Troubleshooting/Service | Honeywell UDC2500 specification

Troubleshooting/Service

7 Troubleshooting/Service

7.1 Overview

Introduction

Instrument performance can be adversely affected by installation and application problems as well as by hardware problems. We recommend that you investigate the problems in the following order:

•installation related problems

•application related problems

•hardware and software related problems

and use the information presented in this section to solve them.

What's in this section?

The following topics are covered in this section.

	TOPIC	See Page
7.1	Overview	158

7.2	Troubleshooting Aids	159
	• Overall Error Messages
	• Controller Failure Symptoms
	• Customer Support
	• Determining the Software Version Number

7.3	Power-up Tests	161

7.4	Status Tests	161

7.5	Background Tests	162

7.6	Controller Failure Symptoms	164

7.7	Troubleshooting Procedures	165
	• Power Failure
	• Current Proportional Output Failure
	• Time Proportional Output Failure
	• Time/Current - Current/Time Proportional Output Failure
	• Alarm Relay Output Failure
	• Keyboard Failure
7.8	Restore Factory Configuration	174

7.9	Software Upgrades	175

158

UDC2500 Universal Digital Controller Product Manual

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Honeywell UDC2500 manual Troubleshooting/Service

Contents

UDC2500 Universal Digital Controller Product Manual WARRANTY/REMEDY Copyright 2007 by Honeywell Revision 5 April Abstract ContactsWorld Wide Web Telephone Symbol Definitions Symbol Definition Contents Monitoring and Operating the Controller 136 151 158177 180 220 221222 226 Tables Introduction Introduction Figures Wiring Connections for Calibrating Current Output Page Features OverviewFunction Easy to Read Displays Mount Anywhere UDC2500 Operator Interface all display items shown 1Function of Displays and Keys Function of Displays and KeysMAN Process Instrument Explorer Software Overview CE Conformity Europe Depiction of infrared communications Introduction Introduction What’s in this section? Pre-installation Information Condensed SpecificationsCondensed Specifications Alarm Outputs RTU Environmental and Operating Conditions Frequency Hz Model Number Interpretation Instructions Model Number Interpretation Control and Alarm Relay Contact Information Alarm RelaysAlarm Relay Contact Information Control Relays Mounting Overall DimensionsPhysical Considerations Mounting Method Mounting ProcedureStep Action Wiring Permissible Wiring Bundling Bundle No Wire Functions Identify Your Wiring Requirements Wiring DiagramsUniversal Output Functionality and Restrictions INU Tpsc Wiring the Controller Composite Wiring Diagram AC/DC Earth Ground HotLine Neutral Voltage L2/N Input #1 RTD Volts Input Milliamps Input Input #2Time Simplex Solid State Relay Output 10 Open Collector Output 11 Dual Electromechanical Relay Option Output 12 Current Output Open CW 15 RS-422/485 Communications Option Connections 17 Auxiliary Output and Digital Inputs Option Connections 26 + 12 + Configuration Configuration Topics Configuration Prompt Hierarchy Configuration Prompt HierarchySet Up Group Function Prompts Configuration Procedure ProcedureConfiguration Procedure Upper Display = SET Tuning Set Up Group Rate T MIN RPMManrst Gain ALL Configuration is Complete I2 MINI2 RPM Secur Disable EnableAutoma RN HLD SP Ramp SP Ramp Set Up GroupTI MIN Finlsp Setpoint Ramp Final SetpointSprate Euhrup Euhrdn SpprogSetpoint RAMP/SOAK Program Strseg State DISHold Pvstrt Accutune Set Up Group Fuzzy Fuzzy Overshoot SuppressionTune Accutune AT ERR 304 Accutune Error STATUS-When anCurrent Accutune Process Algorithm Set Up Group Ctralg401 Onof Outhys PidaProportional Gain-Regulates Derivative Rate-Regulates PD with Manual Reset is used Manrst in the Tuning Set Up groupPdmr Three Position Step Control Period TimerStart Disp ResetIncrmt Output Set Up Group Outalg501 With Control algorithm prompt Tpsc Outrng CrangeCurrent Duplex Range Algorithm For Example English Numeric Code Current Duplex Range SPLIT-ThisCurrent Duplex Range Full RLY TYP Relay Cycle Time Increment MechElectromechanical RELAY-Cycle MTR TI IN1TYP Input 1 Set Up Group601 Input 1 Actuation Type This Transmitter Characterization XMITR1IN1 HI IN1 LO RATIO1Bias FILTR1 Down Downscale Burnout will forceNofs Emiss Input 2 Set Up Group IN2TYP701 Input 2 Actuation Type This XMITR2 IN2 HI IN2 LORATIO2 FILTR2 Control Set Up Group Number of Tuning ParameterPidset 801 TWO Sets PV Automatic TWO Sets SP AutomaticSW VAL LSP’S Power UP Controller Mode RspsrcSP TRK PWR UP Three Position Control Step PwroutAction Band HystFailsf Three Position Step Failsafe Fsmode Failsafe ModeMinrpm Options Group AuxoutAuxiliary Output Selection No Auxiliary Output 0PCT Deviation Process VariableAuxiliary Output LOW Scaling DIGIN1 Auxiliary Output High ScalingNo Digital Input Selections External SP Program Reset Inhibit Integral RESET-ContactManual Failsafe OUTPUT-Controller Keyboard LOCKOUT-Contact closure Initiate Limit Cycle TUNING-Contact Setpoint INITIALIZATION-ContactTo Remote SETPOINT-Contact closure Output Tracks Input 2-Contact DI1COM Digital Input 1 CombinationPlus RUN Setpoint DIGIN2 Communications Group ComstaCommunications Selection Irenab Shed Controller Mode and Output TxdlyWsflt Sdenab Shdsp Shed Setpoint RecallUnits Percent Alarms Set Up Group Deviation from LSP 2 Note TC WThermocouple Warning Note TC F High Alarm LOW AlarmA1S1VA A1S1HL A1S1EV Beginning of SegmentEND of Segment A1S2TY A2S1HL A2S1EVA2S2TY A2S2VA Block ALARM1Diagal Display Set Up Group Decmal1201 Decimal Point LOCATION-This Freq DisplyLwrdsp Lnguag 16 P.I.E. Tool Ethernet and Email Configuration Screens Ethernet Configuration Screen Email Configuration Screen Configuration Configuration Record Sheet Alarms ContrlOption COM Monitoring and Operating the Controller Whats in this section? Operator Interface Entering a Security Code Procedure to Enter a Security Code Lockout FeatureLockout levels Key error Individual key lockout Monitoring Your Controller 4.5.1 Annunciators Annunciators Viewing the operating parameters Lower Display Key Parameter Prompts Diagnostic Messages Diagnostic Messages Functional Overview Block Diagram of the UDC2500 Controller Access the Values Auto-only ModeSingle Display Functionality Exceptions Single Display Parameters Lower Display Prompt Upper Display Value Comments Procedure for Starting Up the Controller Start Up Procedure for OperationUpper Display = PV Value Control Mode Definitions Mode DefinitionsControl Modes What happens when you change modes SetpointsChanging Control Modes Dual Display Only Step Operation Press Result Select Until you see Timer Switching between setpoints10 Procedure for Switching Between Setpoints Configuration check Viewing Times Operation Tuning indicators Accutune Tune for Simplex Outputs 11 Procedure for Starting TuneTune for Duplex Heat/Cool Using Blended Tune at start-up for Duplex Heat/Cool Using Automatic Tune at start-up for Duplex Heat/CoolConfiguration Check for Duplex Using Manual Tune at start-up for Duplex Heat/Cool 108 Error Codes 16 Procedure for Accessing Accutune Error Codes17 Accutune Error Codes Aborting Accutune Using Two Sets of Tuning Constants ConfigurationFuzzy Overshoot Suppression Completing Accutune Set up Procedure 18 Set Up ProcedureUpper Display = the switchover value Upper Display = SET Lower Display = Contrl Upper Display = SET Lower Display = Alarms Alarm SetpointsUpper Display = the PV value Lower Display = Pids X X= 1 or Three Position Step Control Algorithm Estimated Motor PositionDisplay Upper Display = PV Upper Display = range Except 3 Position Step= motor goes to closed position 100 = motor goes to open position Setting Failsafe Mode Set Failsafe Mode 23 Procedure for Setting a Failsafe ModeSetpoint Rate/Ramp/Program Overview PV Hot Start RUN/HOLD key 19Setpoint Ramp24 Running a Setpoint Ramp Power outages Power Outage20Setpoint Rate Review program data and configuration Program Contents25 Program Contents Setpoint Ramp/Soak Programming Contents Definition Ramp unit Ramp/soak profile example RP Unit SEGTo Begin Program record sheet Soak Time Ramp Time Soak SP Run/Monitor the program Run/Monitor functions26 Run/Monitor Functions Function Press Result Lower Display = XXHH.MM Power outage Digital input remote switch operationLower Display = Recxx 22 P.I.E. Tool Maintenance Screens Loop Data Loop Data Maintenance Screen Loop Data Alarm Details Alarm Details Maintenance Screen Loop Data Digital Input Details Digital Input Details Screen Status Data Maintenance Screen Status Data 10 Ethernet Status Maintenance Screen Ethernet Status Configuring your Ethernet Connection Configuring the Controller via Infrared Communications 12 Online Configuration Configuring the Controller via Ethernet Communications 14 Ethernet Communications Type Selection 15 Ethernet Communications Address 16 Configuration Upload in Progress Input Calibration Calibration Steps Minimum and Maximum Range ValuesSelect the Range Values Sensor Type PV Input Range Range Values 100 % W5W26W5W26 low RP20-RP40 Preliminary Information Disconnect the Field WiringVoltage and Milliamp Equivalents for Input 2 Range Values Input 1 Set Up Wiring Thermocouple Inputs Using an Ice Bath Thermocouple Inputs Using a Thermocouple Source Set Up Wiring Procedure for RTD Inputs25R 26+ Millivolt or Volt Source 26+ Set Up Wiring Procedure for 0 to 10 Volts Set Up Wiring Procedure for Milliampere InputsTo 10 Volts Volt Source 100K pair 26+ 10 Input 1 Calibration Procedure Numeric Code Input 1 Calibration ProcedurePreliminary Steps If … Then … Upper Display = Aply Lower Display = IN1SPNLower Display = Cjtemp Input 2 Set Up Wiring To 20 mA or 4 to 20 mA Inputs Input25+ No connection To 2 Volts, 0 to 5 Volts, or 1 to 5 Volt Inputs Input Input 2 Calibration ProcedureNo connection 26 + 13 Input 2 Calibration Procedure Numeric Code Restore Input Factory Calibration 14 Restore Factory Calibration 150 Output Calibration Set Up Wiring Procedure for Current Output Current Output CalibrationCalibrator Connections 19+ Calibrate 0 % Current Output Calibration Procedure Numeric CodeCalibrate 100 % Set Lock in the Tuning Set Up group to None Set Up Wiring Procedure for Auxiliary OutputAuxiliary Output Calibration Auxiliary Output Calibration Procedure Numeric Code Calibration ModeLower Display = Auxout Upper Display = a Value Restore Factory Calibration Procedure Restore Output Factory Calibration ProcedureUpper Display = SET Lower Display = Tuning Output Calibration Step Operation Press Result Troubleshooting/Service Troubleshooting Aids Procedure for Identifying the Software Version Customer supportDetermining the software version 32xx Power-up Tests Status Tests Lower Reason for Failure How to Correct the Problem Display Background TestsBackground Tests Fail Cnferr PV LIMSegerr OUT1FL Controller Failure Symptoms SymptomsOther symptoms Display Output Cause Shooting Procedure Troubleshooting Procedures Procedure #1 Troubleshooting Power Failure SymptomsProcedure #2 Troubleshooting Current Output Failure Procedure #3 Troubleshooting Three Position Step Control Output FailureRefer to Installation for details Refer to Section Procedure #4 Troubleshooting Time Proportional Output Failure Procedure #5 Refer to Output Calibration for details Procedure #6 10 Troubleshooting Alarm Relay Output FailureRefer to Configuration for Refer to Installation for relay contact information Procedure #7 11 Troubleshooting a Keyboard Failure Procedure #8 12 Troubleshooting a RS-485 Communications Failure Procedure #9 13 Troubleshooting an Ethernet Communications FailureProcedure #10 14 Troubleshooting Auxiliary Output Failure 15 Restoring Factory Configuration Restoring Factory ConfigurationStep What to do Software Upgrades 16 Software Upgrades 176 Exploded View UDC2500 Exploded View Software Upgrades see Section Parts IdentificationParts Not Shown Key Part Number Description Removing the chassis General Information Configuration ID TagsOther Modbus Codes Register Name Access Numbers Dec Register Address Structure Integer Parameter TypeFloating Point Parameter Type Register Count Function Code 20 14h Read Configuration Reference Data DescriptionRequest and Response Formats Byte Count Reference Type Definitions File NumberRegister Address Register Address Format for Function Code Read Configuration Examples Example #1 Example #2 Function Code 21 15h Write Configuration Reference Data Write Restrictions Restrictions on Parameter Numbers in One Message Unrestricted RegistersRegister Format Addresses Dec Hex Write Configuration Examples General Information Non-volatile Memory Retention Reading Control Data Register Addresses Read Software Options Status Control Data ParametersRead Option Status Miscellaneous Read Onlys Register Addresses for Read Onlys SetPoint Program Read Only InformationMiscellaneous Read Onlys SetPoint Program Read Only Information Associated Parameters Setpoint Code SelectionsSetpoint Associated Parameters Using a Computer Setpoint Overriding Controller Setpoint 1 Shed Timer ResetComputer Setpoint Selection Shed Computer Setpoint Associated Parameters Configuration Parameters TuningSet-up Group Tuning Reading or Writing Lockout 0084 132 SP Ramp/Rate/Program 10 Set-up Group Setpoint Ramp/Rate Controller Status 00B4 180 200 11 Set-up Group Accutune Algorithm 12 Set-up Group Algorithm Output Algorithms 13 Set-up Group Output Input 14 Set-up Group Input = NNM H Burnout Open 00A4 164 15 Set-up Group Input Input 00AB 171 Control 16 Set-up Group Control = RPM Options 17 Set-up Group Options SP=PV Communications 18 Set-up Group Communications Alarms 19 Set-up Group Alarms Alarm 1 Setpoint 008E 142 INT Display 20 Set-up Group Display Modbus RTU Exception Codes Function Code Field Query Response21 Modbus RTU Data Layer Status Exception Codes Exception Definition Description Code Ethernet TCP/IP Further information Index UDC2500 Universal Digital Controller Product Manual 223 224 UDC2500 Universal Digital Controller Product Manual 225 Sales and Service UDC2500 Universal Digital Controller Product Manual 227 228