _______ 263 Table 5-5 Set Up Wiring Procedure for RTD Inputs _______________________________________ 264 Table 5-6 Set Up Wiring Procedure for Radiamatic, Millivolts, Volts, Carbon, Oxygen or Thermocouple

Differential Inputs (Except 0-10 Volts and –1 to 1 Volts) ________________________________ 265 Table 5-7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the

Factory Setting _________________________________________________________________ 266 Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts or –1 to 1 Volts _________________________ 267 Table 5-9 Set Up Wiring Procedure for Milliampere Inputs _________________________________ 268 Table 5-10 Set Up Wiring Procedure for Dual High Level Voltage Inputs ______________________ 269 Table 5-11 Set Up Wiring Procedure for Dual High Level Milliampere Inputs __________________ 270 Table 5-12 Input Calibration Procedure _________________________________________________ 271 Table 5-13 Restore Factory Calibration _________________________________________________ 273 Table 6-1 Set Up Wiring Procedure for the First Current Output _____________________________ 276 Table 6-2 First Current Output Calibration Procedure______________________________________ 277 Table 6-3 Set Up Wiring Procedure for the Second Current Output ___________________________ 278 Table 6-4 Second Current Output Calibration Procedure ___________________________________ 279 Table 6-5 Set Up Wiring Procedure for the Third Current Output ____________________________ 280 Table 6-6 Third Current Output Calibration Procedure _____________________________________ 281 Table 6-7 Position Proportional and Three Position Step Output Calibration Procedure ___________ 283 Table 6-8 Restore Factory Calibration __________________________________________________ 285 Table 7-1 Procedure for Identifying the Software Version __________________________________ 289 Table 7-2 Procedure for Displaying the Status Test Results _________________________________ 290 Table 7-3 Background Tests__________________________________________________________ 291 Table 7-4 Controller Failure Symptoms_________________________________________________ 296 Table 7-5 Troubleshooting Power Failure Symptoms ______________________________________ 298 Table 7-6 Troubleshooting Current Output Failure ________________________________________ 298 Table 7-7 Troubleshooting Position Proportional Output Failure _____________________________ 300

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Table 7-8 Troubleshooting Time Proportional Output Failure _______________________________ 303 Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure ___________ 304 Table 7-10 Troubleshooting Alarm Relay Output Failure ___________________________________ 305 Table 7-11 Troubleshooting a Keyboard Failure __________________________________________ 306 Table 7-12 Troubleshooting an Analog Input Failure ______________________________________ 307 Table 7-13 Troubleshooting a RS-485 Communications Failure______________________________ 308 Table 7-14 Troubleshooting an Ethernet Communications Failure ____________________________ 310 Table 7-15 Troubleshooting an Email Failure ____________________________________________ 311 Table 7-16 Restoring Factory Configuration _____________________________________________ 312 Table 7-17 Software Upgrades________________________________________________________ 313 Table 8-1 Parts Identification _________________________________________________________ 316 Table 8-2 Parts Not Shown___________________________________________________________ 316 Table 8-3 Software Upgrades (see Section 7.9) ___________________________________________ 317 Table 9-1 Integer Parameter Type _____________________________________________________ 319 Table 9-2 Floating Point Parameter Type________________________________________________ 319 Table 9-3 Register Parameter ID Address Format for Function Code 20 _______________________ 321 Table 9-4 Register Parameter ID Address Format for Function Code 21 _______________________ 325 Table 10-1 Control Data Parameters ___________________________________________________ 330 Table 10-2 Option Status ____________________________________________________________ 331 Table 10-3 Miscellaneous Read Onlys__________________________________________________ 332 Table 10-4 SetPoint Program Read Only Information ______________________________________ 332 Table 10-5 Setpoint Code Selections ___________________________________________________ 333 Table 10-6 Setpoint Associated Parameters ______________________________________________ 334 Table 10-7 Computer Setpoint Selection ________________________________________________ 335 Table 10-8 Computer Setpoint Associated Parameters for Loop 1 ____________________________ 336 Table 10-9 Computer Setpoint Associated Parameters for Loop2 _____________________________ 337 Table 10-10 Set-up Group – Tuning Loop 1 _____________________________________________ 338 Table 10-11 Set-up Group – Tuning Loop 2 ______________________________________________ 340 Table 10-12 Set-up Group – Setpoint Ramp/Rate _________________________________________ 341 Table 10-13 Set-up Group – Adaptive Tune _____________________________________________ 348 Table 10-14 Set-up Group – Algorithm _________________________________________________ 350 Table 10-15 Set-up Group – Math _____________________________________________________ 355 Table 10-16 Set-up Group – Logic_____________________________________________________ 358 Table 10-17 Set-up Group – Output Algorithms __________________________________________ 362 Table 10-18 Set-up Group – Input 1____________________________________________________ 364 Table 10-19 Set-up Group – Input 2____________________________________________________ 366 Table 10-20 Set-up Group – Input 3____________________________________________________ 368 Table 10-21 Set-up Group – Input 4____________________________________________________ 370 Table 10-22 Set-up Group – Input 5____________________________________________________ 372 Table 10-23 Set-up Group – Control ___________________________________________________ 374 Table 10-24 Set-up Group – Control2 __________________________________________________ 377 Table 10-25 Set-up Group – Options ___________________________________________________ 380 Table 10-26 Set-up Group – Communications____________________________________________ 384 Table 10-27 Set-up Group – Alarms ___________________________________________________ 386 Table 10-28 Set-up Group – Maintenance _______________________________________________ 391 Table 10-29 Set-up Group – Time Event ________________________________________________ 394 Table 10-30 Set-up Group – Display ___________________________________________________ 396 Table 10-31 Set-up Group – Clock ____________________________________________________ 397 Table 10-32 Modbus RTU Data Layer Status Exception Codes ______________________________ 399

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Figures

Figure 1-1 UDC3500 Operator Interface __________________________________________________ 6 Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket PC _________________ 8 Figure 1-3 Depiction of infrared communications ___________________________________________ 9 Figure 2-1 Model Number Interpretation _________________________________________________ 18 Figure 2-2 Mounting Dimensions (not to scale)____________________________________________ 20 Figure 2-3 Mounting Methods _________________________________________________________ 21 Figure 2-4 Composite Wiring Diagram___________________________________________________ 27 Figure 2-5 Mains Power Supply ________________________________________________________ 28 Figure 2-6 Input 1 Connections_________________________________________________________ 29 Figure 2-7 Input 2 Connections_________________________________________________________ 30 Figure 2-8 Input 3 Connections_________________________________________________________ 31 Figure 2-9 HLAI Inputs 2 and 4 Connections ______________________________________________ 32 Figure 2-10 HLAI Inputs 3 and 5 Connections _____________________________________________ 33 Figure 2-11 Optional Analog Input Jumper Positions________________________________________ 33 Figure 2-12 First Current Output________________________________________________________ 34 Figure 2-13 Second Current Output _____________________________________________________ 34 Figure 2-14 Output #2 – Electromechanical Relay Output ____________________________________ 35 Figure 2-15 Output #2 – Solid State Relay Output __________________________________________ 35 Figure 2-16 Output #2 – Open Collector OutputThird ______________________________________ 36 Figure 2-17 Output #2 – Third Current Output _____________________________________________ 36 Figure 2-18 Output #2 – Dual Relay Output for Time Duplex _________________________________ 37 Figure 2-19 Output #2 – Dual Relay Output for Position Proportional or Three Position Step Control _ 37 Figure 2-20 RS-422/485 Communications Option Connections________________________________ 38 Figure 2-21 Ethernet Communications Option with Adaptor Board_____________________________ 38 Figure 2-22 Ethernet Communications Option without Adaptor Board __________________________ 39 Figure 2-23 Digital Inputs _____________________________________________________________ 40 Figure 2-24 Optional Electromechanical Relay Outputs______________________________________ 41 Figure 2-25 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open Collector Output_____ 41 Figure 2-26 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Second Current Output ____ 42 Figure 3-1 Mass Flow Example ________________________________________________________ 80 Figure 3-2 Example of Eight Segment Characterizer________________________________________ 88 Figure 3-3 Ethernet Configuration Screen _______________________________________________ 171 Figure 3-4 Email Configuration Screen _________________________________________________ 172 Figure 4-1 Operator Interface_________________________________________________________ 182 Figure 4-2 Auto/Manual Station_______________________________________________________ 213 Figure 4-3 Functional Overview Block Diagram of a Single Loop (Loop #1) or Dual Loop Controller (Loop #1

and Loop #2) __________________________________________________________________ 218 Figure 4-4 Functional Overview Block Diagram of Internal Cascade Controller _________________ 219 Figure 4-5 Hi/Lo Override Selector ____________________________________________________ 220 Figure 4-6 Carbon Potential Control ___________________________________________________ 229 Figure 4-7 Ramp/Soak Profile Example_________________________________________________ 237 Figure 4-8 Program Record Sheet _____________________________________________________ 238 Figure 4-9 Loop Data Maintenance Screen ______________________________________________ 242 Figure 4-10 Alarm Details Maintenance Screen __________________________________________ 243 Figure 4-11 Status Data Maintenance Screen_____________________________________________ 245 Figure 4-12 Diagnostic History Maintenance Screen_______________________________________ 246 Figure 4-13 Ethernet Status Maintenance Screen__________________________________________ 247 Figure 4-14 Healthwatch Data Maintenance Screen _______________________________________ 248

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Figure 4-15 Healthwatch Data Reset Screen _____________________________________________ 249 Figure 4-16 Totalizer Maintenance Screen ______________________________________________ 250 Figure 4-17 Real Time Clock Maintenance Screen ________________________________________ 251 Figure 4-18 IR Communications Address _______________________________________________ 252 Figure 4-19 Configuration Upload in Progress ___________________________________________ 253 Figure 4-20 Ethernet Communications Address __________________________________________ 255 Figure 4-21 Configuration Upload in Progress ___________________________________________ 256 Figure 5-1 Input Wiring Terminals ____________________________________________________ 260 Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath ____________________ 262 Figure 5-3 Wiring Connections for Thermocouple Inputs Using a Thermocouple Source __________ 263 Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device) ____________________ 264 Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts, Carbon, Oxygen or

Thermocouple Differential Inputs (Except 0-10 Volts and –1 to 1 Volts)____________________ 265 Figure 5-6 Wiring Connections for 0 to 10 Volts or –1 to 1 Volts_____________________________ 267 Figure 5-7 Wiring Connections for Milliampere Inputs_____________________________________ 268 Figure 5-8 Wiring Connections for Dual High Level Voltage Inputs __________________________ 269 Figure 5-9 Wiring Connections for Dual High Level Milliampere Inputs_______________________ 270 Figure 6-1 Wiring Connections for Calibrating the First Current Output _______________________ 276 Figure 6-2 Wiring Connections for Calibrating the Second Current Output _____________________ 278 Figure 6-3 Wiring Connections for Calibrating Third Current Output _________________________ 280 Figure 8-1 UDC3500 Exploded View __________________________________________________ 315 Figure 10-1 Software Option Status Information __________________________________________ 331

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Introduction

1 Introduction

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

•3 Universal Analog Inputs (can be configured to act as one Universal and four High Level)

•± 0.10% Analog Input Accuracy (can be Field Calibrated to ± 0.05%)

•16-bit Analog Input resolution typical

•Fast scanning rate (166ms)

•Up to 7 Analog and Digital Outputs

•4 Digital Inputs

•Two Math Functions, two Characterizers, one Polynomial equation and one Totalizer available

•Two Independent Loops or Cascade Loop

•Ethernet TCP/IP with Email or RS-485 Modbus communication

•Infrared PC & Pocket PC configuration

•NEMA4X and IP66 front face protection

•Multilanguage prompts

•¼ DIN Size

•Easily Field Upgradeable

Easy to read displays

Bright, dual displays with multi-language prompts (in English, French, German, Spanish, or Italian) make the operator interface easy to read, understand, and operate. Simple keystrokes let you set operating parameters that meet your process control needs.

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Analog Inputs

The UDC3500 has three universal analog inputs with a typical accuracy of ±0.10% of full-scale input and a typical resolution of 16 bits. These can be configured to act as one Universal and four High Level Inputs for a total of five analog inputs. All analog inputs are sampled six times per second (every 166 ms).

The Process Variable input can be one of the various thermocouple, RTD, Radiamatic or linear actuations. Linear actuations have thermocouple, RTD, and Radiamatic transmitter characterization capability as a standard feature. Linear actuations also have square root capability.

The optional second and third inputs are isolated from each other and all other inputs and outputs and accept the same actuations as input one. Input 3 provides the Slidewire input for Position Proportional control. These optional inputs can each be split into two high level inputs. The fourth input is enabled by first configuring Input 2 as a 20 mA or 5 Vdc type (high level) input and moving a jumper on the Second Optional Input Board. Input 4 will then be available as a high level input. The fifth input is enabled by first configuring Input 3 as a 20 mA or 5 Vdc type (high level) and moving a jumper on the Third Optional Input Board. Input 5 will then be available as a high level input.

All actuations and characterizations are keyboard configurable. Cold junction compensation is provided for thermocouple type inputs. Upscale, downscale or failsafe sensor break protection is keyboard configurable. A configurable digital filter of 0 to 120 seconds provides input signal damping.

Thermocouple Health—In addition to the standard configurable upscale, downscale or failsafe output burnout selections, the condition of the thermocouple can be monitored to determine if it is good, failing or in danger of imminent failure.

Math Functions

Algorithm—Two pre-configured algorithms are available for easy implementation. This includes the capability of using a Ratio and Bias with any input. You can select from the following menu:

Feedforward Summer—Uses any input, followed by a Ratio/Bias calculation, summed directly with the computed PID output value to provide a resultant output to the final control element (standard feature).

Weighted Average —Computes the weighted average of a PV or SP for the control algorithm from two inputs (standard feature).

Feedforward Multiplier—Uses any input, multiplied by the calculated PID output to provide a resultant output, which is sent to the final control element (standard feature).

Summer/Subtractor—Will add or subtract inputs with the result used as the derived PV.

Multiplier/Divider—Uses the analog inputs to calculate a derived PV. It is available with or without Square Root.

Input High/Low Select—Specifies the PV input as the higher or lower of two inputs.

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8 Segment Characterizers—Two characterizers are available that can be applied to any Analog Input, to Loop 1 Output or to Loop 2 Output. The Characterizers can be combined to produce a single 16-segment characterizer.

Totalizer—Calculates and displays the total flow volume as measured by any of the analog inputs or as derived by either Math algorithm. Displayed value is eight digits with a configurable scaling factor. The totalizer value may be reset.

Combinational Inputs—Inputs can be combined for use with Relative Humidity, % Oxygen, Carbon Potential, Dewpoint or Math Algorithms. This controller can accept carbon probes from Cambridge, Marathon Monitors, Corning, A.A.A.C, Barber Coleman, MacDhui, Bricesco or Furnace Controls.

Polynomial Curve Characterizer—A fifth order polynomial equation can be used on any one of the analog inputs.

Logic Gates—Five Logic Gates configurable as OR, NOR, AND, NAND, XOR, XNOR, or COMPARATOR. Each Gate has two inputs and one output. The Gates may be linked together to perform more complex functions.

Digital Inputs

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.

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•Alarm blocking is also available which allows start-up without alarm energized until after it first reaches the operating region.

•PV rate of change alarm.

•Loop break alarm.

•Timer output reset.

•Diagnostic Alarm

Communications

A communications link is provided between the UDC3500 and a host computer or PLC via the RS422/485 Modbus® RTU or Ethernet TCP/IP * communications option. An infrared communication link is also available allowing a non-intrusive configuration of the instrument.

Miscellaneous Features

Auxiliary Output * (optional)—All of the three current outputs can function as Auxiliary Outputs which can be scaled from 4-20 ma for 0 to 100% for any range. These can be configured to represent any analog input, PV, active Setpoint, Local SP1, Deviation, or the Control Output for either control loop.

Transmitter Power—This feature provides up to 30 volts dc to power a 2-wire transmitter (requires the use of open collector output selection or one of the current outputs).

Four Local and one Remote Setpoints—Can be configured to provide four Local and one Remote Setpoints, which are selectable either via the keyboard or by Digital Input.

Universal Switching Power—Operates on any line voltage from 90 to 264 Vac 50/60 Hz without jumpers. 24 Vac/dc instrument power is available as an option.

Timer—This standard feature provides a configurable time period of 0 to 99 hours, 59 minutes or units of minutes and seconds. It can be started via the keyboard, alarm 2, or by a digital input. The timer output is Alarm 1, which energizes at the end of the Timer Period. Alarm 1 can be automatically reset. The Timer Period can be changed between each batch. Status is shown on the lower display.

Healthwatch—Consists of three timers and three counters, which can each be assigned to track UDC3500 controller functions. Selected Maintenance & Diagnostic data can be accessed from the front panel or via communications. Alarms can be configured to activate when a desired threshold is reached. A security code is required to perform resetting of any of the above listed counter or timer functions.

Real Time Clock—An optional battery-backed clock feature that allows the user to perform such things as starting an SP Program on a specific date and time.

Auto/Manual Station Plus Back-up Control—A UDC3500 can act as both an Auto/Manual Station PLUS as a back-up PID Controller, should the primary loop controller fail. Since the PID control is sometimes implemented via a PLC, this feature provides a very cost-effective way to insure the process does not have to shutdown or

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remain in manual mode if the PLC should fail. Switching from the Auto/Manual Station to the back-up control mode is accomplished using the Digital Input option.

Moisture Protection—The NEMA4X and IP66 rated front face permits use in applications where it may be subjected to moisture, dust, or hose-down conditions. UL and CSA approved as Type 4 protection.

Setpoint Ramp/Soak Programming (Optional)—Enables you to program and store ten Ramp and ten Soak segments (total of twenty segments) for setpoint programming. Run or Hold of program is keyboard or remote digital switch selectable.

Setpoint Rate—Lets you define a ramp rate to be applied to any local setpoint change. A separate upscale or downscale rate is configurable. A single setpoint ramp is also available as an alternative.

Output Rate Limiter—A maximum output rate may be configured for both the upscale and the downscale output directions.

CE Mark—Conformity with 73/23/EEC, Low Voltage Directive and 89/336/EEC, the EMC Directive as a standard feature.

Approval Body Options—CSA certification and UL listing are available as an option.

Four Sets of Tuning Constants—Four sets of PID parameters can be configured for each loop and automatically or keyboard selected.

Data Security—Five levels of keyboard security protect tuning, configuration, and calibration data, accessed by a configurable 4-digit code. Nonvolatile EEPROM memory assures data integrity during loss of power.

Diagnostic/Failsafe Outputs—Continuous diagnostic routines detect failure modes, trigger a failsafe output value and identify the failure to minimize troubleshooting time.

High Noise Immunity—The controller is designed to provide reliable, error-free performance in industrial environments that often affect highly noise-sensitive digital equipment.

Accutune III™ —This standard feature provides a truly plug and play tuning algorithm, which will, at the touch of a button or through a digital input, accurately identify and tune any process including those with deadtime and integrating processes. This speeds up and simplifies start-up plus allows retuning at any setpoint. The algorithm used is an improved version of the Accutune IITM algorithm found on earlier controllers. Two possibilities are now offered when tuning your process: Fast Tune and Slow Tune.

Fast Tune will tune the process in such a way that the temp is reached faster, a slight overshoot will be allowed.

Slowtune will minimize overshoot, but it will take more time for the process temperature to reach the target setpoint.

Heat/Cool (Duplex Tune) will automatically tune both the heating and cooling sides of the process.

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Fuzzy Logic—This standard feature uses fuzzy logic to suppress process variable overshoot due to SP changes or externally induced process disturbances. It operates independently from Accutune III™ tuning. It does not change the PID constants, but temporarily modifies the internal controller response to suppress overshoot. This allows more aggressive tuning to co-exist with smooth PV response. It can be enabled or disabled depending on the application or the control criteria.

*The Second Current Output option is mutually exclusive with the Ethernet Communications option.

1.2Operator Interface

Figure 1-1 UDC3500 Operator Interface

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1.2.1 Function of Displays and Keys

Table 1-1 Function of Displays and Keys

Display Indicators

	35002	Upper display with 4 larger digits shows
	35002	Process Variable value (normal operation)
		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
SP 3200500			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
	ALM		Indicates Alarm 1 and/or Alarm 2 conditions
			exist.
			exist.
			Indicates Digital Input 1 and/or 2 on.
		DI	Indicates Digital Input 1 and/or 2 on.

OUT

MAN

Indicates Control Relay 1 and/or 2 on.

Indicates either degrees Fahrenheit or Centigrade.

Indicates either Manual or Auto mode.

Indicates Local Setpoint #1. Also, a bar is lighted when the setpoint being used is shown on the lower display.

Keys and Functions

Func

Loop 1/2

Setup

Lower

Display

Selects functions within each configuration group. Switches between Loop Displays for Two Loop and Cascade units.

Scrolls through the configuration groups.

Returns Controller to normal display from Set Up mode. Toggles various operating parameters for display.

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

Infrared transceiver

Man

Auto

Select

Run

Hold

Selects Manual or Auto mode.

Hold key down to cycle through configured setpoints.

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

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

NEMA4X and IP66 screw attachment (each corner)

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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 #51- 52-25-131.

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

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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.

Figure 1-3 Depiction of infrared communications

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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.

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2 Installation

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.

	TOPIC	See Page
2.1	Overview	11

2.2	Condensed Specifications	13

2.3	Model Number Interpretation	17

2.4	Control and Alarm Relay Contact Information	19

2.5	Mounting	20

2.6	Wiring	22

2.7	Wiring Diagrams	27
Figure 2-4 Composite Wiring Diagram		27
Figure 2-5 Mains Power Supply		28
Figure 2-6 Input 1 Connections		29
Figure 2-7 Input 2 Connections		30
Figure 2-8 Input 3 Connections		31
Figure 2-9 HLAI Inputs 2 and 4		32
Figure 2-10 HLAI Inputs 3 and 5		33
Figure 2-11 Optional Analog Input Jumper Positions		33
Figure 2-12 First Current Output		34
Figure 2-13 Second Current Output		34
Figure 2-14 Output #2 – Electromechanical Relay Output		35
Figure 2-15 Output #2 – Solid State Relay Output		35
Figure 2-16 Output #2 – Open Collector Output		36
Figure 2-17 Output #2 – Third Current Output		36
Figure 2-18 Output #2 – Dual Relay Output for Time Duplex		37
Figure 2-19 Output #2 – Dual Relay Output for Position		37
	Proportional or Three Position Step Control	38
Figure 2-20 RS-422/485 Communications Option		38
		39

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Figure 2-22 Ethernet Communications Option		40
Figure 2-23	Digital Inputs	41
Figure 2-24	Optional Electromechanical Relay Outputs	41
Figure 2-25	Transmitter Power for 4-20 mA — 2 wire
Transmitter Using Open Collector Output		42
Figure 2-26	Transmitter Power for 4-20 mA — 2 Wire
Transmitter Using Second Current Output

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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.

2.2Condensed 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
	Specifications
Analog Inputs	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© Models 10260 and 11280 Slidewire Emulation
Analog Input Signal	Burnout Selections: Upscale, Downscale, Failsafe or None
Failure Operation	Thermocouple Health: Good, Failing, Failure Imminent or Failed
	Failsafe Output Level: Configurable 0-100% of Output range
Stray Rejection	Common Mode
	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)
Digital Inputs (Four)	+30 Vdc source for external dry contacts or isolated solid-state contacts. Digital Inputs are
(Optional)	isolated from line power, earth ground, analog inputs and all outputs.

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	Specifications
Current and Auxiliary	Up to three Milliamp Outputs. These outputs provide a 0 to 21 mA current output into a
Outputs	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 Options	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 (cosϕ = 0.4): 3 amps @ 130 Vac or 250 Vac
	Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
	Motor: 1/6 H.P.
	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 (cosϕ = 0.4): 1 amp @ 130 Vac or 250 Vac
	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 Relay Board	Three SPDT contacts. Both Normally Open and Normally Closed contacts are brought out to
(Optional)	the rear terminals for each relay. These relays are used for Alarm outputs or for the output of
	the second control loop. They may also be used as outputs for Logic Gate functions.
	Resistive Load: 5 amps @ 120 Vac or 240 Vac or 30 Vdc
	Inductive Load (cosϕ = 0.4): 3 amps @ 130 Vac or 250 Vac
	Inductive Load (L/R = 7 milliseconds): 3.5 amps @ 30 Vdc
	Motor: 1/6 H.P.

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			Specifications
Alarm Outputs	A maximum of four alarm relays are available, depending upon the type and quantity of
(Optional)	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.
Isolation (Functional)	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
RS422/485 Modbus	Baud Rate: 4800, 9600,19,200 or 38,400 baud selectable
RTU	Data Format: Floating point or integer
Communications	Length of Link:
Interface (Optional)		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.
Ethernet TCP/IP	Type: 10Base-T
Communications	Length of Link: 330 ft. (100 m) maximum. Use Shielded twisted-pair, Category 5 (STP
Interface (Optional)	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.

RS-485 and Ethernet	Host computer must allow a minimum of 20 milliseconds between Read transactions and a
Transaction rates	minimum of 200 milliseconds between Write transactions.
Infrared	Type: Serial Infrared (SIR)
Communications	Length of Link: 3 ft. (1 m) maximum for IrDA 1.0 compliant devices
(Standard)	Baud Rate: 19,200 or 38,400 baud selectable
Power Consumption	24 VA maximum (90 to 264 Vac)
	18 VA maximum (24 Vac/dc)
Power Inrush Current	10A maximum for 4 ms (under operating conditions), reducing to a maximum of 265 mA (90
	to 264 Vac operation) or 900 mA (24 Vac/dc operation) after one second.
		CAUTION	When applying power to more than one instrument, make sure that sufficient
	power is supplied. Otherwise, the instruments may not start up normally due to voltage drop
	from the inrush current.
Weight	3 lbs. (1.3 kg)

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Environmental and Operating Conditions

Parameter		Reference	Rated	Operative	Transportation and Storage
				Limits

Ambient Temperature	25	± 3 °C	15 to 55 °C	0 to 55 °C	–40 to 66 °C
	77	± 5 °F	58 to 131 °F	32 to 131 °F	–40 to 151 °F
Relative Humidity	10 to 55*		10 to 90*	5 to 90*	5 to 95*
Vibration	0		0 to 70	0 to 200	0 to 200
Frequency (Hz)	0		0 to 70	0 to 200	0 to 200
Acceleration (g)	0		0.4	0.6	0.5
Mechanical Shock	0		1	5	20
Acceleration (g)	0		1	5	20
Duration (ms))	0		30	30	30
Line Voltage (Vdc)
24 Vdc	+24 ± 1		22 to 27	20 to 30	- -
Line Voltage (Vac)	120 ± 1		90 to 240	90 to 264	- -
90 to 240 Vac	120 ± 1		90 to 240	90 to 264	- -
	240 ± 2				- -
24 Vac	24	± 1	20 to 27	20 to 27	- -
Frequency (Hz)	50	± 0.2	49 to 51	48 to 52	- -
(For Vac)	60	± 0.2	59 to 61	58 to 62	- -

*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.

UDC3500 Universal Digital Controller Product Manual

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